Integrated Wheel Hub Drive Unit with Mechanical Brake
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Solution Overview
Problem
The existing separate units for electric drive and mechanical brake in commercial and rail vehicles are complex, costly, and inefficient due to redundant components and separate control systems, leading to space constraints and difficulties in coordinating braking processes.
Innovation Solution
Integration of the electric drive and mechanical brake into a single compact unit with shared components, including a common rotor and control device, allowing the electric drive to handle braking in generator mode with minimal mechanical intervention, and a vibration-decoupled shaft for efficient torque transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electric drive and mechanical brake are provided as separate units, then each unit can be independently controlled and maintained, but the system becomes complex, expensive, and space-consuming with redundant components
Solution Approach 1:
The patent combines the electric drive and mechanical brake into a single integrated drive unit, where the electric motor and mechanical brake share a common housing and mounting structure on the wheel hub. This merging eliminates redundant components and simplifies the overall system architecture while maintaining independent control capabilities through separate control units for each braking mode.
2Adaptability or versatility
If separate control units are provided for electric drive and mechanical brake, then each subsystem can be optimized independently, but the overall system requires more components and higher cost
Solution Approach 1:
The control unit is designed with multi-functionality to handle both electric drive control and mechanical brake control. It can operate in different modes (regenerative braking, friction braking, combined braking) and seamlessly switch between controlling the electric motor and the mechanical brake, thereby providing universal control capability without requiring separate dedicated control units for each function.
3Ease of manufacture
If electric drive and mechanical brake act on the same wheel through separate connections, then each connection can be optimized for its specific function, but installation space increases and coordination becomes difficult
Solution Approach 1:
The mechanical brake is nested within the electric drive unit structure. The brake caliper and braking elements are positioned inside or adjacent to the electric motor housing, sharing the same radial and axial space around the wheel hub. This nesting arrangement allows both connections to be optimized for their specific functions while occupying a compact combined footprint, significantly reducing installation space compared to separate external mounting.
4Ease of operation
If mechanical brake is used for all braking operations, then simple control is required, but wear increases and braking efficiency decreases
Solution Approach 1:
The patent replaces mechanical friction-based braking with electromagnetic braking through the electric motor operating in generator mode. During regenerative braking, the electric motor converts kinetic energy into electrical energy, providing wear-free braking action. The mechanical brake serves as a supplement for situations where regenerative braking is insufficient or unavailable, thereby minimizing wear and maximizing braking efficiency through intelligent mode selection.
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 integration reduces component count, saves space, simplifies control, minimizes wear, and enhances braking efficiency by leveraging the electric drive's generator mode for primary braking with mechanical assistance only when necessary, ensuring precise stopping and reduced oscillating mass.
Implementation Method 1
the electric drive to handle braking in generator mode
Implementation Method 2
a vibration-decoupled shaft for efficient torque transmission
Data Source
Figure 1
Figure 2
AI summary
The invention relates to a drive and deceleration unit (1) comprising a mechanical brake (12) and an electric drive (11), the mechanical brake (12) and the electric drive (11) being provided as a unit for acting on a single wheel connection (21). The invention further relates to method for the open-loop and/or closed-loop control of such a drive and deceleration unit (1).