Brake Caliper Spherical Adjustment for Ball Screw Alignment
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Solution Overview
Problem
Existing brake calipers in electromechanical braking systems face issues such as premature failure due to overturning moments, caliper body deformation, and brake pad eccentric wear, which cause misalignment and non-uniform force distribution in the motion conversion mechanism, and the systems are bulky and complex, making them unsuitable for mass production.
Innovation Solution
A brake caliper with a double-spherical assembly that allows for adjustment in rotation angle and radial displacement, incorporating an adjusting part that forms a spherical pair with mating parts to maintain alignment and uniform load distribution, reducing the impact of forces and minimizing axial height.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a ball screw is used in the motion conversion mechanism, then the structure is simple and cost-effective, but the ball screw is prone to failure due to overturning moments and misalignment
Solution Approach 1:
A spherical adjusting mechanism is introduced as an intermediary component between the ball screw and the brake pad assembly. This spherical mechanism absorbs and compensates for misalignment and deformation, protecting the ball screw from damaging overturning moments while maintaining the simplicity and cost-effectiveness of the ball screw design
Solution Approach 2:
The adjusting mechanism is designed with dynamic adjustment capability, allowing it to adapt to varying alignment conditions during braking operations. The mechanism can dynamically compensate for caliper body deformation and brake pad wear, maintaining optimal alignment with the ball screw throughout the service life
2Strength
If the outer diameter of the ball screw is increased to resist axial force, then the load-bearing capacity improves, but the overturning moment causes deflection and ball track deformation
Solution Approach 1:
The spherical adjusting mechanism serves as a mediator that isolates the ball screw from overturning moments. By allowing controlled deflection and adjustment at the spherical interface, the mechanism protects the ball screw and ball track from deformation while maintaining full axial load-bearing capacity
Solution Approach 2:
The adjusting mechanism provides preliminary compensation for misalignment and deformation before they can transmit damaging forces to the ball screw. This preemptive protection prevents the development of overturning moments that would otherwise cause ball track deformation
3Reliability
If a conical contact structure is used to compensate misalignment, then the alignment improves, but the diameter increases leading to a longer lever arm and larger overturning moment
Solution Approach 1:
A spherical contact surface is used instead of a conical surface for misalignment compensation. The spherical geometry provides effective alignment adjustment while maintaining a compact size, avoiding the increased diameter and longer lever arm that would result from a conical design
4Length of moving object
If the axial height of the brake caliper is reduced for compact layout, then the space efficiency improves, but the motion conversion mechanism has less space to accommodate adjustment mechanisms
Solution Approach 1:
The adjusting mechanism is nested within the existing brake caliper structure, utilizing available spaces efficiently. The spherical adjusting components are integrated into the motion conversion mechanism assembly, allowing compact layout without sacrificing adjustment functionality
Data Source
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AI summary
Disclosed in the present invention is a brake caliper, comprising an actuator, a brake caliper body, a motion conversion mechanism and an adjusting member provided in a force flow transmitted by an axial force between the actuator and a brake disc, wherein the adjusting member and paired members are movably connected, so that the motion conversion mechanism has a degree of freedom to adjust a rotation angle and radial displacement. According to the brake caliper of the present invention, the adjusting member is provided, so that the motion conversion mechanism has an adjustment space for the rotation angle and the radial displacement, and the influence of brake tangential force, brake pad eccentric wear and caliper body deformation on the motion conversion mechanism can be eliminated, thereby prolonging the service life of the motion conversion mechanism.