Die-Cast Brake Actuator Housing for Lightweight Disc Brakes
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Solution Overview
Problem
Current electromechanical brake actuators for disc brakes in commercial vehicles face challenges in achieving high rigidity with low weight, while being exposed to environmental factors like stone chips and dust, and require complex component protection and assembly in limited space.
Innovation Solution
The use of an aluminum die-cast molded housing with specific design features such as stiffening ribs, die-casting configurations, and integrated motor flanges, which reduces material usage and eliminates the need for additional connecting elements, allowing for a lightweight and compact structure that is easy to manufacture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a steel housing is used for the electromechanical brake actuator, then high rigidity and strength are achieved, but the weight increases significantly
Solution Approach 1:
The patent changes the material parameter from steel to aluminum alloy, fundamentally altering the density and weight characteristics of the housing while maintaining structural integrity through optimized design
Solution Approach 2:
The housing is divided into multiple segments (first housing part, second housing part, third housing part) that can be separately manufactured and assembled, allowing for optimized material distribution and weight reduction while maintaining overall strength
2Strength
If the housing is designed with complex stiffening ribs and detailed forms to achieve high rigidity, then structural strength is improved, but manufacturing complexity and post-processing requirements increase
Solution Approach 1:
The patent merges the housing structure with integrated stiffening ribs and mounting features directly into the die-cast component, eliminating the need for separate post-processing operations and reducing manufacturing steps
Solution Approach 2:
The die-casting process parameters are optimized to directly form complex rigid structures with integrated stiffening elements, transforming the manufacturing approach from mechanical assembly to integrated casting
3Strength
If multiple connecting elements such as screws are used to assemble the housing, then structural integrity is ensured, but the number of parts and assembly complexity increases
Solution Approach 1:
The patent merges multiple housing parts into an integrated die-cast structure where connecting elements are eliminated, reducing the bill of materials and simplifying assembly operations
Solution Approach 2:
The housing structure serves multiple functions simultaneously - structural support, component mounting, and protection - through its integrated design, eliminating the need for separate fastening and mounting elements
4Reliability
If the housing is designed to protect multiple interacting components (gear, cam disk, motor) from environmental influences, then reliability is improved, but the housing complexity and space requirements increase
Solution Approach 1:
The patent merges the protection function with the structural housing design, creating an integrated enclosure that protects internal components from environmental influences while maintaining a compact form factor
Solution Approach 2:
The housing design incorporates localized protection features at specific areas where components are most vulnerable to environmental influences, rather than requiring comprehensive complex enclosure throughout
Data Source
Figure 1
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AI summary
The invention relates to an electromechanical brake actuator (2) comprising a housing (1), a first housing part (3) designed as a housing flange for connecting the electromechanical brake actuator (2) to a disc brake (38), a second housing part (4) for receiving a drive (6), and a third housing part (5) arranged between the first housing part (3) and the second housing part (4) and connected to the first housing part (3) and the second housing part (4), wherein the electromechanical brake actuator (2) has means comprising a motor (37), a gearbox (7), a plunger (9) or a spindle for actuating a disc brake (38), and wherein the housing (1) is an aluminum die-cast part.