Integrated Caliper Brake Assembly for Weight and Vibration Control
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Solution Overview
Problem
Conventional electro-mechanical brakes for vehicles face issues with size, stability due to weight concentration, and vibration, particularly due to the lack of self-locking functionality and increased motor and gear load when incorporating electronic parking brake structures.
Innovation Solution
A brake apparatus with a caliper body, a driving unit, a piston unit, a transfer gear unit, and a planetary gear unit, where the driving unit and planetary gear unit are directly fixed to the caliper body via an assembly part, reducing the number of parts and weight concentration by eliminating a separate actuator housing, and enhancing the reduction ratio to minimize the length of the transfer gear unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an EPB structure is added to the EMB to achieve self-locking functionality, then braking reliability is improved, but device complexity and weight increase
Solution Approach 1:
The patent combines the EMB and EPB structures into a single integrated brake device. The motor unit serves dual purposes: as the main braking actuator and as the parking brake actuator through a one-way clutch mechanism. This merging eliminates the need for separate actuators and reduces overall device complexity while maintaining self-locking functionality through the one-way clutch that prevents reverse rotation of the screw mechanism.
Solution Approach 2:
The motor unit is designed to perform multiple functions: main braking, parking braking, and self-locking. The one-way clutch enables the same motor unit to provide both dynamic braking force and static holding force, making the actuator system universal and eliminating the need for dedicated EPB motor while maintaining reliability.
2Reliability
If an EPB structure is added to the EMB to achieve self-locking functionality, then braking reliability is improved, but the motor capacity and gear reduction ratio must be increased
Solution Approach 1:
The patent merges the main brake and parking brake functions into a single motor unit, allowing the motor to operate at different power levels for different functions. The motor provides high power for main braking and maintains lower power for parking brake holding, eliminating the need to oversize the motor for continuous high-power operation while still achieving reliable self-locking through the one-way clutch mechanism.
3Adaptability or versatility
If the motor and gear actuator are mounted on the caliper, then braking functionality is integrated, but weight concentration increases and vibration susceptibility increases
Solution Approach 1:
The patent merges the caliper and actuator housing into a single integrated structure. The caliper body directly houses the motor unit and gear mechanism, eliminating the need for a separate actuator housing and mounting brackets. This integration distributes weight more evenly across the caliper assembly and reduces the number of separate components, thereby reducing overall weight concentration while maintaining functional integration.
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 reduces the overall size and weight of the brake apparatus, stabilizes it against weight concentration and vibration, and enhances the braking performance by optimizing the rotational force generation and distribution.
Implementation Method 1
a planetary gear unit fixed to the caliper body, and moves the piston unit forward and backward in connection with a rotation of the transfer gear unit
Implementation Method 2
enhancing the reduction ratio of a gear
Implementation Method 3
The conventional EMB secures quick responsiveness and high efficiency of the piston through a ball screw
Implementation Method 4
brakes a vehicle by using the frictional force between the pad and the disk
Data Source
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AI summary
A brake apparatus (1) for a vehicle may include: a caliper body (100) to be fixed to a vehicle body, a driving unit (200) fixed to the caliper body (100), and generates a rotational force, a piston unit (300) movably installed in the caliper body (100), and presses or releases a brake pad according to a moving direction of the piston unit (300), a transfer gear unit (400) connected to the driving unit (200), and rotated by the rotational force received from the driving unit (200) and a planetary gear unit (500) fixed to the caliper body (100), and moves the piston unit (300) forward and backward in connection with a rotation of the transfer gear unit (400).