Electric Brake Caliper Layout for Uniform Pad Pressure
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Solution Overview
Problem
Existing brake devices suffer from non-uniform surface pressure of brake pads, increased cost and weight due to multiple ball screw structures and hydraulic cylinders, complex caliper body designs, and issues with center of gravity distribution.
Innovation Solution
A brake device utilizing a motor unit, gear unit, and cylinder unit with multiple pistons, eliminating hydraulic cylinders and incorporating a conversion assembly to convert rotational motion into linear motion, with the motor and gear units positioned centrally to stabilize the device and improve surface pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If one piston and one ball screw structure per brake pad are used, then the brake device can function, but the surface pressure of the brake pad becomes non-uniform and the cost and weight increase
Solution Approach 1:
The brake pad is divided into multiple segments (first, second, third, and fourth brake pads) arranged around the brake disk. Each brake pad is actuated by its own piston and ball screw structure, allowing independent pressure application to different segments of the brake disk, thereby achieving more uniform overall surface pressure distribution.
2Reliability
If one piston and one ball screw structure per brake pad are used, then the brake device can function, but the cost and overall weight increase
Solution Approach 1:
The brake system is segmented into four independent brake pad assemblies, each with its own piston and ball screw structure. This segmentation allows for distributed weight placement and enables the use of lighter materials in each individual component while maintaining overall system reliability through redundancy and distributed actuation.
3Force
If hydraulic cylinders are used to advance and retreat brake pads, then braking force can be applied, but the caliper body structure becomes complicated and manufacturing cost increases
Solution Approach 1:
The invention replaces the hydraulic cylinder mechanism with an electric motor-driven ball screw structure. The motor rotates the ball screw, which converts rotational motion into linear motion to advance and retreat the brake pads. This substitution eliminates the need for hydraulic seals, fluid passages, and associated sealing mechanisms, thereby simplifying the caliper body structure and reducing manufacturing complexity.
4Force
If hydraulic cylinders are used, then braking force can be applied, but the material is limited to metal series causing cost and weight increase
Solution Approach 1:
The hydraulic cylinder is replaced with an electric motor and ball screw assembly. The motor can be mounted on the caliper body and directly drives the ball screw mechanism. This allows the caliper body to be made from lighter materials such as aluminum alloys or even composite materials, as the motor provides sufficient actuation force without requiring the high-strength metal construction needed for hydraulic cylinders.
5Force
If the piston diameter is expanded to secure braking force, then braking force increases, but the size of the device increases and installation space becomes limited
Solution Approach 1:
The invention replaces the hydraulic piston with an electric motor-driven ball screw structure. The motor can be positioned on the caliper body and the ball screw converts rotational motion to linear motion with a compact form factor. This allows sufficient braking force to be generated without requiring large piston diameters, thereby reducing the overall size of the brake assembly and facilitating installation in space-constrained environments.
6Adaptability or versatility
If motor is added for parking braking in addition to hydraulic cylinder, then parking braking function is provided, but the center of gravity of the device is deflected
Solution Approach 1:
The invention integrates both dynamic braking and parking braking functions into a single motor-driven system. The motor can operate in different modes: for dynamic braking, it reverses rotation to push the brake pads against the disk; for parking braking, it locks in position to maintain constant pressure. This multi-functionality eliminates the need for separate hydraulic cylinders and dedicated parking brake motors, thereby maintaining a balanced center of gravity and improving overall system stability.
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
The solution reduces device weight and cost, simplifies the caliper body structure, enhances surface pressure, and stabilizes the center of gravity, facilitating easier manufacturing and installation in limited spaces.
Implementation Method 1
A rotational motion of the motor may be converted into a linear motion of the brake pad by a ball screw structure
Data Source
AI summary
Disclosed is a brake device, including a motor unit operated by an electrical signal, a gear unit having a plurality of gears connected to the motor unit, a cylinder unit having a piston connected to the gear unit to be propelled by operations of a plurality of the gears, a brake pad unit connected to the piston to be propelled by propulsion of the piston, and a caliper body having the cylinder unit seated thereon to guide the brake pad unit. Disclosed is a vehicle having a brake device, the brake device including a motor unit operated by an electrical signal, a gear unit having a plurality of gears connected to the motor unit, a cylinder unit having a piston connected to the gear unit to be propelled by operations of a plurality of the gears, a brake pad unit connected to the piston to be propelled by propulsion of the piston, and a caliper body having the cylinder unit seated thereon to guide the brake pad unit.