Brake Actuator Spindle Locking Without Welded Joints
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Solution Overview
Problem
Conventional actuation devices for brake systems require costly and complex welding processes to create a rotationally fixed connection between the rotation-locking element and the threaded spindle, which increases production costs and assembly complexity.
Innovation Solution
A form-fitting connection is used to connect the rotation-locking element and the threaded spindle, utilizing driver elements and driver toothing to ensure a robust and uniform torque transmission, with the rotation-locking element made of plastic or metal and manufactured through injection molding or cold forming processes to reduce material and assembly costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding is used to create a rotationally fixed connection between the rotation-locking element and the threaded spindle, then a strong mechanical bond is achieved, but production costs and assembly complexity increase
Solution Approach 1:
The patent replaces the welding process (thermal/mechanical system) with a form-fitting connection system. The rotation-locking element features a form-fitting connection geometry that mechanically interlocks with the threaded spindle without requiring welding, thereby reducing production costs and assembly complexity while maintaining connection strength
Solution Approach 2:
The connection interface is segmented into specific geometric features (protrusions and recesses) that form the form-fitting connection. This segmentation allows for precise mechanical interlocking between the rotation-locking element and threaded spindle, eliminating the need for welding while ensuring a strong, rotationally fixed connection
2Strength
If welding is used to create a rotationally fixed connection, then a strong mechanical bond is achieved, but assembly complexity increases
Solution Approach 1:
The patent replaces the complex welding process with a simple form-fitting connection that requires no additional equipment or procedures. The geometric interlocking features enable direct assembly of the rotation-locking element to the threaded spindle, significantly reducing assembly complexity while maintaining connection strength
Solution Approach 2:
The form-fitting connection is designed to self-align and self-lock when the rotation-locking element is assembled to the threaded spindle. The geometric features automatically guide the components into proper alignment and secure the connection without requiring external intervention or complex assembly procedures
3Ease of manufacture
If a form-fitting connection with driver elements is used, then assembly is simplified and costs are reduced, but torque transmission robustness must be maintained
Solution Approach 1:
The patent applies local quality by concentrating the torque transmission function in specific driver elements (protrusions and recesses) within the form-fitting connection. These localized geometric features are designed with appropriate dimensions and orientations to handle the torque loads, ensuring robust torque transmission while maintaining the overall simplicity of the form-fitting connection
Solution Approach 2:
The form-fitting connection combines multiple geometric features (protrusions, recesses, driver elements) into a composite structural solution. This composite approach distributes the torque transmission across multiple contact points and geometric features, enhancing robustness while keeping the connection simple and cost-effective
Data Source
AI summary
An actuation device for a brake system. The actuation device includes: an electric machine, wherein a rotor of the electric machine is arranged on a rotatably mounted drive shaft in a rotationally fixed manner; a displaceably mounted pressure element; and a transmission device, using which the drive shaft is operatively connected to the pressure element, wherein the transmission device has a displaceable threaded spindle, wherein a rotation-locking element is rotationally fixed to the threaded spindle, and wherein the rotation-locking element interacts with a housing of the actuation device and/or with an element of the actuation device that is arranged on the housing in a fixed manner, in order to form an anti-rotation device for the threaded spindle. The rotationally-fixed connection between the rotation-locking element and the threaded spindle is formed by a form-fitting connection.