Electromechanical Actuator Package for Vehicle Brake Assembly
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Solution Overview
Problem
Existing electric brake systems for vehicles face challenges in efficiently transferring torque and maintaining mechanical efficiency while compactly packaging the necessary components, leading to issues with torque ripple and cogging torque in electric motors.
Innovation Solution
An electromechanical actuator package featuring a differential with a planetary harmonic gear assembly and a locking mechanism, which includes a rotatable base with projections and an electromagnet assembly, allows for precise control of the pulley engagement and disengagement, enhancing torque transfer efficiency and reducing the need for a carrier for planet gears.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a gear/belt system is used to transfer torque from the motor to the brake caliper, then the necessary load transfer is achieved, but torque ripple and cogging torque increase
Solution Approach 1:
The patent replaces the traditional gear/belt mechanical transmission system with a direct-drive architecture where the motor shaft is directly coupled to the brake caliper via a pulley and belt system eliminated. This substitution removes the intermediate mechanical components that generate torque ripple and cogging torque, achieving smooth torque transfer while maintaining the necessary braking force.
2Force
If multiple large gears or many small gears are used in the gear system, then the necessary load transfer is achieved, but the device complexity and packaging size increase
Solution Approach 1:
The patent extracts and eliminates the complex gear system entirely from the brake actuator assembly. By removing the multi-gear transmission mechanism and adopting a direct-drive configuration with motor directly connected to the brake caliper, the design achieves the necessary load transfer without the complexity of multiple gears, reducing both device complexity and packaging requirements.
3Force
If a traditional gear system is used, then torque multiplication is achieved, but the packaging size and mass increase
Solution Approach 1:
The patent substitutes the bulky gear-based torque multiplication system with an electric motor that directly provides the required torque. The motor is positioned such that its shaft is in direct alignment with the brake caliper mounting points, eliminating the need for intermediate gear trains and reducing the overall packaging volume while maintaining torque multiplication capability through electronic control.
4Reliability
If a locking mechanism is added to lock the pulley of the differential, then the braking force is maintained, but the device complexity increases
Solution Approach 1:
The patent merges the locking mechanism functionality with the existing differential and pulley assembly. The locking mechanism is integrated into the differential structure, sharing common components and mounting points with the pulley system, thereby achieving reliable braking force maintenance without proportionally increasing device complexity through separate independent locking components.
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 improves mechanical efficiency, reduces packaging size and mass, and provides a scalable torque output, while maintaining the braking force effectively through the planetary harmonic gear assembly and locking mechanism.
Implementation Method 1
an electromagnet assembly disposed adjacent to at least one of the projections, the electromagnet assembly operably associated with at least one of the projections
Data Source
AI summary
An electromechanical actuator package for actuating a brake assembly configured to operate a vehicle brake comprises: a motor; a differential operably connected to the motor, the differential comprising a pulley and an output connectable to the brake assembly; and a locking mechanism configured to lock the pulley of the differential, the locking mechanism comprising: a base configured to be movable, a plurality of projections projecting from the movable base, the projections comprising first and second projections, wherein at least a part of the pulley is positioned between the first and second projections projected from the movable base, an electromagnet assembly disposed adjacent to at least one of the projections, the electromagnet assembly operably associated with at least one of the projections, and one or more springs operably coupled to the movable base and/or at least one of the projections.