Brake Actuator Assembly With Frame Webs for Load Transfer
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Solution Overview
Problem
Existing actuator sub-assemblies for vehicle brakes face challenges in resisting operational loads, particularly in transmitting torque and axial forces to the brake calliper without excessively loading the housing.
Innovation Solution
The actuator sub-assembly incorporates a plate-like frame portion with web-like continuations that extend towards the brake calliper, securely fixing the frame portion to the brake calliper and acting as a force transmission element to distribute axial forces and torque without overloading the housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the housing for the gear mechanism is produced as a cast component, then the capacity for resistance to operational loads is improved, but the production costs and weight increase
Solution Approach 1:
The housing is produced as a composite component by combining a plastics material housing with a metal reinforcement element (frame portion with web-like continuation). This composite structure provides the load-bearing capacity of metal while maintaining the cost-effectiveness and ease of manufacture of plastics molding, thereby resolving the contradiction between strength and manufacturing cost.
2Strength
If the housing for the gear mechanism is produced as a cast component, then the capacity for resistance to operational loads is improved, but the weight of the actuator sub-assembly increases
Solution Approach 1:
The composite construction using plastics material combined with a metal frame portion provides optimized weight distribution. The plastics housing keeps overall weight low while the strategically placed metal reinforcement element provides necessary load-bearing capacity, resolving the contradiction between strength and weight.
3Device complexity
If axial forces are transmitted via the housing to the brake calliper, then the force transmission path is simplified, but the housing becomes excessively loaded
Solution Approach 1:
The frame portion with web-like continuation acts as an intermediary element between the housing and the brake calliper. It provides a dedicated force transmission path for axial forces, preventing excessive loading of the housing while maintaining a relatively simple overall force transmission structure.
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 configuration effectively transmits axial forces and torque to the brake calliper, reducing the load on the housing and allowing for cost-effective production using plastics materials, while maintaining structural integrity and simplicity in assembly.
Implementation Method 1
axial forces are introduced from the frame portion via the web-like continuation into the brake calliper
Implementation Method 2
a torque and axial forces are primarily transmitted to the brake calliper
Data Source
AI summary
An actuator sub-assembly for an electromotive vehicle brake is set out, having a brake calliper, in which an intermediate space for receiving a brake rotor is provided. A spindle drive is also provided, which has a sliding actuation member for applying a brake pad to the brake rotor. The sub-assembly also includes an electro-motively driven spindle for axially moving the sliding actuation member, an electric motor which is drivingly coupled to the spindle by a gear mechanism unit, and a housing, in which the gear mechanism unit is accommodated. A plate-like frame portion, which has a receiving space for at least one gear stage of the gear mechanism unit is also arranged in the housing. Starting from the frame portion, at least one web-like continuation extends in the direction towards the brake calliper and is secured to the brake calliper.