Cam Disc Electromechanical Brake Actuator Torque Transmission
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Solution Overview
Problem
Existing electromechanical brake actuators for commercial vehicles face challenges in achieving low brake actuation times and high brake power while maintaining a small and economical electric motor, due to high structural complexity and space requirements.
Innovation Solution
The use of a cam disc with contact faces that slide or roll against a brake plunger for direct torque transmission, combined with a gear mechanism and a spring element, allows for efficient force transmission with minimal components and reduced installation space, enabling high brake power with low drive power and complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple transmission members and coupling members are used to achieve high brake power, then brake power is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent merges the functions of multiple transmission members and coupling members into a single integrated cam disc mechanism. The cam disc directly converts rotational motor movement into linear plunger movement through its cam profile, eliminating the need for separate coupling members and transmission members while maintaining high brake power transmission capability.
Solution Approach 2:
The cam disc serves multiple functions simultaneously: it acts as a transmission member, a force amplifier, a movement converter (rotational to linear), and a wear compensation mechanism. This multi-functionality reduces the overall component count while achieving the desired brake power output.
2Power
If multiple transmission members and coupling members are used to achieve high brake power, then brake power is improved, but manufacturing and assembly cost increase
Solution Approach 1:
By combining multiple components into the single cam disc structure, the patent reduces the number of manufacturing operations, material requirements, and assembly steps. The cam disc can be manufactured as a single piece or pre-assembled unit, significantly reducing labor and overhead costs compared to assembling multiple transmission members and coupling members.
3Power
If multiple transmission members and coupling members are used to achieve high brake power, then brake power is improved, but installation space increases
Solution Approach 1:
The integration of multiple functions into the cam disc eliminates the spatial requirements for separate coupling members and transmission members. The cam disc mechanism achieves high brake power transmission within a compact footprint by directly converting motor rotation into plunger linear movement through its cam profile geometry.
4Force
If traditional transmission members are used, then brake force transmission is achieved, but force transmission losses increase
Solution Approach 1:
The cam disc utilizes a curved cam profile that optimizes the force transmission path. The curved geometry allows for smooth force transfer from the motor to the plunger, minimizing friction losses and mechanical inefficiencies associated with straight-line or multi-component transmission paths.
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 achieves low-loss force transmission, reduces component complexity, and minimizes installation space, while ensuring high operational reliability and ease of maintenance, allowing for efficient operation with small electric motors.
Implementation Method 1
the cam disc and the brake plunger having contact faces which are in contact with one another and slide or roll on one another for the direct transmission of the drive torque between the cam disc and the brake plunger
Implementation Method 2
contact faces which are in contact with one another and slide or roll on one another for the direct transmission of the drive torque
Implementation Method 3
contact faces which are in contact with one another and slide or roll on one another
Data Source
AI summary
An electromechanical brake actuator (102, 202, 302, 402) for a brake, in particular a commercial vehicle disc brake, has an electric motor (106, 206) for generating a drive torque, a cam disc (108, 208, 308, 408) operatively connected to the electric motor (106, 206) and mounted in a rotationally movable manner, and a brake plunger (114, 214, 314) which can be moved along a plunger axis for the actuation of a brake lever (358) of the brake (368). The cam disc (108, 208, 308, 408) and the brake plunger (114, 214, 314) have contact faces which are in contact with one another and slide or roll on one another for the direct transmission of the drive torque between the cam disc (108, 208, 308, 408) and the brake plunger (114, 214, 314).