Brake Piston Magnetic Retraction for Consistent Air Gap
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Solution Overview
Problem
Existing brake assemblies face challenges in efficiently retracting the brake piston during the release operation of an electric parking brake, leading to potential brake drag and inconsistent air gaps, which can affect braking performance.
Innovation Solution
Incorporating a magnet between the brake piston and a linearly movable structure, such as a spindle nut, to generate a magnetic field that actively retracts the brake piston during the release operation, ensuring precise movement and maintaining a consistent air gap.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a traditional mechanical retraction mechanism is used, then the structure is simple, but the brake piston retraction efficiency is insufficient leading to brake drag
Solution Approach 1:
The patent replaces the traditional mechanical retraction mechanism with a magnetic field-based system. A magnet mounted on the linearly movable structure generates magnetic force that acts on the brake piston, eliminating the need for complex mechanical components while achieving efficient and consistent piston retraction during brake release operation.
Solution Approach 2:
The patent changes the physical state and interaction mechanism by introducing magnetic field parameters. The magnet generates a magnetic field that creates attractive force on the brake piston, transforming the retraction mechanism from mechanical contact to magnetic field interaction, thereby improving retraction efficiency and consistency.
2Manufacturing precision
If no active retraction mechanism is used, then the device complexity is low, but the air gap consistency is poor affecting braking performance
Solution Approach 1:
The patent uses magnetic field interaction to replace mechanical retraction systems, providing precise and consistent control over brake piston position. The magnetic force ensures uniform air gap formation between brake pads and rotor, improving manufacturing precision without requiring complex mechanical adjustment mechanisms.
Solution Approach 2:
The magnetic retraction mechanism automatically adjusts the brake piston position during brake release operation. The magnet on the linearly movable structure continuously exerts magnetic force on the piston, enabling self-adjusting air gap maintenance without additional control systems or complex mechanical feedback mechanisms.
3Object-generated harmful factors
If a magnetic retraction mechanism is implemented, then the brake drag is reduced, but the device complexity increases
Solution Approach 1:
The patent eliminates brake drag by replacing mechanical contact-based retraction with a magnetic field-based system. The magnet generates non-contact attractive force on the brake piston, ensuring complete separation from the rotor during release operation, thereby eliminating friction and drag without requiring complex mechanical clearance adjustment mechanisms.
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 magnetic retraction mechanism improves brake piston retraction efficiency, reduces brake drag, and maintains a consistent air gap between the brake pad and rotor, enhancing braking performance and reliability.
Implementation Method 1
a magnet disposed between the brake piston and the linearly movable structure so that the brake piston is movable toward the linearly movable structure in response to linear movement of the linearly movable structure by magnetic field generated by the magnet
Implementation Method 2
the magnet may be mounted to the linearly movable structure, and the brake piston may have magnetically-attractive material attractable by the magnet so that an attractive magnetic force can be generated between the brake piston and the magnet mounted to the linearly movable structure
Data Source
AI summary
A brake assembly may comprise: a brake piston configured to be movable for a brake apply or release, the brake piston having an inner wall forming a piston cavity; a linearly movable structure positioned within the piston cavity of the brake piston; the linearly moveable structure configured to be linearly movable within the piston cavity in response to rotation of a rotatable structure operably coupled to the linearly movable structure; and a magnet disposed between the brake piston and the linearly movable structure so that the brake piston is movable toward the linearly movable structure in response to linear movement of the linearly movable structure by magnetic field generated by the magnet. The magnet may function to provide active retraction of the brake piston when the linearly movable structure moves in a brake release direction during a brake release operation.