Brake Device Piston Stroke Adjustment for Wear Compensation
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Solution Overview
Problem
The existing brake devices face challenges in maintaining optimal piston stroke and preventing excessive extension due to brake pad wear, leading to potential dragging and compromised brake performance.
Innovation Solution
A brake device with a hydraulic and electric unit configuration, featuring a piston return mechanism and a controller that adjusts the relative position of movable components based on wear indicators, ensuring the piston stroke remains within acceptable limits by integrating wear data and executing adjustments at appropriate times.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the clearance between the piston and brake pad is set to be narrow to prevent dragging, then brake feeling is improved, but the piston stroke becomes excessively large when the brake pad wears
Solution Approach 1:
The brake device dynamically adjusts the piston stroke by incorporating a adjusting mechanism that modifies the piston's movement range based on brake pad wear conditions. This allows the system to maintain optimal brake feeling while compensating for wear-induced stroke increases
Solution Approach 2:
The system uses wear detection means to monitor brake pad thickness and provides feedback to the control mechanism. Based on this feedback, the system automatically adjusts the piston stroke to maintain consistent brake performance throughout the brake pad's service life
2Reliability
If the piston stroke is limited to prevent excessive movement, then brake performance is maintained, but the adjustment mechanism becomes more complex
Solution Approach 1:
The brake device incorporates a self-adjusting mechanism that automatically compensates for brake pad wear without requiring manual intervention. The adjusting mechanism uses the existing brake operation forces to drive the adjustment, eliminating the need for separate power sources or complex control systems
Solution Approach 2:
The adjusting mechanism is integrated with the existing piston and brake assembly structures. The wear detection, adjustment control, and execution components are merged into the conventional brake system architecture, minimizing additional complexity while maintaining reliable performance
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
This configuration effectively reduces dragging and maintains optimal brake performance by adjusting the relative position of movable components in response to brake pad wear, ensuring consistent braking action and improved brake feeling.
Implementation Method 1
a biasing member that is arranged so as to make biasing force, oriented in a retreat direction, elastically act on the piston member in accordance with a relative advancement amount of the piston member with respect to the nut member
Implementation Method 2
an electric brake unit including a nut member that is configured to be relatively movable in a piston movement direction with respect to the piston member by a motor
Implementation Method 3
a hydraulic brake unit including a piston member that is configured to be movable by an action of brake fluid pressure and to press a friction member by advancement
Data Source
AI summary
A friction brake device for a vehicle includes: a hydraulic brake unit including a piston member for pressing a friction member by advancement; an electric brake unit including a nut member being relatively movable in a piston movement direction with respect to the piston member by a motor and for pressing the piston member by advancement; a piston return mechanism including a biasing member for making biasing force, oriented in a retreat direction, elastically act on the piston member in accordance with a relative advancement amount of the piston member with respect to the nut member; and a controller for controlling the motor. The controller determines whether an adjustment permission condition associated with a wear amount of the friction member is satisfied. When the condition is satisfied, the controller allows the motor to perform a relative position adjustment of the nut member with respect to the piston member.