Brake Caliper Flange Layout for Vibration-Resistant Motor Mounting
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Solution Overview
Problem
Existing braking systems in electromechanical brakes face issues with mechanical fatigue and insufficient fixing strength due to the large and heavy motors, which lead to potential motor damage and failure under vibration conditions.
Innovation Solution
A brake caliper design that incorporates a caliper flange with a double through-hole structure, allowing for direct fixation of the motor on the caliper body, thereby distributing motor stress uniformly and enhancing vibration resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the motor is fixed using a flange and screws at the output end housing, then the motor can be mounted on the caliper body, but the motor end experiences significant vibration amplitude and mechanical fatigue due to the cantilever beam structure
Solution Approach 1:
The caliper flange is segmented into multiple fixing points (first fixing point and second fixing point) distributed across the flange structure. This segmentation allows the motor housing to be anchored at multiple locations, transforming the cantilever beam structure into a supported structure that reduces vibration amplitude and prevents mechanical fatigue at the motor end.
Solution Approach 2:
The fixing structure transitions from a single-point or linear fixation to a two-dimensional distributed fixation pattern on the caliper flange. The first and second fixing points are positioned at different locations on the flange, creating a more stable spatial arrangement that reduces vibration and improves motor reliability under vibrational conditions.
2Ease of manufacture
If the motor is mounted with the fixing point at the opposite end of the motor, then the motor can be connected to the caliper body via the housing, but the motor end becomes suspended and susceptible to mechanical fatigue
Solution Approach 1:
The caliper flange acts as an intermediary structure between the motor and the caliper body. By providing multiple fixing points on the flange, it mediates the connection in a way that distributes vibration forces and prevents the motor end from being suspended, thereby reducing vibration damage while maintaining assembly ease.
3Power
If the motor has a large size and high center of gravity, then the motor can provide sufficient braking force, but the fixing strength between the output end housing and caliper flange becomes insufficient
Solution Approach 1:
The caliper flange is designed in advance with predetermined first and second fixing points positioned to optimally support the motor's weight and braking forces. This preliminary structural preparation ensures that when the motor is mounted, the fixing points are already in optimal positions to distribute the loads, preventing fixing strength insufficiency despite the motor's large size and high center of gravity.
Data Source
AI summary
A brake caliper comprising a brake caliper body and an actuator, the actuator comprises a housing and a motor, the brake caliper body is equipped with a caliper flange, which has a double through-hole structure, the double through-hole structure comprises a motor fixing flange hole and a conversion mechanism fixing flange hole, and the motor fixing flange hole is arranged adjacent to the conversion mechanism fixing flange hole, a first fixing point and a second fixing point for installing the housing are arranged on the caliper flange, the first and the second fixing point are located on an external surface of the brake caliper body in an offset manner from the center line of the caliper flange, and the motor fixing flange hole is located between the conversion mechanism fixing flange hole and the second fixing point.