In-Wheel Brake Caliper Layout for Safe e-Corner Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The challenge of integrating a brake apparatus within an in-wheel motor of an e-corner module vehicle is the limited space and the difficulty in achieving braking safety equivalent to traditional caliper brakes while maintaining efficient assembly.
Innovation Solution
A brake apparatus with a caliper body module, pad plate parts, piston module, and guide members, including fastening members and guide pins, is designed to fit within the in-wheel motor, ensuring rigidity and reducing interference, while the internal and external braking devices are fixed to the stator for improved assembly and safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If an existing mass-produced caliper brake is used in an in-wheel motor, then the braking function is provided, but the internal layout conditions of the in-wheel cannot be satisfied and braking safety equivalent to general brake systems cannot be secured
Solution Approach 1:
The brake apparatus is divided into separate modules: a caliper body module containing the piston and pad assembly, and a guide member module that attaches to the in-wheel. This segmentation allows the braking components to be independently optimized and assembled within the constrained in-wheel space while maintaining reliable braking performance through standardized connection interfaces.
Solution Approach 2:
The caliper body module is nested within the guide member structure, with the caliper body positioned inside the guide member's accommodating space. The piston module is nested within the caliper body, and the pad plate is nested between the finger part and cylinder part. This nested arrangement maximizes space utilization within the limited in-wheel volume while maintaining structural integrity and braking reliability.
2Ease of manufacture
If the caliper body module is assembled without proper fastening members, then assembly is simpler, but the caliper body module remains in an unassembled state and cannot function properly
Solution Approach 1:
The fastening members are designed with protrusions that extend from the guide member toward the caliper body module before final assembly. This preliminary positioning ensures proper alignment and prevents misassembly, while the self-aligning features maintain assembly simplicity. The fastening members are pre-configured to guide the caliper body module into its correct position and orientation during assembly.
3Ease of operation
If the guide member is positioned away from the gravity axis, then assembly is easier, but vibration and noise occur during braking
Solution Approach 1:
The guide member is designed with its central axis positioned at substantially the same height as the gravity axis of the caliper body module. This alignment creates a balanced gravitational distribution during braking operations, eliminating uneven force distribution that would cause vibration and noise. The equipotential positioning ensures smooth braking operation without harmful oscillations while maintaining straightforward assembly through standardized mounting features.
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 enhances the assembly efficiency and rigidity of the brake apparatus, preventing vibration and noise, and ensures the internal layout conditions are met, providing effective braking performance.
Implementation Method 1
configured to selectively come into contact with a disk module rotated together with a rotor to generate a braking force
Implementation Method 2
pushes a piston through hydraulic pressure generated from a master cylinder
Implementation Method 3
a friction reduction part configured to surround the guide pin part
Data Source
AI summary
A brake apparatus for a vehicle may include: a caliper body module provided with a finger part and a cylinder part spaced apart from each other and facing each other, a pad plate part disposed between the finger part and the cylinder part, and configured to selectively come into contact with a disk module rotated together with a rotor to generate a braking force, a piston module installed in the cylinder part to be movable forward and backward and configured to press the pad plate part, a guide member disposed on both sides of the caliper body module and configured to movably support the caliper body module, and a first fastening member extending from the guide member and fastened to a first mounting member provided in a stator.