Electric Disc Brake Connector for Rotational Force Control
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Solution Overview
Problem
Existing electric disc brakes face challenges in precise control of the rotating ramp plate for releasing parking brake force, leading to excessive rotational force delivery, potential component damage, and residual drag due to insufficient rotation, increasing manufacturing costs and risk of component damage.
Innovation Solution
The electric disc brake incorporates a connector that delivers rotational force only in the direction of the parking brake generation, using a rotatably coupled output gear and a friction member to prevent excessive force transmission and ensure smooth brake release, with a dual-spring mechanism to maintain disc-pad distance and prevent unnecessary friction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the rotating ramp plate is directly engaged with the output gear to receive rotational force, then the parking brake force can be applied or released, but precise control is required to equalize rotation amounts and additional sensors are needed, increasing manufacturing cost
Solution Approach 1:
A connector is introduced as an intermediary component between the output gear and the rotating ramp plate. The connector rotatably couples to the output gear and delivers rotational force to the rotating ramp plate only in the direction of parking brake generation, eliminating the need for additional sensors and complex control systems while maintaining reliable brake force application and release
2Ease of operation
If the parking brake force is released with insufficient rotation amount of the rotating ramp plate, then the brake can be released, but a drag phenomenon occurs due to continuous contact between the disc and friction pad
Solution Approach 1:
The connector acts as a mediator that ensures complete rotation of the rotating ramp plate during brake release. By rotatably coupling to the output gear and properly transmitting rotational force, the connector eliminates residual brake force that causes drag, ensuring the friction pad completely disengages from the disc while maintaining smooth operation
3Ease of operation
If excessive rotational force is delivered upon releasing the parking brake force, then the brake can be released, but the ball may escape from the ramp unit or excessive weight is applied to internal components causing damage
Solution Approach 1:
The connector serves as a protective intermediary between the output gear and the ramp unit. It delivers rotational force only in the direction of parking brake generation and blocks excessive force transmission in the release direction, preventing ball escape and protecting internal components from damage while enabling smooth brake release
Solution Approach 2:
The connector converts the potentially harmful excessive rotational force during brake release into a beneficial unidirectional force transmission mechanism. By allowing rotation only in the brake generation direction, it transforms what could be a damaging force into a controlled mechanism that protects the ramp unit and internal components
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 prevents component damage, reduces manufacturing costs, and eliminates drag by ensuring precise control of the rotating ramp plate, allowing for smooth brake operation and reduced wear, while maintaining effective brake force application.
Implementation Method 1
a friction member provided at the connector to have a rotational resistance against the output gear
Implementation Method 2
a first elastic member provided in a first spring case to provide an elastic force to the pushrod, and a second elastic member provided in a second spring case to provide an elastic force to the pushrod
Data Source
AI summary
An electric disc brake is disclosed. An electric disc brake comprises a caliper housing configured to include a cylinder at which a piston is installed to be reciprocally movable by a brake hydraulic pressure, an adjuster arranged inside the piston, a pushrod provided inside the cylinder, an actuator configured to decelerate a rotational force according to an activation of a motor to output the decelerated rotational force through an output gear so as to pressurize the piston, and a ramp unit installed inside the cylinder and configured to receive the decelerated rotational force from the actuator to pressurize the pushrod to the piston so as to prevent rotation of the pushrod.