Brake Caliper Linear Actuator With Nested Harmonic Drive Layout
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Solution Overview
Problem
Current electro-actuated brake caliper systems suffer from high complexity, large volume, and numerous components, leading to installation difficulties, increased mechanical clearance, and uncontrolled reversibility in case of failure.
Innovation Solution
A linear actuating device integrating a BLDC motor, wave generator, flex spline, harmonic reducer, and rotary-to-linear motion conversion device, which reduces the number of components and simplifies the layout, allowing for a modular design and improved integration with the brake caliper body.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional electro-actuated brake caliper systems are used, then braking function is achieved, but device complexity and number of components increase
Solution Approach 1:
The patent merges the motor, harmonic reducer, and linear motion conversion mechanism into a single integrated actuating device assembly. The motor (6) with drive shaft (7) directly connects to the wave generator (9) of the harmonic reducer (11), which in turn connects to the linear motion conversion device (12), eliminating the need for separate transmission components and simplifying the overall system architecture while maintaining reliable braking function.
Solution Approach 2:
The actuating device is designed as a universal module that can be applied to various brake caliper configurations. The integrated design with motor, harmonic reducer, and linear motion conversion makes it adaptable to different braking systems, serving multiple functions within a single component assembly.
2Power
If traditional transmission mechanisms are used, then torque multiplication is achieved, but volume and component dimensions increase
Solution Approach 1:
The patent employs a nested arrangement where the linear motion conversion device (12) is positioned inside the hollow drive shaft chamber (14) of the motor (6). The harmonic reducer (11) is integrated with the motor shaft, and the wave generator (9) is at least partially made in one piece with the rotating drive shaft (7). This nesting eliminates the need for separate housings and mounting structures, significantly reducing the overall volume of the actuating device while preserving torque multiplication capability.
3Reliability
If numerous components are integrated, then braking function is achieved, but mechanical clearance increases
Solution Approach 1:
By merging the motor, harmonic reducer, and linear motion conversion device into a single integrated assembly with common mounting structures and alignment features, the patent reduces the cumulative mechanical clearances that would exist between separate components. The direct connection of the wave generator (9) to the drive shaft (7) and the integrated housing eliminate intermediate interfaces, thereby reducing overall mechanical clearance and improving manufacturing precision.
4Reliability
If traditional actuation systems are used, then braking control is achieved, but response time increases
Solution Approach 1:
The patent extracts and eliminates intermediate transmission stages from traditional actuation systems. By using a harmonic reducer with direct motor coupling and integrating the linear motion conversion device inside the motor housing, the design removes unnecessary gears, shafts, and mounting interfaces that would introduce delays. This streamlined architecture reduces the time required for motor actuation to translate into brake pad movement, improving response time while maintaining reliable braking control.
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 achieves weight reduction, decreased component and volume dimensions, simplified integration, and enhanced mechanical reliability, while also reducing response times and noise, and enabling controlled reversibility without additional actuated units.
Implementation Method 1
a harmonic reducer (11) which is elastically deformed and rotated by said rotational wave generator (9)
Implementation Method 2
a rotary-to-linear motion conversion device (12) adapted to transform a rotary motion into a linear motion adapted to bias said at least one brake pad (3) to abut against said braking surface (4) along an axial direction (A-A)
Data Source
AI summary
A linear actuating device for a brake caliper adapted to bias at least one brake pad to abut against a braking surface of a brake disc is provided. The linear actuating device has a motor having a rotating drive shaft and a stator. The rotating drive shaft has a tubular body forming an inner drive shaft chamber. The rotating drive shaft is directly and operatively connected to a harmonic transmission. The harmonic transmission is directly and operatively connected to a rotary-to-linear motion conversion device adapted to transform a rotary motion into a linear motion. The rotary-to-linear motion conversion device is adapted to bias the least one brake pad to abut against the braking surface along an axial direction and is at least partially accommodated inside the inner drive shaft chamber.