Brake Caliper Sleeve Integration for Actuator Stability

Solution Overview

Problem

The existing actuator assemblies for vehicle brakes require a separate guide sleeve for linear guidance of the actuating slide, increasing production costs and complexity.

Innovation Solution

An actuator assembly where the sleeve-like portion for guiding the actuating slide is formed integrally within the brake calliper, eliminating the need for a separate guide sleeve, and incorporating an electric motor with a gear unit and spindle drive for smooth and stable movement of the brake pad between retracted and extended positions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a separate guide sleeve is used for linear guidance of the actuating slide, then the guidance stability is improved, but the production cost and device complexity increase

Engineering Contradiction:

Improveguidance stabilityVSAvoidnumber of components

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The guide sleeve function is merged with the brake caliper by forming a sleeve-like portion integrally in the brake calliper. The running face for linear guidance of the actuating slide is formed directly in the brake calliper, eliminating the need for a separate guide sleeve component while maintaining guidance stability.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The brake calliper is designed to serve multiple functions: it provides structural support, houses the brake disc space, and incorporates the running face for guiding the actuating slide. This multi-functional design reduces the total number of components needed in the system.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If a separate guide sleeve is used for linear guidance of the actuating slide, then the guidance stability is improved, but the production cost increases

Engineering Contradiction:

Improveguidance stabilityVSAvoidproduction cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The guide sleeve function is merged with the brake caliper by forming a sleeve-like portion integrally in the brake calliper. The running face for linear guidance of the actuating slide is formed directly in the brake calliper, eliminating the need for a separate guide sleeve component while maintaining guidance stability.

Inventive Principle:

Principle #5Merging (Combining)

3Device complexity

If the sleeve-like portion is formed integrally in the brake calliper, then the device complexity is reduced, but the manufacturing precision requirement increases

Engineering Contradiction:

Improvenumber of componentsVSAvoidrunning face machining precision

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The guide sleeve function is merged with the brake caliper by forming a sleeve-like portion integrally in the brake calliper. The running face for linear guidance of the actuating slide is formed directly in the brake calliper, eliminating the need for a separate guide sleeve component while maintaining guidance stability.

Inventive Principle:

Principle #5Merging (Combining)

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

This solution reduces production costs and complexity while ensuring stable guidance of the actuating slide, achieving a compact and cost-effective design with reduced friction and reliable force transmission.

Implementation Method 1

The actuating slide is received in the sleeve-like portion and is guided linearly on the running face

Methodology Applied

Scientific EffectFriction: Friction

Implementation Method 2

the actuator assembly comprises an electric motor which is coupled for drive purposes to the actuating slide via a gear unit and a spindle drive

Methodology Applied

Scientific EffectMechanical Advantage: Mechanical Advantage

Data Source

PatentUS20230151862A1Actuator assembly for a vehicle brake

Publication Date: 2023.05.18 ZF ACTIVE SAFETY GMBH

AI summary

An actuator assembly for a vehicle brake is described, with a brake calliper in which a space is formed for a brake disc, and an actuating slide for a brake pad. The actuating slide can be moved optionally between a retracted position and an extended position. In the brake calliper, adjoining the space, a sleeve-like portion is formed with a running face for the actuating slide. The actuating slide is received in the sleeve-like portion and is guided linearly on the running face.