Brake Caliper Torque Distribution for Uneven Piston Loads
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Solution Overview
Problem
Existing brake systems require multiple motors to create and release clamping force, which increases weight, cost, and packaging space, and fail to efficiently distribute torque based on load or resistance differences among brake pistons due to uneven wear, internal component inefficiencies, and system degradation.
Innovation Solution
A brake system with a torque distributing assembly that includes a motor, first and second rotary to linear stage mechanisms, and a gear assembly to distribute torque evenly among multiple brake pistons, adjusting torque supply based on load differences to ensure synchronized clamping force application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple motors are used to create and release clamping force on multiple brake pistons, then braking performance is improved, but weight, cost, and packaging space increase
Solution Approach 1:
The patent combines multiple motor functions into a single motor by using a torque distributing assembly with planetary gears. The single motor drives multiple brake pistons through the gear mechanism, eliminating the need for multiple separate motors while maintaining the ability to create and release clamping force on multiple pistons simultaneously
Solution Approach 2:
The single motor with torque distributing assembly serves multiple functions: it can drive multiple brake pistons, distribute torque based on load conditions, and adapt to uneven wear patterns. The planetary gear system enables one motor to perform the work of multiple motors while adding intelligence through load-sensitive torque distribution
2Reliability
If multiple motors are used to create and release clamping force, then braking performance is improved, but cost increases
Solution Approach 1:
The patent merges multiple motor units into a single integrated motor-gear assembly. This reduces the total component count, simplifies manufacturing processes, and lowers overall system cost while maintaining the functional capability to actuate multiple brake pistons independently through the planetary gear mechanism
3Reliability
If multiple motors are used to create and release clamping force, then braking performance is improved, but packaging space increases
Solution Approach 1:
The planetary gear mechanism enables a nested arrangement where multiple brake pistons are driven from a central motor location. The gear teeth and carriers are arranged concentrically around the motor shaft, allowing compact integration of multiple drive functions within a small volume that would be exceeded by multiple separate motors
4Stability of the object's composition
If torque is distributed evenly among brake pistons, then synchronized clamping force is achieved, but uneven wear and load differences cannot be compensated
Solution Approach 1:
The torque distributing assembly uses dynamic load distribution through planetary gears where torque automatically flows to paths of least resistance. This dynamic behavior allows the system to adapt in real-time to uneven wear patterns and load differences among brake pistons, compensating for variations without active control while maintaining overall synchronized clamping force
Solution Approach 2:
The system changes the torque parameter distribution dynamically based on load conditions. The planetary gear mechanism allows torque magnitude to vary automatically across different piston paths based on resistance, enabling compensation for wear and variations by adjusting torque allocation rather than maintaining fixed equal distribution
5Weight of moving object
If a single motor is used to drive multiple brake pistons, then weight and cost are reduced, but torque distribution control becomes more complex
Solution Approach 1:
The planetary gear assembly acts as an intermediary mechanism that automatically performs torque distribution based on load conditions. This mechanical mediator eliminates the need for complex electronic control systems, sensors, and actuators that would otherwise be required to manage torque distribution from a single motor to multiple pistons
Solution Approach 2:
The torque distributing assembly is self-regulating, automatically directing torque to brake pistons based on their instantaneous load conditions without external control input. The planetary gear mechanism inherently responds to load variations and distributes torque accordingly, making the system self-service and eliminating complex control requirements
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 system reduces the need for multiple motors, optimizes torque distribution, and maintains consistent clamping force despite uneven wear or system variations, enhancing braking performance and reducing weight and cost.
Implementation Method 1
a gear assembly that includes one or more large gears and one or more smaller gears or gears that are generally the same size
Implementation Method 2
a first set of planet gears supported on respective first axles; a second set of planet gears supported on respective second axles
Data Source
AI summary
A brake system (10) comprising: a brake caliper (12) supporting a brake pad (14), and having a first brake piston (24) and a second brake piston (28) that are configured to move the brake pad; a first rotary to linear stage mechanism (32) connected to the first brake piston, and a second rotary to linear stage mechanism (34) connected to the second brake piston; a motor (42) configured to generate torque; a torque distributing assembly (40) configured to receive torque from the motor and then distribute the torque from the motor to the first rotary to linear stage mechanism to move the first brake piston and/or to the second rotary to linear stage mechanism to move the second brake piston; wherein the torque distributing assembly comprises: i) a first driving gear (44) connected to the first rotary to linear stage mechanism; ii) a second driving gear (46) connected to the second rotary to linear stage mechanism; iii) a first set of planet gears (72) supported on respective first axles (74); iv) a second set of planet gears (98) supported on respective second axles; and v) a first carrier plate (88) having a plurality of support features each configured to support a respective one of the first axles and a respective one of the second axles.