Brake Assembly Dynamic Clearance Adjustment via Electric Actuator
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Solution Overview
Problem
Existing brake assemblies lack an efficient mechanism to adjust running clearance dynamically, leading to inconsistent braking performance due to wear of brake friction materials, and require complex mechanical systems for actuation and adjustment.
Innovation Solution
A brake assembly with an air-operated actuator and an electrically operated adjuster mechanism, utilizing a planetary gear box and motor to adjust the running clearance by extending or retracting the adjuster mechanism, which is controlled by a position sensor and microprocessor to maintain optimal brake pad engagement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a mechanical wear sensor system relying on progressive movement of internal brake mechanism is used, then brake pad wear can be monitored, but the system becomes complex and requires progressive movement which may not be reliable
Solution Approach 1:
The patent replaces the mechanical wear sensor system with an electronic actuator system (electric motor or voice coil) that directly adjusts the brake pad position. This substitution eliminates the need for complex mechanical wear sensing mechanisms while achieving reliable wear compensation through electronic control based on wear sensor feedback.
Solution Approach 2:
The brake assembly incorporates an automatic adjustment system where the actuator self-regulates brake pad clearance based on feedback from wear sensors. The system automatically compensates for friction material wear without requiring manual intervention, maintaining optimal braking performance through self-service adjustment.
2Ease of operation
If an electric motor-driven adjuster mechanism is used, then running clearance can be adjusted, but the device complexity increases
Solution Approach 1:
The patent replaces complex mechanical adjuster mechanisms with electronic actuators (electric motors or voice coils) that provide precise control of brake pad clearance. This substitution simplifies the overall system by using electronic control instead of mechanical linkages, gears, and adjustment devices while improving adjustment precision and ease of operation.
Solution Approach 2:
The actuator system changes the physical state or parameters of the brake assembly by precisely controlling the position of brake pads through electronic means. The system adjusts clearance parameters dynamically based on wear feedback, maintaining optimal braking characteristics without complex mechanical adjustment mechanisms.
3Reliability
If brake friction materials wear away progressively, then braking performance degrades, but frequent replacement increases downtime
Solution Approach 1:
The patent implements a dynamic adjustment system that continuously or periodically adjusts brake pad clearance to compensate for friction material wear. The actuator system dynamically maintains optimal running clearance throughout the service life of the brake pads, ensuring consistent braking performance without requiring frequent manual intervention or replacement.
Solution Approach 2:
The automatic adjustment system provides self-service by continuously monitoring wear through sensors and autonomously adjusting brake pad position to maintain optimal clearance. This eliminates the need for frequent manual maintenance interventions and extends the effective service life of brake friction materials while maintaining reliable braking 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
This solution ensures precise adjustment of running clearance, minimizing downtime by allowing easy module replacement and maintaining consistent braking performance despite brake pad wear, while reducing maintenance complexity and extending service life.
Implementation Method 1
wiring 58, a planetary gear box 60, a first gear 62, a second gear 64
Implementation Method 2
The actuator 32 is a mechanically operated actuator, in this case an air operated actuator
Implementation Method 3
an electric motor 25, an output element in the form of a gear 54
Data Source
Figure 1~3
Figure 2
AI summary
A module including a module housing enclosing an electric motor, an output element mounted externally of the module housing, the output element being operably coupled to the electric motor and the module housing including an electrical interface for electrically coupling the motor to one or more components mounted externally of the module housing.