Brake Actuator Gear Layout for Fewer Parts and Flexible Shafts
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Solution Overview
Problem
Existing brake actuators have a high number of parts, limiting design freedom and productivity.
Innovation Solution
A two-stage reduction structure using a crossed helical gear and planetary gear reduction units, with a motor and shafts arranged orthogonally or at arbitrary angles, reducing parts and enabling flexible power transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional brake actuator structure is used, then reliable braking function is achieved, but the number of parts is large, reducing productivity and increasing complexity
Solution Approach 1:
The patent combines the motor support and gear support into a single integrated housing structure. The housing simultaneously supports both the motor and the gear reduction mechanism, eliminating the need for separate support components and reducing the overall number of parts while maintaining structural integrity and functional reliability
2Reliability
If a conventional brake actuator structure is used, then reliable braking function is achieved, but the number of parts is large, increasing manufacturing cost
Solution Approach 1:
The patent integrates multiple support functions into a single housing component, reducing the total part count. This consolidation simplifies the manufacturing process, reduces assembly steps, and lowers manufacturing costs while ensuring the braking function remains reliable through the integrated structural design
3Power
If a worm gear reduction unit is used, then power transmission is achieved, but the shafts must be orthogonally engaged, limiting design freedom
Solution Approach 1:
The patent replaces the fixed orthogonal engagement of worm gears with a dynamic gear reduction mechanism that can adapt to various shaft angle configurations. The gear reduction unit can accommodate different angular relationships between motor shaft and output shaft, providing design flexibility while maintaining effective power transmission
4Force
If multiple gear devices are used for torque multiplication, then sufficient braking torque is achieved, but the number of parts increases, reducing productivity
Solution Approach 1:
The patent combines multiple gear reduction functions into a single integrated gear reduction unit. This unified structure achieves the necessary torque multiplication through internal gear arrangements while reducing the number of separate components, thereby simplifying assembly and improving manufacturing productivity without compromising braking torque performance
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
Reduces the number of parts, improves productivity through weight and cost savings, and enhances design flexibility by allowing non-orthogonal power transmission.
Implementation Method 1
a driving crossed helical gear (41) coupled to a shaft (31) of the motor (30), and a ring wheel (43) provided with a driven crossed helical gear (42) engaged with the driving crossed helical gear (41) on an outer circumference
Implementation Method 2
a planetary gear reduction unit including a sun gear (51) rotating together with the ring wheel (43), a ring gear (52) provided as an internal gear, a plurality of planetary gears (53) engaged with the sun gear (51) and the ring gear (52)
Data Source
AI summary
The present disclosure relates to an actuator for a brake device. The actuator includes a housing having a motor accommodating part and a gear accommodating part, a motor accommodated in the motor accommodating part, and a reduction device accommodated in the gear accommodating part, wherein the reduction device includes, a crossed helical gear reduction unit including a driving crossed helical gear coupled to a shaft of the motor, and a ring wheel provided with a driven crossed helical gear engaged with the driving crossed helical gear on an outer circumference thereof, and a planetary gear reduction unit including a sun gear rotating together with the ring wheel, a ring gear provided as an internal gear, a plurality of planetary gears engaged with the sun gear and the ring gear, and a carrier on which the plurality of planetary gears is rotatably supported and having an output shaft.