Electropneumatic Brake Actuator with Electromagnetic Parking Unit
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Solution Overview
Problem
Conventional brake actuators for commercial vehicles require significant space and weight, and the spring-loaded parking brake mechanism poses safety risks due to high potential energy, necessitating a more compact and safer solution.
Innovation Solution
An electropneumatic brake actuator with an electromagnetic parking brake unit that replaces the mechanical spring-loaded portion, utilizing a DC electric motor with a self-locking screw drive transmission to move the push rod between retention and extension positions, ensuring compactness and safety by eliminating the need for high-energy springs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a spring-loaded parking brake mechanism is used, then parking brake functionality is provided, but the build size and weight of the brake actuator increase
Solution Approach 1:
The patent replaces the mechanical spring-loaded parking brake mechanism with an electromagnetic actuator. The electromagnetic actuator uses electromagnetic fields to generate the forces needed for parking brake application and release, eliminating the need for heavy compression springs and associated mechanical components. This substitution directly reduces the build size and weight while maintaining reliable parking brake functionality through electrical control.
2Reliability
If a spring-loaded parking brake mechanism is used, then parking brake force is provided, but the safety risk increases due to high potential energy in compression springs
Solution Approach 1:
The electromagnetic actuator replaces the spring-loaded mechanism, eliminating compression springs that store high potential energy. The electromagnetic system stores energy in magnetic fields during operation, but when deactivated, it presents no hazardous stored energy. The actuator uses controlled electromagnetic forces to apply and release the parking brake, with no dangerous mechanical energy storage, thereby eliminating the safety risks associated with unauthorized opening of spring-loaded portions.
3Volume of stationary object
If an electromagnetic actuator is used to replace spring-loaded portion, then build size is reduced, but manufacturing complexity increases
Solution Approach 1:
The electromagnetic actuator integrates multiple functions (force generation, positioning, and control) into a single electromechanical component, reducing the overall number of mechanical parts compared to a spring-loaded system. While electromagnetic components require precision manufacturing, the elimination of heavy springs, mounting structures, and associated mechanical linkages simplifies the overall assembly process and reduces manufacturing effort in other areas.
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 a compact, lightweight brake actuator that maintains parking brake functionality even without electricity, ensuring user safety and efficient energy use, while maintaining the parking brake force in case of power failure.
Implementation Method 1
The electromagnetic actuator comprises in a preferred embodiment a stator for generating a rotating (electro-) magnetic field and a rotor, said rotor being driven by the rotating magnetic field
Implementation Method 2
The transmission comprises a, preferably self-locking, screw drive... By reducing the screw pitches sufficiently far, the driving force necessary for the magnetic field of the stator is also reduced... The shaft and the pushrod preferentially are slidably supported with respect to one another
Data Source
Figure 1
AI summary
The invention relates to an electropneumatic brake actuator (1) for a commercial vehicle, said brake actuator (1) comprising a housing (3), a push rod (23) that is slidably arranged in said housing (3) and adapted to move along an axis (A) for transmitting a brake force to a brake mechanism, and a parking brake unit (5). According to the invention the parking brake unit (5) comprises an electromagnetic actuator (39) that is adapted to move the push rod (23) along axis (A) between a retention position and an extension position for transmitting a parking brake force to the brake mechanism.