EPB Brake Actuator Bevel-Planetary Layout for Low Noise
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Solution Overview
Problem
Existing brake actuators for Electronic Parking Brake (EPB) systems suffer from large vibrations, noise issues, and economic infeasibility due to complex structures and assembly challenges.
Innovation Solution
The actuator design incorporates a housing with a motor and reduction gear unit, featuring a power connection unit with helical and bevel gear assemblies to transmit rotational force efficiently, including a first bevel gear part on the power transmission shaft and a second bevel gear part with a cylindrical shape, along with a sun gear, planetary gears, and a carrier for compact and stable operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional EPB actuator structure with motor and reduction gears is used, then the parking brake function is achieved, but large vibrations and noises occur
Solution Approach 1:
The planetary gear set is nested within the housing, with the sun gear, planetary gears, and ring gear arranged in a compact concentric configuration. The motor is positioned above the planetary gear set, and the entire reduction device is integrated within the actuator housing, creating a compact nested structure that reduces vibrations and noises while maintaining the parking brake function.
Solution Approach 2:
The power connection unit merges the motor, power transmission shaft, and planetary gear set into a single integrated assembly. The motor shaft is directly connected to the sun gear through the power transmission shaft, combining the power source and transmission mechanism into one unified structure that reduces vibrations and noises through improved structural integration.
2Power
If a complex actuator structure with multiple gears is used, then the reduction ratio is achieved, but assembly becomes difficult and economic feasibility decreases
Solution Approach 1:
The actuator is segmented into distinct functional modules: the motor unit, the power connection unit with planetary gear set, and the cable connection unit. The planetary gear set itself is segmented into the sun gear, planetary gears, and ring gear as separate components that can be manufactured independently and then assembled together, simplifying the manufacturing process while achieving the required reduction ratio.
Solution Approach 2:
The planetary gear set serves multiple functions simultaneously: it provides the reduction ratio, changes the direction of rotational force, and transmits power from the motor to the cable connection unit. This multi-functionality reduces the need for additional separate components, simplifying assembly while maintaining the required power transmission capabilities.
3Volume of moving object
If the actuator size is reduced for miniaturization, then compactness is achieved, but operational stability may be compromised
Solution Approach 1:
The planetary gear set is nested within the housing with the sun gear, planetary gears, and ring gear arranged in a compact concentric configuration. This nested arrangement achieves miniaturization by efficiently utilizing the internal space, while the rigid housing and proper gear meshing maintain operational stability despite the reduced size.
Solution Approach 2:
The planetary gear set utilizes circular and curved geometries throughout - the sun gear, planetary gears, and ring gear all feature curved tooth profiles and circular arrangements. This spherical/curved geometry enables compact packaging while maintaining smooth rotational motion and operational stability through proper gear engagement.
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 results in a compact, low-noise actuator with improved assembly feasibility and operational stability, enhancing miniaturization and reducing vibrations and noise.
Implementation Method 1
The power connection unit includes a power transmission shaft having a predetermined length and provided between the motor and the reduction device; a first helical gear coupled to a rotation shaft of the motor; a second helical gear installed at one end of the power transmission shaft and meshed with the first helical gear
Implementation Method 2
The second reduction gear unit includes a sun gear coupled to a lower center of the second bevel gear part to rotate together with rotation of the second bevel gear part; a plurality of planetary gears meshed with an outer side of the sun gear
Data Source
AI summary
Disclosed herein an actuator for a brake device includes a housing including a motor accommodating portion configured to accommodate a motor, and a gear accommodating portion configured to accommodate a reduction device; a power connection unit connected to the motor; and the reduction device connected to the power connection unit; wherein the reduction device includes a first reduction gear unit connected to the power connection unit and a second reduction gear unit connected to the first reduction gear unit, and the first reduction gear unit is provided as a bevel gear assembly.