Multi-pad Motor-driven Brake Levers for Reduced Weight
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Solution Overview
Problem
Motor-driven brakes in existing systems require large motor torque to generate a significant braking force, leading to increased size, weight, and cost, as well as reduced fuel efficiency and poor heat dissipation.
Innovation Solution
A motor-driven brake with a multi-pad design that utilizes a torque member, spindle, disc pressing assembly with outside and inside levers, and brake pad assembly, where the levers press both sides of a brake disc to generate a large braking force using a small motor operation force, with a stepped structure and lever supports for efficient operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If large motor torque is used to generate large braking force, then braking force is improved, but motor size and weight increase
Solution Approach 1:
The brake pad assembly is segmented into multiple pads (first outside pad, second outside pad, first inside pad, second inside pad) that contact different regions of the brake disc. This segmentation allows the braking force to be distributed across multiple contact points, enabling the use of a smaller motor while achieving the required total braking force through coordinated action of multiple pads.
Solution Approach 2:
The invention transitions from a single-point or single-plane braking mechanism to a multi-dimensional braking system where pads contact both sides of the brake disc at different radial positions. The outside pads contact the outer region while inside pads contact the inner region, utilizing the dimensional space around the brake disc to multiply the effective braking force without increasing motor size.
2Force
If large motor torque is used to generate large braking force, then braking force is improved, but device size increases
Solution Approach 1:
The braking function is segmented across multiple pads positioned at different locations around the brake disc. This allows the motor to operate at lower torque levels while the segmented pad configuration multiplies the effective braking force through distributed contact points on both sides of the disc.
Solution Approach 2:
The system utilizes the radial and axial dimensions of the brake disc by placing pads at different radii (outside and inside pads) and on both faces of the disc. This multi-dimensional arrangement enables force multiplication without requiring a larger motor, thereby reducing the overall device volume.
3Force
If large motor torque is used to generate large braking force, then braking force is improved, but energy consumption increases
Solution Approach 1:
By segmenting the braking force generation across multiple pads, the system reduces the torque demand on the motor. The motor operates at lower power levels while the segmented pad configuration mechanically multiplies the force output, thereby reducing energy consumption for the same braking force.
Solution Approach 2:
The multi-dimensional pad arrangement allows the system to leverage mechanical advantage through the geometry of the lever arms and pad positions. This enables force multiplication without proportional increases in motor power consumption, improving energy efficiency.
4Force
If large motor torque is used to generate large braking force, then braking force is improved, but heat dissipation performance worsens
Solution Approach 1:
The braking heat generation is segmented across multiple pad-disc contact points distributed on both sides of the brake disc. This segmentation distributes the thermal load across a larger total surface area, improving heat dissipation capacity while maintaining the required braking force.
Solution Approach 2:
By utilizing both sides of the brake disc and multiple radial positions, the system increases the effective heat dissipation surface area. The thermal energy is distributed across more contact zones, preventing localized overheating and improving overall heat dissipation performance.
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 multi-pad design reduces the size and weight of the motor, improves fuel efficiency, and enhances heat dissipation while stably generating a desired large braking force from a small motor operation force, addressing the limitations of existing motor-driven brakes.
Implementation Method 1
Lever return springs are disposed between the outside lever and the inside lever and return the outside lever and the inside lever that may have come closer to each other.
Data Source
AI summary
An actuator-driven brake having a multi-pad, may include a torque member, a spindle that may be operated by a driving force from an actuator, a disc pressing assembly that may be pivotally coupled to the torque member and includes an outside lever and an inside lever, wherein each one end of the outside lever and the inside lever may be connected to the spindle and wherein the outside lever and the inside lever simultaneously press both sides of a brake disc by coming closer to each other when the spindle rotates, and a brake pad assembly that includes an outside pad attached to an inner side of the outside lever and an inside pad attached to an inner side of the inside lever.