Compact Brake Caliper Actuation With Ball Screw Pad Propulsion
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Solution Overview
Problem
Existing brake devices require a significant overall length for the caliper body to accommodate pistons and piston driving members, increasing manufacturing costs and requiring even pressure distribution for optimal brake performance.
Innovation Solution
A brake device with a pad propulsion unit that includes a conversion assembly converting rotational motion into linear motion, utilizing a ball screw nut and bolt system to reduce the caliper body's length, and a piston design with symmetric pressurizing portions for even pressure distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the caliper body is designed to accommodate pistons and piston driving members, then the brake device can achieve effective braking, but the overall length of the caliper body increases
Solution Approach 1:
The patent transitions from a conventional linear piston arrangement to a rotational motion system using a cam mechanism. The cam rotates about an axis perpendicular to the traditional piston movement direction, converting rotational motion into linear piston movement. This dimensional change allows the brake actuation system to be compact in the caliper body length direction while maintaining effective braking capability.
Solution Approach 2:
Instead of using a traditional linear piston driven directly by hydraulic pressure along the caliper body length, the patent inverts the approach by using a rotating cam mechanism where the rotation axis is positioned differently. The cam profile converts rotational motion from an outboard motor into linear piston movement, effectively shortening the caliper body length required for the braking mechanism.
2Ease of manufacture
If the caliper body length is reduced, then manufacturing costs decrease, but accommodating space for pistons and driving members becomes insufficient
Solution Approach 1:
The cam mechanism rotates about an axis that extends in a direction perpendicular to the traditional piston stroke direction. This allows the cam mechanism to occupy space in a different dimensional orientation, reducing the length requirement along the caliper body axis while maintaining sufficient volume for all components through optimized spatial arrangement.
Solution Approach 2:
The patent positions the cam rotation axis and cam mechanism within the caliper body structure in such a way that components are nested efficiently. The cam, follower, and piston are arranged in a compact configuration where the cam mechanism is integrated into the caliper body volume, maximizing space utilization and reducing overall caliper dimensions.
3Device complexity
If pressure is concentrated on a small area of the brake pad, then the brake device structure can be simplified, but uneven wear occurs and piston damage is more likely
Solution Approach 1:
The cam mechanism acts as an intermediary between the hydraulic actuation force and the brake pad. The cam profile is designed to convert the input force into a distributed pressure pattern on the brake pad surface. This intermediary mechanism ensures that pressure is applied evenly across the brake pad contact area, preventing localized stress concentrations and uneven wear while maintaining a relatively simple overall structure.
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 reduces the caliper body's length and weight, lowering manufacturing costs while ensuring even pressure distribution on the brake pad, maintaining brake performance and preventing piston damage.
Implementation Method 1
a conversion assembly engaged to the rotation medium and converting rotational motion into linear motion in conjunction with the rotation medium, and a piston formed to surround one side of the conversion assembly. The conversion assembly may include a ball screw nut coupled to the rotation medium and rotating together with the rotation medium, and a ball screw bolt penetrating through the rotation medium and the ball screw nut and moving forward or backward by the rotation of the ball screw nut
Implementation Method 2
The ball screw nut may include a contact portion formed to protrude from the outer circumferential surface and contacting the ball bearing
Data Source
AI summary
A brake device includes a caliper body, a brake pad mounted on one side of the caliper body, a mounting portion formed inside the caliper body, and a pad propulsion unit located in the mounting portion and configured for pressing one surface of the brake pad. The pad propulsion unit includes a rotation medium rotating, a conversion assembly engaged to the rotation medium and converting rotational motion into linear motion in conjunction with the rotation medium, and a piston formed to surround one side of the conversion assembly. The brake device may secure brake performance while reducing manufacturing costs by reducing the overall length of the caliper body.