Brake Actuation Mechanism Using Ball Screw Drive

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Solution Overview

Problem

Existing disc brake actuation mechanisms for heavy load trucks and utility vehicles experience increased wear at the connection between the pin and recess during frequent brake actuations, compromising functional safety and service life.

Innovation Solution

A brake actuation mechanism incorporating a ball screw drive that converts translational movement into rotational movement, reducing friction and wear, and decoupling the amplification mechanism from the adjustment device, eliminating direct mechanical connections like pins and recesses.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If a pin or similar element is provided at a suitable point on the hollow shaft to be received by a recess in the lever, then the hollow shaft can be set in rotation by a pivoting movement of the lever, but the connection between pin and recess is subject to increased wear during frequent brake actuations

Engineering Contradiction:

Improvebrake actuationVSAvoidfunctional safety

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The patent replaces the direct mechanical pin-and-recess connection with a ball screw drive mechanism. The ball screw drive converts the linear movement of the lever into rotational movement of the hollow shaft through a ball screw and nut assembly, eliminating the need for direct contact between pin and recess. This substitution reduces friction and wear while maintaining the ability to set the hollow shaft in rotation during brake actuation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Ease of operation

If a pin or similar element is provided at a suitable point on the hollow shaft, then the hollow shaft can be set in rotation by a pivoting movement of the lever, but the service life is reduced due to wear

Engineering Contradiction:

Improvebrake actuationVSAvoidservice life

Core Design Contradiction:

Ease of operationVSDuration of action of moving object

Solution Approach 1:

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The ball screw and nut assembly act as an intermediary mechanism between the lever and the hollow shaft. Instead of direct contact, the ball screw drive transmits the motion and force from the lever to the hollow shaft through rolling contact balls, which significantly reduce wear compared to sliding or pivoting contact.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Force

If the amplification mechanism and thrust element are directly connected, then the clamping force can be transmitted, but friction and wear increase during frequent actuations

Engineering Contradiction:

Improveclamping forceVSAvoidfunctional safety

Core Design Contradiction:

ForceVSReliability

Solution Approach 1:

The patent replaces the direct mechanical connection between the amplification mechanism and thrust element with a ball screw drive. The ball screw and nut assembly transmit the clamping force while converting linear motion to rotational motion, reducing friction through rolling contact and eliminating wear-prone pin-and-recess connections.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 ball screw drive mechanism reduces wear and enhances service life by minimizing friction and drive power, allowing for precise adjustment with lower force expenditure and maintaining a compact design.

Implementation Method 1

A brake actuation mechanism incorporating a ball screw drive that converts translational movement into rotational movement, reducing friction and wear

Methodology Applied

Scientific EffectBall screw drive: Screw

Data Source

PatentUS11255394B2Disk brake and brake actuation mechanism

Publication Date: 2022.02.22 HALDEX AB

AI summary

The present invention concerns a brake actuation mechanism for a disc brake, in which a translational movement in the direction of the brake disc leads to a rotation of an input element of an adjustment device, the input element of the adjustment device being designed as part of a ball screw drive. Furthermore, the invention concerns a disc brake with such a brake actuation mechanism.