In-Wheel Motor Brake Caliper Layout to Suppress Rotational Moment
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Solution Overview
Problem
Conventional in-wheel motor braking systems generate rotational moment due to the placement of the caliper, making it difficult to reduce the size and weight of the caliper, and preventing accurate measurement of runout in chassis modules.
Innovation Solution
A braking device with a caliper mounted on a bracket within the wheel, featuring a body part coupled to a knuckle, extension parts connected to the stator, and a mounting part that guides the caliper's linear movement, reducing the caliper's size and weight while minimizing rotational moment generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the caliper is mounted on the rear surface of the electric caliper module with gearbox, motor assembly, and ECU, then the gravity center moves backward, but rotational moment is generated during operation
Solution Approach 1:
The patent extracts the caliper from the conventional electric caliper module assembly (which includes gearbox, motor assembly, and ECU mounted on the rear surface). By mounting the caliper separately on the bracket within the wheel, the harmful rotational moment generation is eliminated while maintaining braking functionality.
Solution Approach 2:
The patent introduces a bracket as an intermediary component mounted in the wheel. The caliper is mounted on this bracket, which serves as a mediator to position the caliper optimally within the wheel structure, preventing rotational moment generation during braking operation.
2Ease of manufacture
If a torque member for housing the pad is mounted on the conventional caliper, then the pad is housed, but it becomes difficult to dispose the caliper in the wheel
Solution Approach 1:
The patent segments the caliper system into separate functional components: the caliper body mounted on the bracket, and the torque member with pad housing integrated into the wheel structure. This segmentation allows the caliper to be disposed in the wheel while maintaining pad housing functionality.
Solution Approach 2:
The patent merges the torque member for housing the pad with the wheel structure rather than mounting it on the conventional caliper. This integration allows the caliper to be freely disposed in the wheel while the pad housing function is maintained through the merged torque member structure.
3Ease of manufacture
If the caliper is freely placed over the in-wheel motor without bracket mounting, then installation is simple, but runout cannot be measured in units of chassis modules
Solution Approach 1:
The bracket serves multiple functions: it provides structural support for mounting the caliper in the wheel, enables proper positioning for runout measurement in chassis modules, and maintains installation simplicity. This multi-functionality resolves the contradiction between easy installation and measurement capability.
4Weight of moving object
If the caliper size is reduced to reduce vehicle weight, then weight decreases, but braking performance may be compromised
Solution Approach 1:
The patent applies local quality optimization by strategically positioning the reduced-size caliper on the bracket within the wheel at locations that maximize braking efficiency. The bracket mounting allows the caliper to be placed in optimal positions for force application on the brake disk, maintaining performance despite size reduction.
Data Source
AI summary
A braking device for an in-wheel motor may include: a stator; a rotor configured to rotate when power is applied to the stator; a disk interlocked with the rotor; a bracket coupled to the stator and a knuckle; and a caliper mounted on the bracket, and configured to press the disk.