Brake Actuator Reduction Gears for Compact Low-Noise EPB Packaging

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Solution Overview

Problem

Existing actuators for brake devices, particularly those using motor-on-caliper (MOC) type Electric Parking Brake (EPB) systems, suffer from complex gear structures, increased weight, noise, and reduced durability due to high friction and heat loss.

Innovation Solution

The actuator incorporates a planetary gear assembly as the first reduction gear unit and a bevel gear assembly as the second reduction gear unit, simplifying the gear connection structure and enabling miniaturization, which reduces weight and enhances efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If a conventional gear structure is used in the MOC-type EPB actuator, then the torque transmission is achieved, but the structure becomes complicated and the weight increases

Engineering Contradiction:

Improvegear structure complexityVSAvoidactuator weight

Core Design Contradiction:

Device complexityVSWeight of moving object

Solution Approach 1:

The gear system is divided into two distinct units: a first reduction gear unit (planetary gear assembly) and a second reduction gear unit (bevel gear assembly). This segmentation allows each unit to perform a specific function with optimized structure, reducing overall complexity while maintaining torque transmission capability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The planetary gear assembly and bevel gear assembly are combined in a compact arrangement where the output of the first reduction gear unit directly drives the second reduction gear unit. This merging of functions into a integrated transmission system reduces the number of separate components and simplifies the overall structure.

Inventive Principle:

Principle #5Merging (Combining)

2Force

If multiple gear devices are used to increase torque, then the torque multiplication is achieved, but the number of connecting parts increases and heat loss increases

Engineering Contradiction:

ImprovetorqueVSAvoidheat loss

Core Design Contradiction:

ForceVSLoss of energy

Solution Approach 1:

The planetary gear assembly provides continuous contact between gear teeth during rotation, creating a dynamic load distribution that reduces sliding friction and heat generation. The bevel gear assembly similarly maintains optimal contact patterns, minimizing energy loss through friction while achieving the required torque multiplication.

Inventive Principle:

Principle #15Dynamics

3Force

If multiple gear devices with many connecting parts are used, then the torque transmission is enhanced, but the durability decreases due to friction

Engineering Contradiction:

Improvetorque transmissionVSAvoiddurability

Core Design Contradiction:

ForceVSReliability

Solution Approach 1:

The design extracts and eliminates unnecessary connecting parts and intermediate components from the transmission system. By using a compact two-unit gear arrangement, the patent removes redundant elements that would otherwise increase friction points and potential failure locations, thereby improving durability while maintaining torque transmission.

Inventive Principle:

Principle #2Taking out (Extraction)

4Volume of moving object

If a compact design is pursued for miniaturization, then the size is reduced, but the gear structure becomes more complex to fit in limited space

Engineering Contradiction:

Improveactuator sizeVSAvoidgear connection structure

Core Design Contradiction:

Volume of moving objectVSDevice complexity

Solution Approach 1:

The planetary gear assembly is arranged concentrically around the motor shaft, with planetary gears nested within the annular space between the sun gear and ring gear. The bevel gear assembly is similarly compacted by positioning the gears in a nested configuration that minimizes radial and axial dimensions, achieving miniaturization without excessive complexity.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The transmission system utilizes three-dimensional spatial arrangement efficiently, with the planetary gear unit occupying the radial dimension and the bevel gear unit extending in the axial dimension. This multi-dimensional packing allows compact miniaturization while maintaining simple gear connection structures through optimized spatial layout.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

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, lightweight actuator with improved efficiency and reduced noise, effectively addressing the limitations of existing MOC-type EPB systems.

Implementation Method 1

the first reduction gear unit is provided as a planetary gear assembly

Methodology Applied

Scientific EffectPlanetary gear mechanism: Epicyclic Gearing

Implementation Method 2

deceleres power generated from a motor while increasing torque by using a plurality of gear devices

Methodology Applied

Scientific EffectMechanical advantage: Mechanical Advantage

Implementation Method 3

the second reduction gear unit is provided as a bevel gear assembly

Methodology Applied

Scientific EffectBevel gear mechanism: Gear

Data Source

PatentUS12319254B2Actuator for brake device

Publication Date: 2025.06.03 HL MANDO CORP

AI summary

Disclosed is an actuator for a brake device. In accordance with an aspect of the disclosure an actuator for a brake device includes a motor; a first reduction gear unit connected to the motor; and a second reduction gear unit connected to the first reduction gear unit; wherein the first reduction gear unit is provided as a planetary gear assembly, and the second reduction gear unit is provided as a bevel gear assembly.