Split Drive Housing for Lightweight Electromechanical Brakes
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Solution Overview
Problem
Existing electromechanical brakes for motor vehicles are not economically viable and have high weight due to the use of heavy materials and complex manufacturing processes.
Innovation Solution
The electromechanical brake is designed with a separate drive housing and brake clamp, allowing for the use of different materials and manufacturing processes, including deep-drawing, to reduce weight and production costs, with the drive housing divided into two parts for improved assembly and material efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the brake clamp and drive housing are made as a single integrated component using heavy cast material to absorb braking forces, then the structural strength and reliability are improved, but the weight and production cost increase significantly
Solution Approach 1:
The brake assembly is divided into separate components: the brake clamp (brake caliper) and the drive housing are manufactured as distinct parts. The brake clamp is made from heavy cast material to absorb braking forces, while the drive housing is made from lighter material. This segmentation allows each component to be optimized for its specific function, reducing overall weight while maintaining structural strength where required.
2Stability of the object's composition
If the drive housing is made as a single integrated component to accommodate all components, then the structural integrity is improved, but the manufacturing complexity and material usage increase
Solution Approach 1:
The drive housing is segmented into a first housing part and a second housing part that are connected together. The first housing part accommodates the transmission unit and can be manufactured using more economical processes with lighter material, while the second housing part accommodates the spindle drive unit and is connected to the brake clamp. This segmentation simplifies manufacturing by allowing different production methods and material selections for different sections, reducing overall material usage and production complexity.
3Force
If heavy cast material is used for the entire brake assembly to ensure strength, then the load-bearing capacity is improved, but the production cost and manufacturing complexity increase
Solution Approach 1:
Different materials with appropriate properties are used in different locations based on local requirements. The brake clamp, which requires high strength to absorb braking forces, is made from heavy cast material. The drive housing, which has lower structural requirements, is made from lighter material. This local quality approach ensures load-bearing capacity is maintained where needed while reducing overall production cost and material usage.
Data Source
AI summary
An electromechanical brake for a motor vehicle. The electromechanical brake includes an electric motor which drives a spindle drive unit via a transmission unit, via which spindle drive unit a brake actuator is axially movable for braking. A drive housing which accommodates at least the transmission unit and the spindle drive unit is provided. The drive housing is provided as a separate part to a brake clamp encompassing a brake disc and is connected to the brake clamp. The drive housing is formed by two interconnected housing parts, at least the transmission unit being arranged in a first housing part and at least the spindle drive unit being arranged in a second housing part.