Electric Drive Module With Selective Friction Brake Coupling
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Solution Overview
Problem
Existing electric drive modules for vehicles lack advanced braking and traction capabilities, particularly when regenerative braking is not feasible, necessitating the integration of conventional disk brakes and complex coordination with other vehicle systems.
Innovation Solution
An electric drive module with a housing containing pairs of drive units, each equipped with a motor unit and a friction brake, along with a coupling unit that selectively couples the friction brakes, allowing for various operational modes including propulsion, regenerative braking, friction braking, and auxiliary modes to enhance braking and traction capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional disk brakes are integrated into electric drive modules for braking when regenerative braking is not feasible, then braking capability is improved, but device complexity increases due to coordination requirements with other vehicle systems
Solution Approach 1:
The patent combines the friction brake system with the electric motor assembly, integrating the brake mechanism within the motor housing structure. This merging eliminates the need for separate brake assemblies and reduces coordination complexity between independent braking and propulsion systems.
Solution Approach 2:
The electric motor assembly is designed to serve multiple functions: propulsion during acceleration and braking during deceleration through regenerative and friction braking modes. This multi-functionality reduces the need for dedicated single-purpose components and simplifies system architecture.
2Reliability
If friction brakes are added to provide braking capability when regenerative braking is not feasible, then braking reliability is improved, but manufacturing complexity increases
Solution Approach 1:
The friction brake components are integrated into the motor assembly structure, sharing common housing and mounting features. This reduces the total number of discrete parts and simplifies manufacturing processes compared to adding separate brake systems.
3Ease of operation
If independent drive units with friction brakes are used to enhance braking and traction capabilities, then vehicle control is improved, but device complexity increases
Solution Approach 1:
The drive system is divided into independent drive units, each with its own motor and friction brake assembly. This segmentation allows independent control of each wheel, enhancing vehicle control capabilities while maintaining modular simplicity in each unit.
Solution Approach 2:
Each drive unit is designed as a universal assembly capable of propulsion, regenerative braking, and friction braking operations. This multi-functionality reduces the need for separate specialized components for each function.
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 provides enhanced braking and traction capabilities by enabling selective operation of friction brakes and coupling units, allowing for efficient energy regeneration and improved vehicle control, reducing the need for conventional brakes and simplifying system coordination.
Implementation Method 1
The friction brake can be operated to create a rotational drag force that resists rotation of the second portion relative to the first portion
Implementation Method 2
The motor unit has a stator, which is non-rotatably coupled to the housing, and a rotor that is rotatable about a motor axis and configured to drive a wheel of a vehicle
Implementation Method 3
the electric motors are driven by the vehicle wheels to generate electrical energy that can be employed to recharge the battery
Data Source
AI summary
An electric drive module that includes a housing, a pair of drive units and a coupling unit. The drive units are disposed in the housing and each drive unit includes a motor unit and a friction brake. The motor unit has a stator, which is non-rotatably coupled to the housing, and a rotor that is rotatable about a motor axis and configured to drive a wheel of a vehicle. The friction brake has a first portion, which is non-rotatably coupled to the housing, and a second portion that is drivingly coupled to the rotor. The friction brake can be operated to create a rotational drag force that resists rotation of the second portion relative to the first portion. The coupling unit is configured to selectively rotatably couple the second portions of the friction brakes to one another.