Electromechanical Brake System Modular Housing Design
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Solution Overview
Problem
Existing electromechanical brake systems face difficulties in maintenance due to the direct insertion of the linear motion mechanism into the caliper body, making it challenging to detach and reassemble components for maintenance, and the system lacks structural rigidity to handle axial reaction forces effectively.
Innovation Solution
The electromechanical brake system incorporates a linear motion mechanism housing and a reduction gear mechanism housing, both of which are designed as single assemblies with components assembled together, allowing for easy detachment and maintenance, and a housing-fixing plate that receives axial reaction forces, enhancing structural rigidity and facilitating easier assembly and disassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the linear motion mechanism is directly inserted into the caliper body, then the structure is simplified, but maintenance becomes difficult and assembly/disassembly is challenging
Solution Approach 1:
The caliper body is divided into separate functional modules: the linear motion mechanism housing containing the linear motion mechanism, and the reduction gear mechanism housing containing the reduction gear mechanism. These modules can be independently removed and maintained through the opening, simplifying the overall structure while enabling easy maintenance of individual components.
2Manufacturing precision
If the receiving hole is formed from the side closer to the brake disk, then the diameter reducing step can be formed, but the receiving hole cannot be accurately formed due to the claw portion position
Solution Approach 1:
Instead of forming the receiving hole from the side closer to the brake disk (conventional approach), the opening is formed from the side opposite to the brake disk. This inverted approach allows accurate formation of the opening without interference from the claw portion, while still achieving the desired functional outcome through the housing-fixing plate structure.
3Force
If the linear motion mechanism is supported by the diameter reducing step, then axial reaction force is received, but the linear motion mechanism interferes with the claw portion during insertion
Solution Approach 1:
The support function is segmented from the caliper body's claw portion to a dedicated housing-fixing plate. The linear motion mechanism housing is separately formed and then fixed to the caliper body, allowing the linear motion mechanism to be supported by the housing-fixing plate without interfering with the claw portion during insertion.
Solution Approach 2:
The linear motion mechanism housing acts as an intermediary component between the linear motion mechanism and the caliper body. It provides the support surface (housing-fixing plate) for receiving axial reaction forces while preventing direct interference between the linear motion mechanism and the claw portion during assembly.
4Productivity
If multiple components are assembled together as single assemblies, then maintenance efficiency is improved, but the initial assembly complexity increases
Solution Approach 1:
The brake system is segmented into modular assemblies (linear motion mechanism housing and reduction gear mechanism housing) that are pre-assembled as complete functional units. This segmentation enables easy maintenance by allowing entire assemblies to be removed and replaced as single units, while the modular structure actually simplifies the overall system architecture.
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 enables easy maintenance by handling the linear motion mechanism and reduction gear mechanism as single assemblies, ensuring the system's structural integrity to receive axial reaction forces, thus improving maintenance efficiency and system reliability.
Implementation Method 1
a linear motion mechanism configured to convert the rotation transmitted from an electric motor to a linear motion, and press one of the friction pads against the brake disk
Implementation Method 2
a housing-fixing plate which is disposed on one of two sides of the linear motion mechanism housing that is opposite from the brake disk, and to which the linear motion mechanism housing is detachably fixed
Data Source
AI summary
An electromechanical brake system includes a linear motion mechanism configured to convert the rotation transmitted from the electric motor to a linear motion, thereby pressing a friction pad against a brake disk; a linear motion mechanism housing in which the linear motion mechanism is received as a single assembly with the components of the linear motion mechanism assembled together; and a caliper body shaped to extend across the outer periphery of the brake disk. The caliper body includes a claw portion axially supporting a friction pad; a housing-fixing plate which is arranged on the side of the linear motion mechanism housing opposite from the brake disk; and an outer shell portion through which the claw portion and the housing-fixing plate are coupled together.