Disc Brake Adjuster Layout for Compact Sealed Maintenance Access
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Solution Overview
Problem
Existing disc brake electrical adjusting devices face challenges in minimizing space usage and simplifying maintenance, with complex arrangements and additional space requirements, and lack efficient power transmission mechanisms.
Innovation Solution
The electrical adjusting device features an axially parallel electric motor arrangement with the actuating unit, integrated with a sensor unit on a support plate, utilizing a compact worm gear and bevel gear power transmission system, and a modular design for easy assembly and disassembly, with a circumferential seal for environmental protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the electric motor is arranged axially parallel to the actuating unit and sensor unit facing the brake disc, then the installation space is minimized and service access is simplified, but the components require protective sealing from environmental influences
Solution Approach 1:
The brake caliper is divided into a first region containing the brake pads and a second region containing the electric motor, actuating unit, and sensor unit. This spatial segmentation allows the components to be arranged compactly in separate zones while maintaining functional relationships, minimizing overall installation space while protecting sensitive components from brake pad environmental influences.
Solution Approach 2:
A support plate serves as an intermediary structure that mounts the electric motor, actuating unit, and sensor unit in a fixed spatial relationship. This intermediary platform enables compact arrangement of components while providing a sealed enclosure that protects them from environmental factors such as water, dust, and brake dust.
2Ease of repair
If the electric motor and actuating unit are integrated on a common support plate, then maintenance is simplified through single-step access, but the power transmission mechanism requires compact worm gear and bevel gear design
Solution Approach 1:
The electric motor, actuating unit, and sensor unit are merged onto a single support plate, creating an integrated assembly that can be accessed and serviced as one unit. This merging simplifies maintenance procedures while the compact power transmission mechanism using worm gear and bevel gear reduces the spatial footprint of the combined assembly.
Solution Approach 2:
The power transmission mechanism employs nested gearing where the worm gear drives a intermediate gear that in turn drives the bevel gear, which connects to the actuating unit. This nested arrangement of transmission elements allows efficient power transfer from the electric motor to the actuating unit while minimizing the overall size and complexity of the mechanism.
3Area of stationary object
If the sensor unit is arranged coaxially below the actuating unit, then space is optimized within the brake caliper, but the sensor must accurately detect clearance in a constrained axial position
Solution Approach 1:
The sensor unit is arranged coaxially below the actuating unit in the axial dimension, utilizing the vertical space within the brake caliper rather than expanding the radial or lateral dimensions. This axial arrangement optimizes space utilization while the sensor's measurement capability extends in the radial direction to accurately detect the clearance between brake pads and brake disc despite the constrained axial positioning.
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 minimizes space usage, simplifies maintenance by allowing single-step component access, and ensures efficient power transmission and protection from environmental influences, enhancing the overall performance and reliability of the disc brake.
Implementation Method 1
The power transmission device comprises a worm gear and a bevel gear
Data Source
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AI summary
The invention relates to an electric adjusting device (1) for a disc brake (2), comprising a brake disc and a brake calliper (2a) of a vehicle, for adjusting the wear of brake linings (3, 3a). The electric adjusting device (1) comprises a motor (4), a force transmission device (5), a sensor unit (7) and an actuating unit (6).