Electromechanical Brake Ball-Screw Recirculation for Torque Conversion
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Solution Overview
Problem
Existing electromechanical brake systems face inefficiencies in converting motor torque to axial movement of brake pads due to complex and weight-resistant ball-screw designs, particularly in recirculating ball nut assemblies.
Innovation Solution
A ball-screw drive with a recirculating ball return system featuring a tube with deflectors and dimples that forms a bi-directional, continuous loop for ball circulation, combined with a helical track winding and a planetary gear stage to enhance torque conversion efficiency and reduce weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a complex ball-screw design with weight-resistant features is used, then reliability is improved, but device complexity increases
Solution Approach 1:
The ball-screw assembly is segmented into distinct functional components: the ball screw with exterior track winding, the ball nut with interior track winding, and the separate tube for ball recirculation. This segmentation allows each component to be optimized independently for its specific function while maintaining overall reliability without excessive complexity.
Solution Approach 2:
The ball recirculation function is extracted from the traditional integrated ball-screw design and implemented through a separate tube that extends through the recess. This extraction simplifies the main ball-screw structure while ensuring reliable ball recirculation, resolving the contradiction between reliability and complexity.
2Stability of the object's composition
If a traditional ball-screw design is used, then structural stability is maintained, but weight increases
Solution Approach 1:
The tube used for ball recirculation is designed as a thin-walled structure that provides sufficient structural stability for its function while minimizing weight. The tube extends through the recess in an unsupported manner, utilizing its flexibility and structural efficiency to maintain stability without adding excessive weight to the moving components.
3Ease of manufacture
If an unsupported tube is used for ball recirculation, then ease of manufacture is improved, but structural stability decreases
Solution Approach 1:
The unsupported tube is designed to perform its ball recirculation function through its own structural properties without requiring additional support structures or complex mounting mechanisms. The tube's geometry and material properties enable it to maintain sufficient stability while being easy to manufacture and install, resolving the contradiction between ease of manufacture and structural stability.
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 provides efficient conversion of motor torque to axial movement of brake pads, reduces system weight, and optimizes ball recirculation, enhancing the overall performance and efficiency of electromechanical brakes.
Implementation Method 1
A tube extends continuously through the recess between the openings and cooperates with the track windings to form a recirculation loop for the balls during brake application
Implementation Method 2
a ball screw rotatable about an axis and having an exterior track winding extending around the ball screw
Implementation Method 3
A ball-screw drive for an actuator assembly of a vehicle brake... efficient conversion of motor torque to axial movement of brake pads
Implementation Method 4
The first and second ends have deflectors for directing balls into and out of the respective first and second openings
Data Source
AI summary
A ball-screw drive for an actuator assembly of a vehicle brake includes a ball screw rotatable about an axis and having an exterior track winding extending around the ball screw from a first opening to a second opening. An inner recess extends into the ball screw and is connected to the first and second openings. A ball nut includes an interior track winding and is positioned over the ball screw so as to be movable along the axis in response to rotation of the ball screw for applying the vehicle brake. Balls are provided between the track windings. A tube extends continuously through the recess between the openings and cooperates with the track windings to form a recirculation loop for the balls during brake application.