Electric Brake Load Sensor Contacts for Easier Assembly Phasing
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Solution Overview
Problem
The assembly of components in existing electric brake devices is hindered by the need for precise alignment and phasing, which affects productivity.
Innovation Solution
The electric brake device incorporates a transmission mechanism that converts rotary motion into linear motion, with a sensor to detect pressing load, and a housing and case design that allows for relative rotation during assembly, ensuring electrical connections remain intact despite phase changes, facilitating assembly by allowing for mechanical and electrical connections to be made without interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If components are assembled with precise alignment and phasing requirements, then the mechanical connection between rotational section and transmission mechanism is reliable, but the assembly work becomes complex and productivity decreases
Solution Approach 1:
The patent applies the dynamics principle by making the electrical connection flexible rather than rigid. The contact section is designed to maintain electrical connection through relative rotation between housing and case, allowing the system to adapt to phase changes during assembly without requiring precise alignment. This dynamic connection approach resolves the contradiction by eliminating the need for precise phasing while maintaining connection reliability.
Solution Approach 2:
The patent changes the parameter of electrical connection from fixed/rigid to flexible/adaptive. By designing the contact section with annular or arc-shaped contacted section that can accommodate rotational movement, the electrical connection parameter is changed to allow relative rotation. This parameter change enables assembly without precise alignment while maintaining reliable electrical connection.
2Stability of the object's composition
If the housing and case are firmly assembled, then the structural stability is improved, but the ability to rotate relative to each other for phasing adjustment is reduced
Solution Approach 1:
The patent applies dynamics by creating a semi-rigid connection that allows controlled movement. The housing and case are designed to be assembleable with moderate firmness, allowing relative rotation during the phasing adjustment process. Once phased correctly, the structure maintains sufficient stability for operation. This resolves the contradiction by making the connection dynamically adjustable during assembly but stable during operation.
Solution Approach 2:
The patent applies preliminary action by allowing the housing and case to be preliminarily assembled in a loose state that permits relative rotation. This preliminary assembly stage enables phasing adjustment before final tightening. The preliminary action of assembling without firm fixation allows ease of operation for phasing, while subsequent final assembly provides the required structural stability.
3Reliability
If the contact section is designed for precise alignment, then the electrical connection reliability is improved, but the tolerance to relative rotation between housing and case is reduced
Solution Approach 1:
The patent applies dynamics by designing the contact section to dynamically adapt to relative rotation. The contacted section with annular or arc shape allows the contact section to maintain electrical connection even when the housing and case rotate relative to each other. This dynamic design maintains electrical connection reliability while accommodating rotational movement, resolving the contradiction between reliability and adaptability.
Solution Approach 2:
The patent applies dimensionality change by transitioning from a point or linear contact to an annular or arc-shaped contacted section. This dimensional change from 0D/1D to 2D contact area provides tolerance to relative rotation while maintaining electrical connection. The increased dimensional footprint of the contact interface allows angular variation without losing connection, resolving the contradiction.
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 design simplifies the assembly process by allowing for relative rotation of housing and case components, reducing the need for precise alignment and phasing, thereby improving manufacturing efficiency and tolerance.
Implementation Method 1
converts rotary motion transmitted by the transmission mechanism from rotary motion of a rotational section into linear motion of a linear motion section in the linear motion conversion mechanism
Implementation Method 2
a sensor that detects a pressing load of the friction member against the rotary body and outputs a signal corresponding to the detected pressing load
Implementation Method 3
The other of the output section and the connection section has a contact section that electrically connects the output section and the connection section by contacting the contacted section
Data Source
AI summary
An electric brake device has: a housing that stores a load sensor and holds a rotational section of a linear motion conversion mechanism to be rotatable; and a case assembled to the housing. The case holds a transmission mechanism, which transmits rotary motion of an electric motor, to be rotatable, and the rotational section of the linear motion conversion mechanism mechanically meshes with the transmission mechanism. In such an electric brake device, a first terminal that has an annular shape and is arranged around a rotation axis of the rotational section of the linear motion conversion mechanism is installed on the load sensor, and a second terminal electrically connected to the first terminal by contact with the first terminal is installed in the case.