Electromechanical Brake Actuator Cam Coupling for Compact Integration
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Solution Overview
Problem
Existing electromechanical brake actuators require large installation space and complex designs, making them incompatible with existing brake systems and necessitating costly redesigns, while also requiring high drive power and component complexity.
Innovation Solution
A coupling mechanism with a movably guided coupling element along a cam track converts a uniform drive movement into a sectionally non-uniform adjustment movement of the brake plunger, utilizing a non-linear transmission element that is compact and modular, allowing integration with conventional brake systems and reducing drive power requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If a cam disk with predetermined outer contour is used to generate non-uniform adjustment movement, then the brake plunger achieves varying adjustment speed, but the installation space requirement increases
Solution Approach 1:
The cam track is divided into multiple sections (first cam track section, second cam track section, third cam track section) with different transmission ratios. This segmentation allows the brake plunger to achieve varying adjustment speeds in different phases of operation without requiring a large overall cam disk structure, thereby reducing installation space while maintaining speed control.
Solution Approach 2:
The coupling element is movably guided along the cam track rather than being rigidly fixed, allowing dynamic adaptation of the transmission ratio throughout the adjustment range. This dynamic configuration enables non-uniform adjustment speed control while using a more compact cam track design compared to traditional fixed cam profiles.
2Adaptability or versatility
If a ramp drive and threaded drive with different transmission ratios are used, then non-linear transmission behavior is achieved, but the design complexity increases and integration with existing brake systems becomes difficult
Solution Approach 1:
The coupling mechanism with the movably guided coupling element serves multiple functions: it provides non-linear transmission behavior, enables integration with existing brake systems through standardized mounting interfaces, and maintains compact dimensions. This multi-functional design eliminates the need for separate ramp and threaded drives, reducing overall complexity while preserving adaptability.
Solution Approach 2:
The coupling element acts as an intermediary between the drive means and the brake plunger, translating drive movement into adjusted plunger movement with non-linear transmission. This intermediary mechanism simplifies the overall design compared to direct coupling while maintaining compatibility with existing brake system architectures.
3Speed
If a non-linear transmission mechanism is used to convert uniform drive movement into non-uniform adjustment movement, then the brake plunger achieves sectionally varying speeds, but the drive power requirement increases
Solution Approach 1:
The transmission ratio between the drive means and brake plunger is varied continuously through the different cam track sections rather than being fixed. This parameter change allows the system to achieve high adjustment speeds when needed (first cam track section) while reducing drive power requirements in other phases (second and third cam track sections), optimizing the power-speed trade-off.
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 solution achieves a compact design that fits within limited vehicle space, is easily integrated with existing brake systems, and reduces drive power needs, while maintaining effective braking performance.
Implementation Method 1
a coupling mechanism with a movably guided coupling element along a cam track converts a uniform drive movement into a sectionally non-uniform adjustment movement of the brake plunger
Data Source
Figure 1~2
Figure 3a~4
AI summary
The invention relates to an electromechanical brake actuator (10) for a brake of a vehicle (100), in particular for a commercial vehicle disc brake (1), comprising a substantially translationally movable brake plunger (14) for transmitting a pressure force (F) in the direction of a brake pad (6, 6'), a drive means (16) which is configured to generate a drive movement (A), preferably a rotary drive movement, and a coupling mechanism (18) which operatively connects the drive means (16) and the brake plunger (14) and is configured to convert the drive movement (A) of the drive means (16) into an adjusting movement (B) of the brake plunger (14).The coupling mechanism (18) has a coupling element (38) in contact with the brake plunger (14), which is movably guided along at least one cam track (40, 60) and is designed to convert the drive movement (A) acting on the coupling element (38) with a substantially uniform drive speed (A') into the adjusting movement (B) of the brake plunger (14) with a sectionally non-uniform adjusting speed (B').