Dry Brake Caliper Roller Screw Assembly for Lower-Cost Load Handling
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Solution Overview
Problem
Current planetary roller lead screws, particularly standard, reverse, cyclic, and differential types, face challenges such as high manufacturing costs, limited production capacity, and reliability issues under heavy loads, making them unsuitable for widespread use in the automotive industry and automotive safety systems.
Innovation Solution
An electromechanical dry brake caliper design featuring a planetary roller lead screw assembly with a torsion spring, anti-rotation projections, and a cage that allows rollers to rotate within the cage, eliminating the need for cams and grooves, reducing machining complexity and costs, while maintaining high load-bearing capacity and transmission efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a wet brake caliper design is used, then heat dissipation is improved, but water contamination and corrosion occur
Solution Approach 1:
The patent extracts and eliminates the brake fluid reservoir from the caliper assembly, creating a dry-type brake caliper that operates without brake fluid. This removes the source of water contamination and corrosion while maintaining heat dissipation capabilities through alternative cooling design
Solution Approach 2:
The patent introduces ceramic materials as an intermediary between the braking surfaces and the environment. The ceramic liner and ceramic components provide thermal management and protection against corrosion, serving as a mediator that enables dry operation while maintaining heat dissipation
2Ease of manufacture
If traditional brake pad materials are used, then cost is reduced, but brake dust generation and corrosion increase
Solution Approach 1:
The patent employs composite materials combining ceramic particles with metal matrices to create brake pads and liners. This composite structure reduces brake dust generation and corrosion compared to traditional organic or semi-metallic materials while maintaining manufacturing feasibility through established ceramic processing techniques
Solution Approach 2:
The patent changes the material composition parameters by incorporating ceramic materials with specific physical and chemical properties. These parameter changes in material composition reduce harmful emissions and corrosion while maintaining cost-effectiveness through optimized ceramic loading and processing
3Object-generated harmful factors
If ceramic materials are used in brake components, then brake dust generation and corrosion are reduced, but manufacturing complexity increases
Solution Approach 1:
The patent segments the ceramic component manufacturing into separate, modular parts such as ceramic liners, ceramic pins, and ceramic-containing brake pads. This segmentation allows each component to be manufactured and processed independently, reducing overall manufacturing complexity while maintaining the corrosion and dust reduction benefits of ceramic materials
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 solution reduces manufacturing costs, enhances load-bearing capacity, and maintains high transmission efficiency by using sliding friction during the empty stroke and rolling friction during the loading stage, ensuring rapid unloading and alignment adjustments, thus overcoming the limitations of existing technologies.
Implementation Method 1
The brake caliper is particularly suitable for use with ceramic brake pads and ceramic liners which have become increasingly popular in recent years due to the many benefits they offer over conventional organic or semi-metallic materials.
Implementation Method 2
Electromechanical actuators have been used in an increasing number of automotive applications in recent years
Data Source
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AI summary
An electromechanical dry-type brake caliper. A planetary roller screw assembly (10) is mounted in a cylinder hole of a brake caliper assembly (11); a motor and a speed reduction mechanism are directly or indirectly connected to the planetary roller screw assembly (10); the planetary roller screw assembly (10) comprises a lead screw (1), a nut (2), and rollers (3) mounted between the lead screw (1) and the nut (2); the rollers (3) are mounted on a retainer (5) located between the lead screw (1) and the nut (2); a torsion spring (8) is mounted between the retainer (5) and the nut (2); anti-rotation bosses (4a, 4b) which are matched with each other are provided on the retainer (5) and the nut (2); one side edge of the second anti-rotation boss (4b) on the retainer (5) is attached to one side edge of the first anti-rotation boss (4a) on the nut (2) by means of the elastic force of the torsion spring (8); and the attachment position is the initial position of the rollers (3) and the retainer (5).