In-Wheel Disk Brake Torque Member Design
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Solution Overview
Problem
Conventional disk brake apparatuses in in-wheel driving systems face challenges with non-uniform friction performance and noise due to uneven surface pressure distribution between the brake disk and pad, leading to increased wear and heat on the outer diameter portion, and space constraints that interfere with other components like in-wheel motors.
Innovation Solution
A disk brake apparatus with a structure that includes two torque members supporting the brake pads on either side, eliminating the need for a main beam and tie bar, allowing direct coupling to the stator instead of the knuckle, which reduces weight, improves design freedom, and minimizes interference with other components, while also reducing the radial distance for stress reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If the brake apparatus is installed at the outer diameter portion of the brake disk, then the braking force is improved, but the surface pressure becomes non-uniform and noise is generated
Solution Approach 1:
The patent applies local quality by positioning pad support parts at specific locations on the torque member to distribute brake pad support forces uniformly across different radial positions of the brake disk. This ensures that both outer diameter and inner diameter portions receive appropriate surface pressure, eliminating non-uniform friction and noise while maintaining effective braking force.
2Strength
If the conventional torque member structure with main beam and tie bar is used, then the structural strength is ensured, but the weight and device complexity increase
Solution Approach 1:
The patent extracts and eliminates the main beam and tie bar components from the conventional torque member structure. By redesigning the torque member as an integrated single piece with strategically positioned pad support parts, the invention maintains necessary structural strength for brake pad support while significantly reducing weight and simplifying the overall device complexity.
Solution Approach 2:
The patent merges multiple separate components (main beam, tie bar, and support structures) into a single integrated torque member. This consolidation maintains the functional requirements for supporting brake pads and providing structural strength while reducing the total number of parts, lowering weight, and simplifying assembly.
3Ease of operation
If the brake apparatus components are arranged in the limited wheel space, then the braking function is provided, but interference with in-wheel motor and other components occurs
Solution Approach 1:
The patent utilizes the radial dimension of the wheel assembly by positioning the torque member and brake pads in the radial direction between the wheel rim and the in-wheel motor. This spatial arrangement in the radial dimension allows the braking components to coexist with the in-wheel motor and other components without interference, effectively solving the space constraint problem.
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
This design enhances friction uniformity, reduces noise, improves assembly efficiency, and decreases the overall weight and cost by eliminating unnecessary components, while allowing for more compact and efficient installation within the wheel.
Implementation Method 1
a disk brake apparatus that generates a braking force by pressing a brake pad against either side of a disk-shaped brake disk rotated with a wheel
Data Source
AI summary
A disk brake apparatus of an in-wheel driving system may include: an in-wheel driving device having a rotor and stator, and positioned within a wheel; a first torque member installed on the stator, and configured to support one side portions of a pair of brake pads; a second torque member spaced apart from the first torque member, and configured to support the other side portions of the brake pads; and a caliper body having one side portion coupled to the first torque member and the other side portion coupled to the second torque member, and configured to press the brake pads toward a wheel disk.