Electro-mechanical Brake Differential Gear Efficiency
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Solution Overview
Problem
Existing electro-mechanical brakes with differential gears face issues of low driving power transmitting efficiency, high manufacturing costs, and increased vehicle weight due to the use of ball screw methods, which also result in uneven wear between inner and outer pads, affecting responsiveness and reliability.
Innovation Solution
An electro-mechanical brake system utilizing a spur gear or helical gear, a rack, and a pinion gear as a driving power transmitting device, with a differential gear unit that simultaneously clamps both the inner and outer surfaces of the disc brake, minimizing wear differences and improving initial braking power.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If ball screw method is used for driving power transmission, then braking force is generated, but driving power transmitting efficiency is low and manufacturing cost is high
Solution Approach 1:
The patent replaces the ball screw mechanical transmission system with a direct motor-driven brake caliper system. The motor directly drives the brake caliper without intermediate ball screw mechanisms, eliminating the efficiency losses and high manufacturing costs associated with ball screw components while maintaining the electro-mechanical braking function.
Solution Approach 2:
The patent extracts and removes the ball screw transmission components from the braking system. By taking out the ball screw mechanism that causes efficiency losses and high costs, the system achieves direct motor-to-caliper power transmission, improving both efficiency and manufacturability.
2Force
If ball screw method is used, then braking force is generated, but vehicle weight is increased
Solution Approach 1:
The patent extracts and removes the heavy ball screw transmission components from the braking system. By eliminating these unnecessary intermediate mechanical components, the overall vehicle weight is reduced while the motor directly provides the required braking force through the brake caliper.
Solution Approach 2:
Instead of using a complex transmission mechanism (ball screw) to generate braking force, the patent inverts the approach by having the motor directly drive the brake caliper. This simplification removes unnecessary weight while maintaining the force generation capability.
3Force
If inner pad is clamped first and outer pad is clamped by repulsive force, then braking is achieved, but wear difference between pads occurs and initial braking power is insufficient
Solution Approach 1:
The patent merges the clamping actions of both inner and outer pads by having the motor simultaneously drive both brake calipers. This unified driving approach ensures both pads are applied at the same time with equal force, eliminating wear differences and providing sufficient initial braking power without relying on repulsive forces.
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
This configuration enhances driving power transmitting efficiency, reduces manufacturing costs, and ensures almost simultaneous clamping of both disc surfaces, improving responsiveness and reliability by minimizing wear differences between inner and outer pads.
Implementation Method 1
a first shaft and a second shaft which are disposed in a straight line to be a rotational shaft are rotated in the same direction by a rotational force provided by the driving unit through a gear
Implementation Method 2
a brake serves to decelerate or stop a vehicle by converting kinetic energy of a driving vehicle into heat energy by mechanical friction of a friction material
Data Source
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AI summary
There is provided an electro-mechanical brake with a differential gear. The electro-mechanical brake with a differential gear includes a driving unit that generates a rotational force by a power that is selectively applied along with the operation of the brake pedal by the user, a differential gear unit that is connected to the driving unit through a gear and in which a first shaft and a second shaft that are disposed in a straight line to serve as a rotational shaft are rotated in the same direction by the rotational force provided by the driving unit, an external braking unit that is connected to the first shaft of the differential gear unit through a gear to provide a braking power to an outer surface of the disc along with the rotation of the first shaft of the differential gear unit, and an internal braking unit that is connected to the second shaft of the differential gear unit through a gear to provide a braking power to an inner surface of the disc along with the rotation of the second shaft of the differential gear unit. When the driving unit is driven, the rotational force of the driving unit is transmitted to the differential gear unit, and the external braking unit and the internal braking unit that are connected to the differential gear unit simultaneously provide the braking powers to the disc along with the rotation of the differential gear unit.