Disc Brake System Using Motor-Driven Rack and Self-Boosting
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Solution Overview
Problem
Hydraulic brake systems face issues with pipe damage, delayed pressure response, and increased component count, while electric motor-based systems often lack sufficient braking force.
Innovation Solution
A disc brake system utilizing a motor, rack, and self-boosting mechanism, where a driving gear on the motor's rotational shaft meshes with a rack that linearly moves perpendicular to the brake disc, and a self-boosting mechanism compresses the brake shoe against the disc, leveraging rotational inertia for enhanced braking force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a hydraulic brake system is used, then braking force can be generated, but the hydraulic pipe is susceptible to damage and the number of components increases
Solution Approach 1:
The patent removes the hydraulic pipe and fluid from the brake system, extracting the problematic hydraulic components while retaining the braking function through an electric motor-driven mechanical system. This eliminates the susceptibility to pipe damage and reduces component count.
Solution Approach 2:
The patent replaces the hydraulic mechanical system with an electric motor-driven rack and pinion mechanical system. The electric motor converts electrical energy to mechanical motion, which is then transmitted through the rack and pinion mechanism to activate the brake shoes, eliminating the need for hydraulic components.
2Force
If a hydraulic brake system is used, then braking force can be generated, but the response against transmission time of the hydraulic pressure is deteriorated
Solution Approach 1:
The patent replaces the hydraulic pressure transmission system with an electric motor-driven system. The electric motor provides direct mechanical motion through the rack and pinion mechanism, eliminating the time delay associated with hydraulic pressure buildup and transmission. The electric system responds more quickly to activation signals.
3Volume of moving object
If only a small electric motor is mounted in the brake system, then the system structure is compact, but sufficient braking force may not be obtained
Solution Approach 1:
The patent introduces a self-boosting mechanism as an intermediary between the small electric motor and the brake shoes. This mechanism uses the rotational inertia of the brake disc to amplify the force generated by the small motor, allowing sufficient braking force to be achieved despite the compact motor size.
Solution Approach 2:
The self-boosting mechanism utilizes the periodic rotational motion of the brake disc to generate oscillating forces that amplify the braking effect. The rotational inertia of the disc creates periodic force variations that enhance the overall braking force beyond what the small motor could produce alone.
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 system achieves sufficient and stable braking force by using a small electric motor and rotational inertia, overcoming the limitations of hydraulic systems and providing consistent braking performance.
Implementation Method 1
A rack meshes with the driving gear and linearly moves in the perpendicular direction to a brake disc
Implementation Method 2
A self boosting means is located between the rack and activating brake shoe for transmitting the force of the rack to the activating brake shoe
Implementation Method 3
A lining is mounted at activating brake shoe 3 to face brake disc 9
Data Source
AI summary
A brake system using an electric motor to provide sufficient braking force by generating the self boosting operation using the motor and rotational inertia of the brake disc, thereby stabilizing the braking operation.