Drum Brake Adapter Frame for Modular Actuator Integration
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Solution Overview
Problem
Existing electromechanically actuated drum brake systems face challenges in adaptability to different vehicle models and installation conditions, leading to complex and inefficient designs that require high-power motors and specific components, increasing manufacturing complexity and costs.
Innovation Solution
A drum brake module with a thin-walled adapter frame that supports the cable pull actuator, allowing for identical-parts strategy and modular construction, featuring a planar fastening flange with angled struts and a cable pull guide body with a U-shaped cross section to optimize installation space and reduce friction losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a central cable pull actuator is used for electromechanical parking brake function, then the brake system is universally suitable for small and lightweight vehicles as well as heavy vehicles, but separate installation and articulation of the cable pull on the wheel brake is necessary, increasing the complexity of manufacture
Solution Approach 1:
The brake system is divided into modular components: a standardized cable pull actuator unit and vehicle-specific adapter brackets. The adapter bracket segments the installation complexity, allowing the main actuator to remain unchanged while only the adapter needs adaptation for different vehicle models. This enables mass production of the actuator while maintaining versatility.
Solution Approach 2:
An adapter bracket serves as an intermediary component between the standardized cable pull actuator and the vehicle-specific brake assembly. This mediator allows the actuator to interface with different vehicle models without requiring modification of the actuator itself, thus reducing manufacturing complexity while maintaining adaptability.
2Adaptability or versatility
If different vehicle requirements and installation conditions are accommodated, then the brake system can be adapted to various motor vehicle models, but highly individual adaptations to components are necessary, increasing design complexity
Solution Approach 1:
The design separates the brake system into a standardized core component (cable pull actuator) and vehicle-specific adapter elements. This segmentation allows the majority of the design to remain standardized while only the adapter portions require individual adaptation to different vehicle models, significantly reducing overall design complexity.
Solution Approach 2:
The cable pull actuator is designed as a universal component that can serve multiple vehicle types through the use of interchangeable adapter brackets. This multi-functionality approach allows a single actuator design to be used across different vehicle models, reducing the need for highly individual adaptations.
3Force
If high-power motors are used to drive the spindle arrangement, then the actuation force is sufficient for various vehicle weights, but the power demands and energy consumption increase
Solution Approach 1:
The brake system utilizes a self-boosting mechanism where the initial actuation force from the motor is amplified by the hydraulic system and mechanical leverage of the brake assembly. This dynamic force multiplication allows a lower-power motor to generate sufficient actuation force for various vehicle weights, reducing power demands while maintaining effectiveness.
Solution Approach 2:
The brake system incorporates self-boosting effects where the applied force is amplified by the system's own mechanical and hydraulic characteristics. The motor provides only the initial actuation force, and the system's inherent mechanical advantage and hydraulic pressure multiplication provide the remaining force needed, reducing the power burden on the motor.
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
Enables simple and efficient adaptation to various vehicle applications, reducing manufacturing complexity and power demands on motors, while maintaining high efficiency and stability throughout the service life.
Implementation Method 1
an electromechanical cable pull actuator which is arranged on an outer side of the anchor plate and which serves for driving a rotation-translation converter for converting a rotational drive input rotary movement into a translational actuation movement (B) of brake pads
Data Source
AI summary
A drum brake module for motor vehicles, the drum brake module being driven by an electric motor and having at least one parking brake function, includes an electromechanical cable pull actuator which is fastened on the anchor plate with the aid of an adapter. The adapter is designed as a one-piece, thin walled frame having at least one fastening flange for receiving the cable pull actuator and is held in place on the anchor plate.