Electromechanical Brake Stopper for Controlled Pad Separation
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Solution Overview
Problem
Conventional electromechanical brake systems face challenges in maintaining operational stability and facilitating smooth maintenance, particularly due to excessive movement of brake pads during separation, which can lead to wear, collision, or stuck phenomena between components.
Innovation Solution
The electromechanical brake system incorporates a mechanical stopper mechanism that restricts the allowable retraction range of the ball screw shaft and the maximum separation distance of the brake pad from the disc, ensuring controlled movement and preventing collisions or sticking between components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the brake pad is allowed to separate excessively from the disc during maintenance, then maintenance accessibility is improved, but component wear and collision risk increase
Solution Approach 1:
The stopper is pre-positioned to prevent excessive retraction of the ball screw shaft before maintenance operations begin. By establishing a mechanical limit in advance, the system prevents the harmful condition (excessive separation causing wear and collision) from occurring, while still allowing sufficient travel distance for maintenance accessibility.
2Ease of repair
If the ball screw shaft retraction range is increased to facilitate brake pad removal, then maintenance ease is improved, but the risk of stuck phenomena between components increases
Solution Approach 1:
The stopper provides a pre-established mechanical boundary that prevents the ball screw shaft from retracting beyond the safe limit. This preliminary constraint allows maintenance personnel to remove brake pads with sufficient clearance while preventing the condition that would lead to stuck phenomena between components.
3Reliability
If mechanical elements are added to restrict ball screw shaft movement, then operational reliability is improved, but device complexity increases
Solution Approach 1:
The stopper function is extracted as a separate, dedicated component from the overall brake system. This modular approach allows the reliability function (restricting ball screw shaft movement) to be implemented with a simple, focused mechanical element rather than integrating complexity into existing components.
Solution Approach 2:
The stopper is positioned at a specific location where it contacts the ball screw shaft to provide the restriction function. This localized intervention achieves the reliability improvement without requiring system-wide modifications or multiple distributed mechanical elements throughout the brake assembly.
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 solution enhances operational reliability by preventing excessive movement of brake components, facilitating easier maintenance, and improving the durability and stability of the brake system.
Implementation Method 1
a ball nut that rotates by receiving the power from the reduction gear unit, a ball screw shaft that engages with the ball nut and advances or retreats by rotation of the ball nut in both directions
Implementation Method 2
an actuator housing that has the motor, the reduction gear unit, and at least a portion of the power conversion unit accommodated or supported therein and is mounted on a caliper housing, in which the power conversion unit may include... a ball screw shaft that engages with the ball nut and advances or retreats by rotation of the ball nut in both directions, and is connected to the footer, and the actuator housing may include a stopper that is provided to be able to contact at least a portion of a rear surface or a rear end portion of the ball screw shaft and restricts an allowable retraction range of the ball screw shaft
Data Source
AI summary
An electromechanical brake system may include a footer that is provided to advance and retreat, a motor that provides power, a reduction gear unit that reduces and transmits the power of the motor, a power conversion unit that receives the power reduced by the reduction gear unit, converts a rotational motion into a linear motion, and provides the power to the footer, an actuator housing, and a stopper that is provided to be in contact with at least a portion of a rear surface or a rear end portion of the ball screw shaft and restricts an allowable retraction range of the ball screw shaft or a maximum separation range of the brake pad with respect to a disc.