Vehicle Friction Brake System with Nested Wear Compensation
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Solution Overview
Problem
Friction brake systems for vehicles, particularly those used in front wheels, face challenges in compact installation and interference with other components, requiring a robust and efficient solution for reliable operation and pad wear compensation.
Innovation Solution
A friction brake system comprising a first gear unit for converting rotary motion into braking motion and a second gear unit for pad wear compensation, with a spindle and nut mechanism that allows for compact and robust design, enabling separate braking and pad wear compensation operations with independent stroke lengths, and includes a ball-in-ramp gear or ball-screw configuration for efficient conversion and reduced motor power requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional brake caliper design is used for front wheels, then braking function is achieved, but interference with steering mechanism and other components occurs due to limited installation space
Solution Approach 1:
The second gear unit for pad wear compensation is nested within the first gear unit for braking motion conversion. The spindle and nut mechanism is positioned inside the housing that contains the ball-in-ramp gear, allowing both functions to share the same installation space without interfering with steering components.
Solution Approach 2:
The brake system is divided into two independent gear units: the first gear unit (ball-in-ramp mechanism) for braking motion and the second gear unit (spindle-nut mechanism) for pad wear compensation. This segmentation allows each unit to have independent stroke lengths and be optimized for its specific function while fitting within constrained space.
2Adaptability or versatility
If separate mechanisms for braking and pad wear compensation are used, then independent stroke lengths are achieved, but device complexity increases
Solution Approach 1:
Both the first gear unit for braking and the second gear unit for pad wear compensation share a common housing and are driven by a single electric motor through a differential mechanism. This merging reduces overall system complexity while maintaining independent stroke control through the differential's inherent mechanical properties.
Solution Approach 2:
The differential mechanism serves multiple functions: it distributes power to both gear units, enables independent stroke lengths through its mechanical design, and provides a compact means of achieving both braking and pad wear compensation from a single motor drive.
3Area of stationary object
If compact design is implemented to fit limited space, then component interference is reduced, but manufacturing complexity increases
Solution Approach 1:
The nested arrangement of the spindle-nut mechanism within the ball-in-ramp gear housing creates a compact overall size that fits limited installation spaces. While the internal arrangement is complex, the external dimensions are minimized, and the nested structure actually simplifies assembly by providing a self-contained unit.
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 achieves reliable and compact braking operations, suitable for challenging spaces, with efficient pad wear compensation and reduced component interference, enabling effective braking even in limited installation areas.
Implementation Method 1
a first gear unit (10) having a first member (11, 12) and a second member (11, 12), wherein the first gear unit (10) is configured for converting a rotary motion of the first member (11, 12) into a braking motion of the second member (11, 12)
Implementation Method 2
a second gear unit (15) having a spindle (20) and nut (16) for converting a rotary motion into a linear motion for pad wear compensation
Implementation Method 3
the second member of the first gear unit and the nut of the second gear unit are or may be mechanically coupled such that, during the braking motion, the second member of the first gear unit pushes against the nut of the second gear unit to press the brake pad against a friction surface
Data Source
AI summary
A friction brake system comprises a first gear unit having a first member and a second member, the first gear unit is configured for converting a rotary motion of the first member into a braking motion of the second member, the first member is configured such that the rotary motion may be driven by an electric motor, the brake system further comprises a second gear unit having a spindle and nut for converting a rotary motion into a linear motion for pad wear compensation, the spindle is connectable to a brake pad, the second member of the first gear unit and the nut of the second gear unit are or may be mechanically coupled such that, during the braking motion, the second member of the first gear unit pushes against the nut of the second gear unit to press the brake pad against a friction surface.