The electric parking brake actuator sector is positioned in a highly competitive industrial context, characterized by the presence of numerous global players. Despite this strong competition, the market is continuously expanding due to the growing adoption of automated braking systems. What makes this segment particularly interesting is that, unlike other automotive components undergoing radical transformation with the advent of electric vehicles, the parking brake actuator continues to maintain its relevance regardless of the vehicle's powertrain.
In this scenario, FAIST Control Systems approach has focused on optimizing the product's features without compromising its core performance. Our mission was to develop an actuator that not only meets established performance standards but also offers significant advantages in terms of production efficiency, flexibility, and sustainability. This approach was driven by the desire to create a product that stands out not only for its operational capabilities but also for its ability to adapt to an ever-evolving industrial environment, and it led us through the following developments.
Design optimization
Designing an efficient electric parking brake actuator requires careful consideration of every detail. One of the main challenges is optimizing the shape to minimize assembly complexity. A simplified design not only reduces production time but also lowers costs and improves the overall quality of the final product.
During the development phase, engineering and design teams worked closely to create a shape that combined functionality and efficiency. Using advanced CAD modeling software, numerous design variations were analyzed. The final choice was a modular approach that integrated various functions into a few key components, thereby reducing the need for complex joints and fasteners.
A practical example of this optimization is the simplification of assembly and anchoring points. Reducing the number of screws and connections not only improved assembly efficiency but also contributed to better structural strength. Additionally, eliminating unnecessary elements reduced the potential for errors during production, ensuring consistent product quality.
From a commercial perspective, reducing assembly complexity translates to a significant competitive advantage. A leaner and faster production allows for a quicker response to market demand, increasing penetration capacity across different regions and market segments. This results in higher productivity and lower production costs, factors that positively impact profit margins.
Materials and mechanical strength
Another crucial area we focused on was shape optimization to achieve more efficient material use without compromising the actuator's mechanical strength. Reducing the overall weight and optimizing the distribution of forces were central to a development process based on advanced simulations.
The use of finite element analysis (FEA) software allowed FAIST CS’ engineering team to test various stress and load scenarios on the actuator, identifying critical areas and optimizing the geometry accordingly. This type of analysis helped pinpoint solutions that balance weight reduction with the need to maintain a robust structure.
Optimized material use not only has a positive impact on production costs but also on the environment. Reducing the material needed to manufacture the actuators results in lower resource consumption and decreased energy use during production. In a sector increasingly focused on environmental issues, offering a product that minimizes environmental impact adds value that can positively influence brand perception and consumer choice.
Motor Sizing
The motor is a central component of the electric parking brake actuator, and its sizing represents a crucial challenge for developers. An oversized motor leads to unnecessarily high costs, while an undersized one could compromise system performance.
To find the right balance, the team conducted extensive studies on motor sizing, using dynamic simulations to analyze system behavior under various operating conditions. These studies helped select materials and configurations that maximized energy efficiency while maintaining the torque and durability needed for safe operation.
A key aspect of sizing was the choice of materials for windings and magnets. The use of innovative materials allowed for reduced energy loss and increased overall motor efficiency. This not only kept costs under control but also enhanced the actuator's longevity, ensuring consistent performance over time.
Scalability
Finally, scalability was a key success factor in making this actuator suitable for a wide range of applications and markets. The ability to adapt the base design to motors with different performance levels allowed for the development of a versatile product.
The modular architecture of the design enabled customization of the actuator without the need for complete redesigns. This flexibility allows FAIST CS Business Unit to respond quickly to the specific requirements of different market segments, offering actuators with tailored performance for various types of vehicles, from light to heavy-duty models.
The development of FAIST Control Systems’ electric parking brake actuator has focused on maintaining performance while optimizing key features to meet the demands of an expanding yet highly competitive market. Through careful design and an integrated approach based on shape optimization, efficient material use, targeted motor sizing, and scalability, it was possible to create a product distinguished by quality, efficiency, and versatility.
This actuator represents a state-of-the-art solution that meets the current needs of the automotive industry and offers significant, not only meeting market standards but setting a new benchmark for the future of electric actuator development.
