Electromechanical Brake C-Ring Assembly for Secure Caliper Joining
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Solution Overview
Problem
Existing electromechanical brakes for motor vehicles are difficult and costly to assemble due to complex designs and material constraints.
Innovation Solution
The brake caliper housing and brake clamp are designed as separate components connected via a C-shaped ring, allowing for tool-free assembly and utilizing positive-locking elements like knurls to set angular alignment, with grooves and retaining rings to absorb opposing forces, and a forming process for cost-effective production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the brake caliper housing and brake clamp are designed as separate components, then ease of manufacture and assembly is improved, but device complexity increases
Solution Approach 1:
The brake caliper housing and brake clamp are designed as separate components that can be manufactured independently using different materials and processes. This segmentation allows each component to be optimized for its specific manufacturing requirements, improving overall ease of manufacture while the modular design actually reduces complexity compared to a monolithic design.
2Ease of operation
If a C-shaped ring is used to connect the brake caliper housing and brake clamp, then assembly ease is improved, but connection strength may be reduced
Solution Approach 1:
The C-shaped ring is designed with a flexible cross-section that allows it to be compressed during assembly to pass through grooves in both the brake caliper housing and brake clamp. Once assembled, the ring expands to provide a secure mechanical connection. This flexible design enables tool-free assembly while maintaining adequate connection strength for the application.
3Reliability
If positive-locking elements are added to block rotation, then reliability of angular positioning is improved, but device complexity increases
Solution Approach 1:
The positive-locking elements are integrated directly into the grooves of the brake caliper housing and brake clamp, combining the connection function and the angular positioning function into a single structural feature. This merging approach ensures reliable angular positioning without adding separate, complex locking mechanisms.
Data Source
AI summary
An electromechanical brake for a motor vehicle. The electromechanical brake includes a brake clamp, which at least partially surrounds a brake disk, and a brake caliper housing, in which an adjusting unit driven by an electric motor is arranged, via which adjusting unit a braking force can be applied to a brake piston, so that a brake pad can be applied to the brake disk for braking. The brake caliper housing and the brake clamp are formed as separate components, wherein the brake caliper housing and the brake clamp each form a groove in a connecting region, wherein a C-shaped ring is provided, which is partially arranged in both grooves and blocks a relative movement of the brake clamp to the brake caliper housing at least when the braking force is applied.