Ball Nut Deflector Layout for Balanced Brake Actuator Loads
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Solution Overview
Problem
Existing ball nut assemblies in vehicle brake systems experience unbalanced bending moments due to unbalanced bearing forces, leading to noise, vibration, harshness, and wear, and are constrained by packaging size limitations.
Innovation Solution
The design incorporates multiple ball nut deflectors with specific acute angles and overlapping recirculation tracks to balance bending moments, reduce noise and vibration, and optimize packaging space, featuring a spindle with a ball nut supported by bearing elements and deflector structures that distribute forces evenly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If traditional ball nut assembly design is used, then the structure is simple, but unbalanced bearing forces cause unbalanced bending moments leading to noise, vibration, and wear
Solution Approach 1:
The ball nut assembly is segmented into multiple recirculation tracks (first, second, third, and fourth tracks) with bearing elements distributed across these tracks. This segmentation allows the bearing forces to be distributed more evenly around the ball nut, balancing the bending moments and reducing noise, vibration, and wear caused by unbalanced forces.
2Object-affected harmful factors
If ball nut assembly size is increased to improve bearing force balance, then bearing force balance improves, but packaging space requirements increase
Solution Approach 1:
The bearing elements are arranged in multiple recirculation tracks that extend in different spatial dimensions around the ball nut. This multi-dimensional arrangement allows the bearing forces to be balanced in multiple directions simultaneously without requiring a proportional increase in the overall assembly volume, thus maintaining compact packaging while achieving force balance.
3Object-affected harmful factors
If multiple ball nut deflectors are added to balance bending moments, then noise and vibration reduce, but device complexity increases
Solution Approach 1:
The ball nut deflectors are designed to perform multiple functions: they guide the bearing elements through the recirculation tracks, support the ball nut, and balance the bending moments by distributing forces evenly. This multi-functionality reduces the need for additional separate components, thereby limiting the increase in device complexity while achieving noise and vibration reduction.
Data Source
AI summary
A ball nut assembly comprises a spindle having a longitudinal axis, a ball nut, and bearing elements supporting the ball nut on the spindle. First, second, third, and fourth ball nut deflectors are between the ball nut and the spindle. First, second, and third planes extend parallel to the axis. The first and fourth ball nut deflectors are in the first plane, the second ball nut deflector is in the second plane, the third ball nut deflector is in the third plane. Furthermore, the second and third ball nut deflectors are on opposite sides of the first plane. A first acute angle is between the first and second planes and a second acute angle is between the first and third planes.