Electric Booster Segmented Motor Casing for Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional brake boosters, particularly vacuum boosters, face challenges with reduced negative pressure in engine inlet pipes due to advancements in fuel efficiency and exhaust-gas cleaning, leading to increased complexity and cost in installation and manufacturing, prompting the need for alternative solutions like electric boosters.
Innovation Solution
An electric booster design featuring an electric motor with a stator, rotor, and annular motor casing, where the rotation-linear motion converting mechanism is integrated within the motor casing, allowing for testing and installation without disassembling the motor casing, thus simplifying the manufacturing process and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the motor casing is designed as a box-type structure to contain the stator and rotor, then the electric motor can be properly manufactured and assembled, but the rotation-linear motion converting mechanism cannot be installed after manufacturing, requiring disassembly of the motor casing which complicates the manufacturing process and increases cost
Solution Approach 1:
The motor casing is segmented into two parts: a main body portion and a cover portion. The cover portion can be removed to provide access to the interior space, allowing the rotation-linear motion converting mechanism to be installed after the electric motor is manufactured and tested. This segmentation resolves the contradiction by enabling both proper motor assembly and post-manufacturing component installation without requiring complete disassembly.
Solution Approach 2:
The electric motor is manufactured, assembled, and tested first while the cover is removed. The rotation-linear motion converting mechanism is then installed in a subsequent step. This preliminary action approach allows the motor to be fully functional before adding the motion conversion mechanism, simplifying the overall manufacturing process and reducing costs.
2Reliability
If the rotation-linear motion converting mechanism is attached to the rotor in advance, then the electric motor can be tested properly, but the mechanism cannot be installed after manufacturing with a box-type motor casing
Solution Approach 1:
The segmented motor casing with a removable cover allows the electric motor to be tested with the rotation-linear motion converting mechanism already attached to the rotor, while maintaining a simple box-type overall structure. The cover can be removed to access the interior for testing purposes, and the mechanism remains securely attached during operation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design facilitates easier and less expensive manufacturing of electric boosters by enabling testing of the electric motor without disassembly, improving installability and reducing costs while maintaining effective brake hydraulic pressure generation.
Implementation Method 1
a stator including a coil therein, a rotor in which the rotation-linear motion converting mechanism is fitted, and which rotates by applying a current to the stator
Implementation Method 2
a rotation-linear motion converting mechanism (ball screw)
Data Source
AI summary
An electric booster which drives an electric motor (40) in response to a movement of an input member (9) moving together with a brake pedal (B), and generates a brake hydraulic pressure in a master cylinder (10) through a ball screw mechanism (50). The electric motor (40) includes a stator (41) having a coil therein, a rotor (42) which rotates by applying current to the stator (41), and an annular motor casing (2) containing the stator (41) and the rotor (42). The ball screw mechanism (50) is fittedly disposed in the rotor (42). An opening (3b) on one axial end side of the motor casing (2) has a larger diameter than an outer diameter of the ball screw mechanism (50). In manufacturing, after the electric motor (40) alone is tested, the ball screw mechanism (50) is inserted through the opening (3b) and installed without the need of disassembling the motor casing (2).