Brake Caliper Helical Connection Mounting for Coaxial Alignment
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Solution Overview
Problem
The assembly of the helical connection mechanism in electromechanical disc brake calipers is complicated due to potential misalignment with the longitudinal axis, which affects the connection between the drive member and the electric motor.
Innovation Solution
A helical connection mechanism with rotational stopping and axial holding means, comprising a plate and axial extensions, ensures the sleeve and drive member are coaxially aligned and rotationally locked to the piston, facilitating assembly by cutting, bending, and stamping a metal sheet.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the helical connection mechanism is assembled without rotational stopping means, then the assembly process is simpler, but the alignment between the drive member and electric motor becomes inaccurate
Solution Approach 1:
The plate with notches is pre-formed and attached to the sleeve before assembly, establishing the rotational stopping positions in advance. This preliminary preparation ensures that when the mechanism is assembled, the alignment is automatically correct without requiring complex adjustment procedures during assembly.
Solution Approach 2:
The plate with notches acts as an intermediary element between the sleeve and the piston. It mediates the rotational positioning by providing notches that engage with ribs on the piston, thereby ensuring accurate alignment of the drive member with the electric motor while maintaining relatively simple assembly procedures.
2Manufacturing precision
If a complex rotational stopping mechanism is used, then the alignment precision is improved, but the manufacturing cost and device complexity increase
Solution Approach 1:
Instead of making the entire mechanism complex, the solution applies local quality by adding only specific features (notches on the plate and corresponding ribs on the piston) at the critical locations where rotational stopping is needed. The rest of the mechanism remains simple and easy to manufacture.
Solution Approach 2:
The invention changes the parameter of rotational freedom to rotational discretization by introducing notches at specific angular positions. This parameter change enables precise coaxial alignment through the engagement of notches with ribs, while the overall manufacturing complexity remains low because the notches are simply cut or formed features on an existing plate.
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 mechanism simplifies the assembly process, allowing for accurate alignment and reduced manufacturing costs, enabling automated mounting and improved vehicle stability.
Implementation Method 1
means for rotationally stopping the sleeve in the piston, said stopping means also ensuring holding of the sleeve and the drive member in a position coaxial to the piston
Implementation Method 2
The actuator has an output shaft coupled to a driver or drive member forming part of a helical type connection located in the cylindrical housing and partly in the piston, to be interposed between the actuator and the piston head. When the actuator is activated, it exerts a torque via its output shaft, which is transformed into a pressing force by a helical connection mechanism
Data Source
AI summary
A helical connection mechanism for an electromechanical brake piston is configured to be mounted in the piston, including a sleeve and a drive member cooperating by a helical connection of longitudinal axis (AX), and a locking structure for rotationally locking the sleeve relative to the piston about the longitudinal axis (AX) and for axially holding the mechanism. The locking structure includes a plate attached to the sleeve and extending orthogonally to the longitudinal axis (AX), at least three axial extensions cooperating with an axial wall of the piston and at least one radial shape cooperating with the axial wall of the piston.