Hybrid Brake Caliper Structure for Stable Heavy-Vehicle Braking
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Solution Overview
Problem
Conventional electromechanical brakes face challenges in applying stable braking to heavy vehicles or large passenger vehicles due to operational deviations and increased costs associated with multiple motors, gears, and bolt screws, while hydraulic brakes require complex systems and large brake fluid capacities.
Innovation Solution
A hybrid brake device that combines elements of both systems, featuring a caliper body with a master cylinder, braking motor, and multiple caliper pistons, where the braking motor pressurizes brake fluid to uniformly press brake pads on both sides of the disk, reducing the need for multiple motors and gears and minimizing system complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If an electromechanical brake system is used to reduce the number of hydraulic components, then the system complexity and part count are reduced, but operational deviations occur due to motor speed variations and gear transmission, and multiple motors and gears are required for stable braking
Solution Approach 1:
The brake device is divided into two independent actuation systems: a hydraulic system with a master cylinder and caliper pistons, and an electromechanical system with a motor and bolt screw. This segmentation allows each system to handle different braking scenarios, with the hydraulic system providing stable baseline braking and the electromechanical system providing auxiliary braking or emergency backup, thereby resolving the contradiction between simplified structure and reliable operation
Solution Approach 2:
The patent merges the hydraulic brake system and electromechanical brake system into a single integrated brake device that shares common components such as the caliper body, brake pads, and brake disk. This combination allows the system to leverage the stability of hydraulic braking while incorporating the simplified structure and controllability of electromechanical braking, achieving both reduced complexity and improved reliability
2Reliability
If multiple motors, gears, and bolt screws are added to achieve stable braking in electromechanical systems, then braking reliability is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
Instead of using multiple motors and gears to achieve stable braking, the patent employs a single motor that provides partial or excessive braking force, supplemented by the hydraulic system. The motor does not need to provide the full braking force alone, but works in conjunction with the hydraulic system to achieve the required braking stability, thereby reducing the number of components while maintaining reliability
Solution Approach 2:
The hydraulic system acts as an intermediary between the motor and the brake pads, translating the motor's rotational force into linear braking force through the bolt screw and caliper pistons. This intermediary mechanism allows a single motor to effectively control multiple brake pads without requiring multiple motors or complex gear systems, reducing component count while maintaining braking stability
3Reliability
If a hydraulic brake system is used to achieve stable braking force, then braking reliability is improved, but the system requires large brake fluid capacity and complex hydraulic lines
Solution Approach 1:
The hydraulic system is segmented into a master cylinder with limited brake fluid capacity and multiple caliper pistons that distribute the braking force. Instead of requiring a large reservoir to provide sufficient braking force, the system divides the hydraulic function across multiple small pistons, each requiring minimal brake fluid, thereby reducing the total brake fluid capacity while maintaining stable braking force
Solution Approach 2:
The patent replaces part of the traditional hydraulic transmission system with an electromechanical actuation system using a motor and bolt screw. This substitution eliminates the need for extensive hydraulic lines and large brake fluid reservoirs, as the electromechanical system directly actuates the brake pads for auxiliary or emergency braking, reducing the quantity of brake fluid required while maintaining braking reliability
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 hybrid brake device provides stable and efficient braking for heavy vehicles with reduced part count and complexity, minimizing operational deviations and costs, while allowing for a lightweight and miniaturized design that frees up space for other components.
Implementation Method 1
when the braking motor is driven, the master piston pressurizes the brake fluid in the master cylinder and transfers the brake fluid to the caliper cylinder
Implementation Method 2
the caliper piston protrudes by a pressure of the brake fluid to pressurize the brake pad
Implementation Method 3
a braking motor positioned on the side surface of the caliper body and providing a force to drive the master piston
Data Source
AI summary
A structure of a brake system that pressurizes a brake pad as brake fluid in a master cylinder uniformly drives a plurality of caliper pistons by a master piston driven by receiving power of a braking motor of the present disclosure may be simplified, and an opposed type brake system that simultaneously drives a pair of brake pads may be implemented.