Modular Electromechanical Brake for Variable Axial Force
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Solution Overview
Problem
Existing electromechanical brakes for motor vehicles require significant modification efforts and are not economical when designed for different axial forces.
Innovation Solution
A modular design with interchangeable module variants, including a brake caliper housing, spindle drive unit, and a worm gear, optionally with a planetary gear, allowing for different braking forces using identical components and a shared electric motor, and utilizing plastics for planet wheels to reduce weight and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If different electromechanical brakes are designed for different axial forces, then the braking force varies, but the design effort and manufacturing complexity increase significantly
Solution Approach 1:
The brake caliper housing is designed as a universal component that can accommodate different module variants (with or without planetary gear) within the same housing structure. This allows a single housing design to support multiple braking force configurations, reducing overall design complexity while maintaining force variability.
Solution Approach 2:
The electromechanical brake is divided into modular components: a common brake caliper housing and interchangeable module variants. The module variant without planetary gear serves as a base configuration, while the variant with planetary gear adds functionality. This segmentation allows independent design and manufacturing of modules that can be assembled into different braking force configurations.
2Force
If electromechanical brakes are designed for different axial forces, then the braking performance varies, but the manufacturing cost increases
Solution Approach 1:
The brake caliper housing serves multiple functions across different module variants, acting as both the structural housing and the mounting platform for different gear configurations. This universality allows a single housing design to be manufactured once and used across multiple product variants, significantly reducing tooling costs and manufacturing complexity.
Solution Approach 2:
The braking force is varied by changing the gear configuration parameter (presence or absence of planetary gear) rather than redesigning the entire brake assembly. This parameter-based differentiation allows manufacturers to produce a base model and then create higher-force variants by simply adding or modifying the gear module, reducing manufacturing costs through component standardization.
3Force
If the brake caliper housing diameter is increased to accommodate higher braking forces, then the braking force increases, but the compactness is reduced
Solution Approach 1:
Instead of increasing the radial dimension (housing diameter) to accommodate higher braking forces, the invention utilizes the axial dimension by stacking the planetary gear above the worm gear within the same housing footprint. This vertical arrangement allows higher braking force capability without increasing the overall diameter of the brake caliper housing, maintaining compactness while achieving force multiplication.
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
Enables production of electromechanical brakes with varying braking forces efficiently and economically, while maintaining compactness and reducing material costs and maintenance needs.
Implementation Method 1
a worm gear operatively connected to the spindle drive unit are arranged, which are driven by an electric motor
Implementation Method 2
comprises a planetary gear, which is also arranged in the brake caliper housing, between the worm gear and the spindle drive unit
Implementation Method 3
via which a transmission ratio between the worm gear and the spindle drive unit is modified in comparison to the first module variant
Implementation Method 4
an electric motor drives a spindle drive unit, via which brake pads arranged on a brake clamp of the brake caliper can be applied to a brake disk for braking
Data Source
AI summary
An electromechanical brake for a motor vehicle. The electromechanical brake has a modular design, and a first module variant includes a brake clamp and a brake caliper housing connected to the brake clamp, in which housing a spindle drive unit and a worm gear operatively connected thereto are arranged, which are driven by an electric motor. A force can be applied to a brake piston for braking via the spindle drive unit. A second module variant, in addition to the first module variant, includes a planetary gear, which is also arranged in the brake caliper housing, between the worm gear and the spindle drive unit.