Brake Caliper Pad Thruster for Uniform Multi-Piston Pressure
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Solution Overview
Problem
Conventional brake devices experience uneven pressure distribution across brake pads due to uneven wear or manufacturing tolerances, leading to increased likelihood of piston breakage and reduced brake performance.
Innovation Solution
A brake device with a pad thruster that includes a conversion assembly to convert rotational motion into linear motion, featuring a bolt screw, movable nut, and pivotable linkage, which ensures even pressure distribution across multiple pistons, minimizing the risk of piston breakage and improving surface pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple pistons are used to press the brake pad, then the brake performance is improved, but the likelihood of piston breakage increases due to uneven pressure distribution
Solution Approach 1:
A linkage mechanism is introduced as an intermediary between the pistons and brake pad. The linkage includes a first arm connected to a first piston and a second arm connected to a second piston, with both arms pivoting about a common pivot point. This intermediary mechanism equalizes the force distribution to both brake pads, preventing excessive pressure on any single piston and reducing breakage risk while maintaining effective braking power.
2Device complexity
If a single piston is used to press the brake pad, then the device complexity is reduced, but the surface pressure uniformity on the brake pad deteriorates
Solution Approach 1:
The brake actuation system is segmented into multiple independent pistons (first piston and second piston), each acting on different portions of the brake pad through separate linkage arms. This segmentation allows for more uniform distribution of contact pressure across the brake pad surface, improving manufacturing precision and pressure uniformity compared to a single piston system.
3Manufacturing precision
If manufacturing tolerances of actuators are tight, then the pressure distribution across brake pads is more uniform, but the manufacturing cost increases
Solution Approach 1:
The linkage mechanism introduces dynamic adaptability to the system. The pivoting arms can rotate about the common pivot point, allowing the system to dynamically adjust and equalize forces between the two brake pads regardless of minor variations in piston positioning or brake pad wear. This dynamic compensation mechanism achieves uniform pressure distribution without requiring extremely tight manufacturing tolerances, thereby reducing manufacturing costs.
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 reduces piston breakage and enhances brake performance by ensuring uniform pressure application on the brake pads, even in the presence of uneven wear or manufacturing tolerances, while reducing manufacturing costs and noise.
Implementation Method 1
a bolt screw configured to rotate about an axis, and a movable nut connected to the bolt screw, wherein the movable nut may be moved along a longitudinal direction of the cylinder space by rotation of the bolt screw
Implementation Method 2
a pivotable linkage pivotably connected to a head of the movable nut. The movable nut may be moved along a direction of the cylinder space by rotation of the bolt screw, and the pivotable linkage may rotate about a vertical axis extending through the head of the movable nut
Implementation Method 3
a brake device used to slow or stop a moving vehicle, or to keep a vehicle stationary, brakes the vehicle by strongly pressing a circular brake disk, which rotates along with the wheels of the vehicle, against brake pads on both sides
Data Source
AI summary
A brake device includes a brake pad, a pad thruster connected to the brake pad to linearly move the brake pad, and a caliper body provided with a cylinder space allowing the pad thruster to be seated therein. The pad thruster may include a conversion assembly configured to convert rotational motion into rectilinear motion, and at least two pistons connected to one end of the conversion assembly. The conversion assembly is seated in the cylinder space, and the at least two pistons are positioned outside of the cylinder space.