Electric Disk Brake Connector for Unidirectional Force Transfer
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Solution Overview
Problem
Existing electric disk brakes face issues with excessive rotation force transfer to the rotating ramp plate when the parking brake force is released, leading to potential component damage and loss of balls from the ramp unit.
Innovation Solution
Incorporating a connector that connects the final output gear to the rotating ramp plate, with arc-shaped holes and protrusions, which allows rotation force transfer only in the direction of brake force generation, preventing excessive force transfer during brake release by rotating the connector and protrusions in opposite directions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the rotating ramp plate is directly connected to the final output gear to transfer rotation force, then the brake force generation is effective, but excessive rotation force during brake release causes component damage and ball escape
Solution Approach 1:
A connector is introduced as an intermediary component between the final output gear and the rotating ramp plate. This connector includes a connector body with a connector hole and a connector protrusion that engages with the gear. The connector acts as a mediator that allows unidirectional force transfer - it transmits rotation force from the gear to the ramp plate during brake application, but allows the ramp plate to rotate freely during brake release without transmitting excessive reverse forces, thus preventing component damage while maintaining effective brake force generation
Solution Approach 2:
The connector is designed with dynamic characteristics that allow it to adapt its engagement state based on the direction of rotation force. During brake application, the connector protrusion engages with the gear to transmit force to the ramp plate. During brake release, when excessive reverse rotation force occurs, the connector allows relative movement or disengagement, enabling the system to dynamically adjust its force transmission state to prevent damage while maintaining operational effectiveness
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
Prevents damage to internal components and maintains control over the actuator by ensuring rotation force is only transferred during brake force generation, effectively managing excessive rotation forces and preventing ball escape.
Implementation Method 1
an elastic member that is disposed in a spring case formed between an inner circumferential surface of the cylinder and the push rod and provides an elastic force to the push rod
Implementation Method 2
a connector having one end coupled to a rotating ramp plate of the ramp unit so that the connector is rotated together with the rotating ramp plate, and having the other end connected to a final output gear among a plurality of gears configured to decelerate a rotation force generated from the actuator so that the rotation force is transferred only in a direction in which a brake force is generated in the rotating ramp plate
Data Source
AI summary
Disclosed herein is an electric disk brake including: a carrier in which a pair of pad plates for pressing both sides of a rotating disk together with wheels are installed to make advance and retreat; a caliper housing that is slidably installed in the carrier and has a cylinder in which a piston is installed to make advance and retreat due to brake hydraulic pressure; an adjuster disposed in the piston; a push rod that is installed in the cylinder and is screw-coupled to the adjuster; a ramp unit that is installed to penetrate the rear of the cylinder, converts a rotation motion into a rectilinear motion by receiving a rotation force from an actuator that generates a parking brake force, and presses the push rod toward the piston; and an elastic member that is disposed in a spring case formed between an inner circumferential surface of the cylinder and the push rod and provides an elastic force to the push rod, further including a connector having one end coupled to a rotating ramp plate of the ramp unit so that the connector is rotated together with the rotating ramp plate, and having the other end connected to a final output gear among a plurality of gears configured to decelerate a rotation force generated from the actuator so that the rotation force is transferred only in a direction in which a brake force is generated in the rotating ramp plate, wherein at least one hole is spaced by a predetermined distance apart from a center of the connector in a radial direction and is formed in an arc shape, and protrusions are formed in the final output gear to penetrate the at least one hole and to rotate, and the connector includes: a first coupling part that penetrates a center of the final output gear and is coupled to the rotating ramp plate; and a second coupling part, which extends from the first coupling part in a radial direction and in which the at least one hole is formed in the radial direction of a center of the second coupling part.