Electric Caliper Brake Mechanical Self-Locking
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Solution Overview
Problem
Existing electric caliper brakes require additional electronic components and complex electrical systems to maintain braking force, which increases cost and manufacturing complexity, and may not function accurately without precise alignment of mechanical components.
Innovation Solution
A mechanical self-locking structure using a torsion spring is integrated into the electric caliper brake, allowing it to maintain braking force without additional electrical signals, simplify installation, and automatically adjust the piston position due to pad wear, by transferring rotational power through a system of connectors and gears.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a solenoid-based latch structure is used to maintain braking force, then braking force can be maintained when power is off, but the device complexity increases due to additional electronic components and electrical circuits
Solution Approach 1:
The patent replaces the solenoid-based electronic locking mechanism with a purely mechanical self-locking structure. The worm gear (231) and worm wheel (232) combination creates inherent mechanical self-locking that maintains braking force without requiring additional electronic components like solenoids. The mechanical advantage and friction in the worm gear mechanism prevent reverse motion, automatically maintaining the braking state.
Solution Approach 2:
The worm gear mechanism provides automatic self-locking functionality without requiring external control systems. The mechanical design inherently maintains the braking force through its geometric configuration and friction characteristics, eliminating the need for separate locking control circuits or additional electronic components to maintain the braking state.
2Reliability
If a solenoid-based latch structure is used for self-locking, then braking force can be maintained, but the manufacturing cost increases due to additional electronic components and circuit connections
Solution Approach 1:
The patent eliminates solenoids and associated electrical circuits by using a worm gear-based mechanical self-locking system. This substitution removes the need for expensive electronic components, wiring, and control systems, significantly reducing manufacturing costs while maintaining the self-locking function through pure mechanical means.
Solution Approach 2:
The patent extracts and removes the solenoid-based electronic locking system from the design, retaining only the essential mechanical components (worm gear, worm wheel, gears) needed for both braking and self-locking functions. This extraction eliminates unnecessary electronic components and reduces manufacturing complexity and cost.
3Reliability
If a solenoid-based latch structure is used, then braking force can be maintained, but the installation space requirement increases due to additional electronic components
Solution Approach 1:
The patent merges the self-locking function with the existing gear transmission system by integrating the worm gear mechanism into the gear assembly. The worm gear (231) and worm wheel (232) are combined with the existing gears (221, 222, 223) to perform both power transmission and self-locking functions simultaneously, eliminating the need for separate solenoid components and reducing overall installation space.
Solution Approach 2:
The worm gear mechanism is nested within the existing gear assembly structure, with the worm gear and worm wheel integrated into the same housing space that already contains the motor and other gears. This nesting approach utilizes existing structural space efficiently, avoiding the need for additional external locking components that would increase installation volume.
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 solution provides a cost-effective, simplified electric caliper brake with stable self-locking and automatic piston adjustment, reducing reliance on electrical signals and enhancing manufacturing efficiency, while maintaining consistent braking force even with pad wear and potential electrical signal errors.
Implementation Method 1
the torsion spring elastically deformed according to a load from a time point at which the pad plates pressed by the piston begins to contact the disc, to restrict rotation of the disc
Data Source
AI summary
Disclosed herein is a electric caliper brake with a parking function. The electric caliper brake includes a caliper submodule to apply pressure to a piston to press the disc by converting rotational motion into rectilinear motion through the received rotation power, an actuator submodule to produce braking force to perform the braking function and parking function, and a self-locking module to transfer the braking force by connecting the caliper submodule to the actuator submodule.