Wet Brake Clutch Cooling and Counterforce Structure
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Solution Overview
Problem
Existing vehicle brake systems for electric vehicles lack efficient heat management and counterforce mechanisms, leading to potential damage and reduced performance during braking.
Innovation Solution
A wet brake clutch system with a toroidal piston design, cooling ports, and a counterforce mechanism using an axially extended portion of the clutch housing, which provides a balanced force during clutch pack compression.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a conventional brake system is used without efficient heat management, then the structure is simpler, but heat accumulation causes potential damage and reduced performance
Solution Approach 1:
The brake system is segmented into multiple functional components: clutch pack with alternating friction and steel plates, toroidal piston, cooling ports, and counterforce mechanism. This segmentation allows each component to handle specific aspects of heat management and braking function independently, improving heat dissipation efficiency while maintaining manageable system complexity
Solution Approach 2:
The system uses a toroidal piston that receives pressurized fluid through a fluid port to displace the piston and compress the clutch pack. This hydraulic mechanism provides controlled force application for braking while enabling efficient heat management through the integrated cooling fluid circulation system
2Temperature
If cooling ports and cooling fluid circulation are added to manage heat, then heat management improves, but device complexity increases
Solution Approach 1:
The cooling system is merged with the clutch housing structure. Cooling ports are integrated directly into the clutch housing, allowing cooling fluid to circulate through the clutch pack. This integration provides efficient heat management while minimizing additional structural complexity, as the cooling function is combined with the existing housing rather than adding separate cooling components
3Force
If a counterforce mechanism using axially extended portion is implemented, then braking performance and balance improve, but device complexity increases
Solution Approach 1:
The clutch housing includes an axially extended portion that provides a counterforce to balance the forces generated during clutch pack compression. This counterforce mechanism, integrated into the housing structure, improves braking performance and force balance while minimizing additional complexity by utilizing the existing housing geometry rather than adding separate counterweight components
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 system effectively manages heat through cooling fluid circulation, reduces rotational drag with spring-loaded clutch plates, and provides a balanced counterforce to enhance braking performance and durability.
Implementation Method 1
a cooling fluid towards the clutch pack
Implementation Method 2
effectively manages heat through cooling fluid circulation
Implementation Method 3
the piston is sealed to the inner circumferential surface and the outer circumferential surface. In an example embodiment, the toroidal portion has a fluid port for receiving a pressurized fluid for displacing the piston
Implementation Method 4
a plurality of springs disposed between individual clutch plates of the first plurality of clutch plates, or individual clutch plates of the second plurality of clutch plates
Data Source
AI summary
A braking system for a vehicle includes a clutch. The clutch includes a rotational axis, a clutch housing, arranged to be rotationally fixed relative to the vehicle and sealed to an axle shaft end, a clutch carrier arranged to be rotationally fixed to a first drive portion of the axle shaft end, a clutch pack and a piston for compressing the clutch pack to brake the axle shaft end. The clutch pack includes a first plurality of clutch plates, rotationally fixed to the clutch housing, and a second plurality of clutch plates intermixed with the first plurality of clutch plates and rotationally fixed to the clutch carrier. The clutch may also include a plurality of springs disposed between individual clutch plates of the first plurality of clutch plates, or individual clutch plates of the second plurality of clutch plates.