Planet Carrier Output Toothing for Lower-Cost Brake Actuation
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Solution Overview
Problem
Conventional braking force generators for motor vehicles require high manufacturing costs due to the need for additional gear wheels with low component tolerances to house the output toothing, which complicates the production process.
Innovation Solution
Integrating the output toothing directly into the planet carrier of the planetary gear set, eliminating the need for an additional gear wheel and allowing for a more cost-effective and space-efficient design, with the planet carrier being made of plastic for easier manufacturing and precise actuation through a multi-stage transmission unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If an additional gear wheel is mounted on the planet carrier to provide output toothing, then the braking force generator can be actuated, but the manufacturing costs increase and component tolerances must be kept low
Solution Approach 1:
The output toothing is integrated directly into the planet carrier structure, merging the function of the planet carrier with the function of the output gear wheel. This eliminates the need for a separate additional gear wheel, reducing component count and manufacturing complexity while maintaining the necessary actuation function.
Solution Approach 2:
The planet carrier is designed to serve multiple functions: it supports the planet wheels, provides structural connection to the sun wheel, and simultaneously provides the output toothing for actuation. This multi-functionality reduces the overall component count and simplifies the manufacturing process.
2Volume of moving object
If an additional gear wheel is used for output toothing, then the transmission function is achieved, but the space requirement increases
Solution Approach 1:
By integrating the output toothing directly into the planet carrier, the patent eliminates the need for an additional separate gear wheel component. This merging of functions reduces the overall volume and space requirements of the transmission unit while maintaining the necessary mechanical advantage and actuation capability.
3Ease of manufacture
If the planet carrier is made of plastic with integrated output toothing, then manufacturing cost decreases, but manufacturing precision requirements increase
Solution Approach 1:
The patent changes the material parameter of the planet carrier from metal to plastic, which enables integrated manufacturing of the output toothing through injection molding. This material change allows for cost-effective production while the molding process inherently provides sufficient precision for the application, eliminating the need for separate high-precision gear manufacturing and assembly.
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 approach reduces manufacturing costs and allows for precise actuation of the hydraulic piston, enhancing the efficiency and cost-effectiveness of the braking system while maintaining stability through the use of a metallic support rod.
Implementation Method 1
an electric motor, which includes a rotor and at least one motor winding, the rotor being situated on the drive shaft in a rotatably fixed manner and being rotatable via an energization of the motor winding
Implementation Method 2
a transmission unit, which operates between the drive shaft and the actuating element in such a way that the actuating element is displaced during a rotation of the drive shaft, the transmission unit including a planetary gear set
Data Source
AI summary
A braking force generator for a braking system. The braking force generator includes a drive shaft, rotatably mounted in a housing, an electric motor, which includes a rotor and at least one motor winding, an actuating element, which is displaceably mounted, and a transmission unit, which operates between the drive shaft and the actuating element in such a way that the actuating element is displaced during a rotation of the drive shaft. The transmission unit includes a planetary gear set encompassing a sun wheel connected to the drive shaft in a rotatably fixed manner, a rotatably mounted planet carrier, at least one planet wheel rotatably mounted at the planet carrier, and an output toothing assigned to the actuating element. The output toothing is formed in a lateral wall of an end area of the planet carrier facing away from the electric motor.