Brake Actuator Lever Layout for Compact Wheel-End Packaging
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Solution Overview
Problem
Existing braking systems for commercial vehicles face significant space constraints due to the arrangement of actuators, leading to collisions and limited lever size, especially when incorporating a parking brake function, and require improved flexibility and reduced installation space.
Innovation Solution
A braking system with decoupled brake actuators arranged at different sides of a lever, allowing for offset orientations and flexible lever geometry, reducing axial and radial installation space and enabling efficient actuation without collisions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If actuators are arranged in a conventional configuration (axial or radial brake), then braking function is achieved, but significant axial or radial installation space is consumed
Solution Approach 1:
The patent transitions from conventional axial or radial actuator arrangements to a configuration where actuators are positioned at different sides of the lever with offset orientations. This dimensional repositioning allows the actuators to operate in previously unused spatial zones, significantly reducing the axial and radial installation space while maintaining full braking functionality.
Solution Approach 2:
The braking system is segmented into independent actuator units positioned at different sides of the lever. Each actuator can be independently arranged and oriented, allowing flexible spatial distribution that minimizes the overall installation footprint while preserving individual actuation capabilities for service and parking brake functions.
2Volume of moving object
If actuators are positioned closer together to reduce space, then installation space is reduced, but collisions between actuators or with wheel components occur
Solution Approach 1:
The actuators are positioned asymmetrically at different sides of the lever with offset orientations rather than symmetrically on the same side. This asymmetric arrangement naturally separates the actuators in space, eliminating collision risks with wheel rims and axle bodies while allowing the overall brake assembly to occupy less installation space.
3Force
If lever size is increased to improve braking performance, then braking effectiveness is improved, but space constraints limit the maximum lever size
Solution Approach 1:
By repositioning actuators to different sides of the lever with offset orientations, the patent creates additional spatial freedom that allows the lever to be sized optimally for braking performance without being constrained by the limited space between knuckle and rim or axle and rim that plagues conventional configurations.
4Volume of moving object
If actuators are arranged in series in a common housing, then compact arrangement is achieved, but separation of service brake and parking brake portions is not possible
Solution Approach 1:
The braking system is divided into separate service brake and parking brake portions with their own independent actuators positioned at different sides of the lever. This segmentation allows each brake portion to be independently optimized, positioned, and oriented, providing versatility in arrangement while still achieving a compact overall configuration.
Solution Approach 2:
The lever mechanism serves as a universal interface that can accommodate multiple types of actuators (service brake actuator and parking brake actuator) with different orientations and positions. This multi-functional design allows both brake portions to operate independently through the same lever system, providing adaptability while maintaining compactness.
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 solution provides a more compact braking system with improved space utilization, reduced dynamic load on guidance, and enhanced flexibility in actuator positioning, optimizing brake mechanism performance.
Implementation Method 1
a lever (32) that is configured such that it transfers a force exerted by the first brake actuator (38) or the second brake actuator (40) to the stationary brake element
Implementation Method 2
the braking pads and the caliper generate a clamping force that acts on the brake disc such that relative movement, in particular relative rotation between the brake disc and the braking pads are slowed down by friction between the brake disc and the braking pads
Data Source
AI summary
A braking system for a vehicle, includes: a rotatory braking element that is fixedly connected to a wheel or wheel axle in a manner to rotate conjointly with the wheel having a rotational plane, a stationary braking element that is fixedly connected relative to a vehicle chassis so as not to rotate conjointly with the wheel, a first brake actuator that is configured to actuate the stationary braking element so as to urge the stationary braking element towards the rotatory braking element, a second brake actuator that is configured to actuate the stationary braking element so as to urge the stationary braking element towards the rotatory braking element, and a lever that is configured such that it transfers a force exerted by the first brake actuator or the second brake actuator to the stationary brake element. The first brake actuator is connected to the lever via a first connection portion and the second brake actuator is connected to the lever via a second connection portion such that the second brake actuator operates decoupled from the first brake actuator when the second brake actuator is actuated.