Electromechanical Brake Stopper for Pad Retraction Limits
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional electromechanical brake systems face issues with operational stability due to excessive retraction of brake pads, leading to wear, collision, and stuck phenomena between components during maintenance, which affects durability and reliability.
Innovation Solution
An electromechanical brake system with a stopper mechanism that restricts the allowable retraction range of the ball screw shaft and brake pad, using mechanical elements to prevent excessive separation and collision, and includes a controller to detect and stop motor operation when the retraction range is exceeded.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If the brake pad is allowed to retract freely for maintenance purposes, then the brake pad can be separated from the disc for replacement, but excessive retraction causes wear, collision, and stuck phenomena between component elements
Solution Approach 1:
The stopper is pre-positioned to prevent excessive retraction of the ball screw shaft before it can cause harmful effects. By anticipating the potential for over-retraction during maintenance operations, the stopper provides preliminary counter-action that limits the retraction distance, thereby preventing wear, collision, and stuck phenomena while still allowing sufficient separation for brake pad replacement.
Solution Approach 2:
The stopper acts as an intermediary mechanical element between the ball screw shaft and the actuator housing. It mediates the retraction motion by providing a physical barrier that limits the maximum retraction distance, thus protecting the ball screw shaft and other component elements from harmful effects while maintaining the functionality of the brake system.
2Ease of operation
If the ball screw shaft retracts excessively to separate the brake pad from the disc, then maintenance can be performed, but component elements experience wear and collision reducing product lifespan
Solution Approach 1:
The stopper provides preliminary protection by limiting the retraction distance of the ball screw shaft before excessive separation can occur. This pre-established mechanical constraint prevents the ball screw shaft from retracting beyond the safe limit, thereby avoiding wear and collision that would reduce product lifespan while still enabling sufficient brake pad separation for maintenance operations.
3Ease of repair
If no retraction limit is imposed on the ball screw shaft, then the brake pad can be fully separated for maintenance, but stuck phenomena occur between component elements reducing operational stability
Solution Approach 1:
The stopper provides preliminary prevention against stuck phenomena by limiting the retraction distance of the ball screw shaft. This mechanical constraint ensures that component elements remain within their operational ranges, preventing stuck phenomena that would compromise operational stability while still allowing sufficient separation for maintenance accessibility.
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 enhances operational reliability by preventing component collisions, facilitates smooth maintenance, and improves durability and stability by limiting the separation distance of brake pads from the disc.
Implementation Method 1
a ball nut that rotates by receiving the power from the reduction gear unit, a ball screw shaft that engages with the ball nut and advances or retreats by rotation of the ball nut in both directions
Implementation Method 2
the actuator housing may include a stopper that is provided to be able to contact at least a portion of a rear surface or a rear end portion of the ball screw shaft and restricts an allowable retraction range of the ball screw shaft
Data Source
Figure 1
Figure 2
Figure 3
AI summary
An electromechanical brake system may include a footer that is provided to advance and retreat, a motor that provides power, a reduction gear unit that reduces and transmits the power of the motor, a power conversion unit that receives the power reduced by the reduction gear unit, converts a rotational motion into a linear motion, and provides the power to the footer, an actuator housing, and a stopper that is provided to be in contact with at least a portion of a rear surface or a rear end portion of the ball screw shaft and restricts an allowable retraction range of the ball screw shaft or a maximum separation range of the brake pad with respect to a disc.