In-Wheel Brake Caliper Layout With Hydraulic Pressure Transfer
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Solution Overview
Problem
The challenge of integrating a brake apparatus into an in-wheel motor system of an e-corner module vehicle is the limited space, which leads to interference with adjacent components and difficulty in securing braking safety equivalent to traditional systems.
Innovation Solution
A brake apparatus with a stator unit, rotor unit, disc unit, caliper units, and a transfer unit that allows hydraulic pressure to be transferred between caliper units using a transfer member, fixing part, sealing part, and stopper part, ensuring stable operation and synchronization without additional hydraulic pressure generation means.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a fixed caliper brake is applied to an in-wheel motor, then higher braking force may be secured, but it interferes with adjacent components due to limited space
Solution Approach 1:
The caliper is divided into two separate caliper units (first caliper unit and second caliper unit) that are disposed at both sides of the disc unit. Each caliper unit has its own piston part, allowing independent mounting on limited space while maintaining balanced braking force through the disc unit.
2Volume of moving object
If caliper units are separated from each other, then interference with adjacent components is prevented, but hydraulic pressure transfer becomes complex
Solution Approach 1:
A transfer unit is introduced as an intermediary component connected between the first and second caliper units. This transfer unit includes a transfer member with a flow part that enables hydraulic pressure to be transferred from one caliper unit to the other, simplifying the system by using a dedicated transfer mechanism rather than complex routing.
Solution Approach 2:
The transfer unit serves multiple functions: it transfers hydraulic pressure between caliper units, provides structural support for connecting the separated calipers, and maintains system synchronization. This multi-functionality reduces overall system complexity despite the separated caliper configuration.
3Reliability
If sealing part is added to prevent brake fluid leakage, then reliability is improved, but manufacturing complexity increases
Solution Approach 1:
A sealing part in the form of a ring-shaped seal is installed within the transfer unit at the connection interface between caliper units. This flexible sealing element prevents brake fluid leakage through the connection points while maintaining a relatively simple structure that can be easily manufactured and assembled.
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 enables stable hydraulic pressure application, prevents interference with adjacent components, and maintains operational stability by synchronizing caliper units, reducing the risk of fluid leakage and component damage.
Implementation Method 1
a cylinder configured to generate hydraulic pressure by a brake fluid flowing into the cylinder
Implementation Method 2
a transfer unit connected to the pair of caliper units, and configured to transfer hydraulic pressure applied to one of the pair of caliper units to a remaining one of the pair of caliper units
Implementation Method 3
a sealing part installed between the transfer member and the caliper body part, and configured to prevent the brake fluid from leaking to an outside of the caliper body part
Implementation Method 4
a rotor unit disposed to face the stator unit and rotated by electromagnetic interaction with the stator unit
Data Source
AI summary
A brake apparatus for a vehicle may include: a stator unit fixed to an inside of a wheel of the vehicle, a rotor unit disposed to face the stator unit and rotated by electromagnetic interaction with the stator unit, a disc unit connected to the rotor unit and rotated together with the rotor unit, a pair of caliper units disposed on both sides of the disc unit and configured to generate a braking force by contacting with the disc unit as hydraulic pressure is applied, and a transfer unit connected to the pair of caliper units, and configured to transfer hydraulic pressure applied to one of the pair of caliper units to a remaining one of the pair of caliper units.