Brake Actuator Angle Compensation for Lateral Load Decoupling
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Solution Overview
Problem
Existing brake actuators for friction brakes are susceptible to lateral forces, which cause tilting of the piston and require oversized gearboxes to accommodate these forces, leading to increased costs and complexity.
Innovation Solution
The integration of an angle compensation element, such as a ball joint or rolling bearing, decouples the rotational-to-translational gearbox from lateral forces, allowing the gearbox to be designed solely for axial loads, reducing the need for oversizing and enhancing cost-effectiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the gearbox is designed to accommodate lateral forces, then the brake actuator can handle tilting piston forces, but the gearbox becomes oversized and more expensive
Solution Approach 1:
The brake actuator is divided into two functional segments: the piston assembly with angle compensation capability and the gearbox for pure axial force transmission. The angle compensation element (ball joint or spherical bearing) separates the lateral force handling function from the gearbox, allowing each component to be optimized for its specific function without oversizing
Solution Approach 2:
An angle compensation element (ball joint or spherical bearing) is introduced as an intermediary between the piston and the gearbox. This intermediary component absorbs and compensates for lateral forces and piston tilting, preventing these forces from being transmitted to the gearbox, thereby allowing the gearbox to be sized only for axial loads
2Reliability
If the gearbox is oversized to accommodate lateral loads, then lateral forces can be handled, but manufacturing costs increase
Solution Approach 1:
The system is segmented into lateral force handling components (angle compensation element) and axial force transmission components (gearbox). This segmentation allows the gearbox to be manufactured at optimal size for axial loads only, reducing material usage and manufacturing costs while maintaining overall system reliability
Solution Approach 2:
The angle compensation element acts as a mediator that protects the gearbox from lateral loads. By introducing this intermediary component, the gearbox can be manufactured more cost-effectively without the need to oversize it for lateral force capacity, as the intermediary absorbs these forces before they reach the gearbox
3Productivity
If the piston is directly coupled to the gearbox, then axial force transmission is direct, but lateral forces cause piston tilting that affects the gearbox
Solution Approach 1:
An angle compensation element is introduced as an intermediary between the piston and gearbox. This intermediary maintains direct axial force transmission while simultaneously protecting the gearbox from lateral forces by allowing controlled piston tilting without transmitting these forces to the gearbox
Solution Approach 2:
The angle compensation element changes the mechanical parameters by allowing angular movement (tilting) of the piston while maintaining axial force transmission. This parameter change enables the piston to accommodate lateral forces through angular adjustment without transmitting these forces to the gearbox, thus protecting the gearbox while maintaining productivity
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 design ensures the gearbox is manufactured cost-effectively without oversizing, while maintaining the necessary axial force transmission, reducing wear and complexity, and improving the robustness of the brake actuator.
Implementation Method 1
an angle compensation element, such as a ball joint or rolling bearing, decouples the rotational-to-translational gearbox from lateral forces
Implementation Method 2
an angle compensation element, such as a ball joint or rolling bearing, decouples the rotational-to-translational gearbox from lateral forces
Implementation Method 3
a rotational-to-translational gearbox, for example a ball screw drive or a threaded drive
Implementation Method 4
a rotational-to-translational gearbox, for example a ball screw drive or a threaded drive
Implementation Method 5
generate a required contact force for generating friction between brake pads and a rotor of the friction brake
Data Source
AI summary
A brake actuator for a friction brake. The brake actuator includes a piston and a rotational-to-translational gearbox for converting a rotary motion of a drive into a linear motion of the piston. An angle compensation element for decoupling the translational component from transverse forces on the piston is arranged between a translational component of the gearbox and the piston.