Disk Brake Bus Bar Electrical Connection Reliability
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Solution Overview
Problem
Existing disk brake systems face reliability issues due to damage from contact with the reduction gear, particularly with the flexible harness extending to the outer circumferential side.
Innovation Solution
A disk brake design incorporating a caliper with a piston driving mechanism that includes a housing with a speed reduction mechanism and a connector portion using bus bars made of metallic plates to connect the electric motor's supply terminals and motor terminals, ensuring robust connections and protection from the reduction gear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a flexible harness is used for electric connection between the electric motor and connector, then ease of installation and flexibility are improved, but the harness may be damaged due to contact with the reduction gear, worsening reliability
Solution Approach 1:
The patent replaces the flexible harness with a rigid bus bar structure that is integrated into the housing. This eliminates the vulnerable flexible component and uses a more durable, fixed electrical connection system that cannot be accidentally damaged by moving parts like the reduction gear.
Solution Approach 2:
The bus bar is integrated directly into the housing structure, merging the electrical connection component with the mechanical housing. This integration eliminates separate vulnerable components and creates a unified structure where the electrical connection is protected by the housing itself.
2Volume of moving object
If the harness is disposed to extend to the outer circumferential side of the reduction gear, then space utilization and compactness are improved, but the harness is exposed to contact with the reduction gear, worsening reliability
Solution Approach 1:
The vulnerable harness is completely extracted from the system and replaced with a bus bar integrated into the housing. This removes the component that was causing the reliability issue while maintaining the compact space utilization through the integrated design.
Solution Approach 2:
The housing structure serves as an intermediary that protects the electrical connection. Instead of the harness being directly exposed to the reduction gear area, the integrated bus bar is shielded by the housing, preventing contact with moving parts.
3Reliability
If a bus bar made of metallic plate is used to connect supply terminal and motor terminal, then connection strength and reliability are improved, but manufacturing complexity and precision requirements increase
Solution Approach 1:
The bus bar is merged with the housing structure, eliminating the need for separate assembly steps. This integration simplifies manufacturing by reducing the number of components and assembly operations, while maintaining the strong electrical connection provided by the metallic bus bar.
Solution Approach 2:
The housing serves multiple functions: it provides mechanical support, protects internal components, and integrates the electrical connection system through the bus bar. This multi-functionality reduces overall device complexity by combining several components into one unified structure.
Data Source
AI summary
A disk brake (1) including a connector portion (35) provided at a housing (30). The connector portion (35) includes supply terminals (131) for supplying power to a motor (32). The supply terminals (131) of the connector portion (35) and motor terminals (32C) of the motor (32) are connected to each other via bus bars (130) made of metallic plate. Further, the bus bars (130) are held in a loosely fitted state on another-side surface (138B) of a plate-like portion (138) of a support member (135) attached to the housing (30).