Electromechanical Brake Actuator for High-Pressure Test Bench
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Solution Overview
Problem
Existing brake test benches face challenges in replicating the high pressure and pressure gradients required for simulating a vehicle driver's braking action, particularly in achieving repeat accuracy and efficiently managing brake pressure, due to the complexity of pneumatic/hydraulic systems and the limitations of electrically driven actuators in maintaining hydraulic systems.
Innovation Solution
A brake test bench equipped with an electromechanical brake actuator featuring an electric motor and a planetary roller screw drive, which mechanically actuates the pressure generating assembly to simulate the braking force and pressure build-up, while maintaining the hydraulic braking principle and incorporating a bypass valve for pressure relief and improved repeat accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If pneumatic/hydraulic systems are used to generate brake pressure, then high pressure and pressure gradients can be achieved, but device complexity increases due to special valves and friction-reduced cylinders
Solution Approach 1:
The patent replaces the pneumatic/hydraulic actuator system with an electric motor-driven mechanical system. The electric motor directly drives a piston through a mechanical connection, eliminating the need for complex pneumatic valves, hydraulic pumps, and friction-reduced cylinder mechanisms. This substitution maintains the ability to generate high brake pressure while significantly reducing system complexity.
2Stress or pressure
If hydraulic actuators are used to simulate braking foot, then brake pressure can be generated, but repeat accuracy of simulated brake applications deteriorates
Solution Approach 1:
The patent replaces hydraulic actuators with an electric motor-driven mechanical system that provides more precise and repeatable brake application simulation. The electric motor offers controlled, consistent force application through direct mechanical coupling to the piston, eliminating hydraulic variability and improving repeat accuracy of simulated brake applications.
Solution Approach 2:
The mechanical system is designed to automatically return the piston to its initial position using a return spring mechanism. This self-returning feature ensures consistent starting conditions for each brake test, thereby improving repeat accuracy without requiring additional active control systems.
3Device complexity
If electric motor is used to actuate brake, then device complexity is reduced, but ability to reach high pressure gradients deteriorates
Solution Approach 1:
The patent employs a dynamically optimized mechanical transmission system with a crank mechanism that converts the electric motor's rotational motion into reciprocating piston motion. The crank geometry and motor speed control are optimized to generate high pressure gradients during the power stroke while maintaining system simplicity. The mechanical advantage varies through the stroke to maximize pressure build-up rate.
4Stress or pressure
If bypass valve is added for pressure relief, then pressure management is improved, but device complexity increases
Solution Approach 1:
The patent introduces a bypass valve as an intermediary pressure relief mechanism that activates when the piston reaches its maximum travel position. This simple two-position control (normal operation vs. pressure relief) provides effective pressure management without requiring complex active control systems. The bypass valve serves as a passive safety and pressure management device that adds minimal complexity.
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 enables precise simulation of braking behavior with high repeat accuracy and efficient pressure management, allowing for the generation of high brake pressures and reliable pressure relief, even under thermal conditions, thus enhancing the reproducibility of brake test results.
Implementation Method 1
an electric motor that can be activated by a test bench control
Implementation Method 2
a planetary roller screw drive that is driven by the electric motor
Implementation Method 3
a pressure generating assembly for providing a brake fluid with an increased hydraulic pressure
Data Source
AI summary
A test bench for testing a brake comprises a pressure generating assembly for providing a brake fluid with an increased hydraulic pressure, a test bench control, and an electromechanical brake actuator. The pressure generating assembly is actuated mechanically and the brake fluid is supplied to the brake to actuate the brake. The electromechanical brake actuator, which simulates a vehicle driver's braking foot, is provided for mechanical actuation of the pressure generating assembly. The brake actuator comprises an electric motor activated by the test bench control and a planetary roller screw drive driven by the electric motor. The planetary roller screw drive is mechanically coupled to the pressure generating assembly to mechanically actuate the pressure generating assembly.