Integrated Electric Brake System with Spherical Inductor
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Solution Overview
Problem
The existing electric brake systems for electric vehicles are complex due to separate control of main service brakes and electromagnetic brakes, requiring multiple actuators, friction disks, and controllers, which complicates the configuration and limits mounting space, with the electromagnetic brake only applying braking force during parking.
Innovation Solution
An integrated electric brake system that includes a spherical inductor, springs, a disk-shaped armature, and a friction disk, with a brake member and actuator to generate braking force by operating the friction disk toward the armature, allowing proportional control and enabling the electromagnetic brake to function as both a parking and service brake.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate main service brake and electromagnetic brake systems are provided, then braking safety is improved, but device complexity increases and mounting space is reduced
Solution Approach 1:
The patent combines the main service brake and electromagnetic parking brake into a single integrated brake assembly. The friction disk serves both braking functions, with the electromagnetic brake applying force to the same friction disk surface. This merging eliminates the need for separate brake actuators and controllers for each system, reducing overall device complexity while maintaining dual-brake safety functionality
Solution Approach 2:
The friction disk is designed to serve multiple functions: it acts as the braking surface for both the hydraulic main service brake and the electromagnetic parking brake. The electromagnetic brake mechanism can independently apply braking force to the friction disk, enabling the same component to fulfill both service braking and parking brake requirements, thereby simplifying the overall system configuration
2Reliability
If separate main service brake and electromagnetic brake systems are provided, then braking safety is improved, but mounting space is reduced
Solution Approach 1:
The patent merges the electromagnetic brake mechanism directly into the wheel hub assembly, where it shares space with the main service brake components. The electromagnetic brake actuator and friction disk are integrated within the same spatial envelope, eliminating the need for separate mounting spaces that would be required for independent brake systems
3Device complexity
If electromagnetic brake is configured for parking only, then component simplicity is maintained, but braking versatility is reduced
Solution Approach 1:
The electromagnetic brake is designed with multi-functionality, capable of operating in both parking brake mode and service brake mode. The brake control system detects driving conditions and automatically switches between functions: applying electromagnetic braking force during normal driving for energy recovery and assistance, and maintaining parking brake function when stationary. This enables a single brake system to adapt to multiple operational requirements
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
Simplifies the brake system configuration, reduces the need for multiple components, and allows the electromagnetic brake to provide braking force during driving, enhancing safety and securing mounting space by eliminating the need for separate actuators and controllers.
Implementation Method 1
an armature 7, in a disk shape, attached to the inductor 1 while the spring 8 is compressed by an electromagnetic force of the inductor 1, or separated from the inductor 1 by a repulsive force of the spring 8
Implementation Method 2
a friction disk 2 is coupled to an outer circumference of the hub 3 so that the armature 7 constrains the friction disk 2 or releases the constraint, thereby activating or deactivating the braking operation
Data Source
AI summary
The present disclosure relates to an electric brake system for an electric vehicle, which is more economical by simplifying a configuration of an electric vehicle that includes a main service brake and an electromagnetic brake, the electric brake system including an inductor, in a spherical shape, formed so that a drive axle penetrates through a center portion of the inductor; a plurality of springs inserted into holes defined in the inductor; an armature, in a disk shape, provided to contact the spring; and a friction disk mounted on a side of a motor, where a braking force is generated by operating the friction disk toward the armature.