Electric Disk Brake With Dual Rotary-to-Linear Conversion
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Solution Overview
Problem
Conventional electric disk brakes face challenges in achieving a compact size while generating large braking force, as the reduction mechanism required for increased speed reducing ratio becomes large, and output expansion is limited when using a pair of rotary-to-linear conversion mechanisms.
Innovation Solution
The electric disk brake design incorporates a single electric motor with a pair of rotary-to-linear conversion mechanisms and a reduction mechanism that transfers the rotary output to one side and reaction force to the other, utilizing a planetary gear mechanism or differential deceleration mechanism to achieve increased thrust force without the need for a large reduction mechanism.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a reduction mechanism with enlarged speed reducing ratio is used, then the braking force is increased, but the size of the reduction mechanism becomes large
Solution Approach 1:
The patent divides the single electric motor's output into two separate pathways: one for generating braking force through the first rotary-to-linear conversion mechanism, and another for recovering energy through the second rotary-to-linear conversion mechanism. This segmentation allows the system to achieve high braking force without requiring an oversized reduction mechanism, as each conversion mechanism operates independently with optimized parameters.
Solution Approach 2:
The patent introduces a dual-output dimension by splitting the motor's rotary output into two distinct linear motion pathways. Instead of using a single high-ratio reduction mechanism, the system employs two lower-ratio mechanisms that operate in parallel, effectively transitioning from a single-dimension force multiplication approach to a multi-dimensional force distribution approach.
2Power
If a pair of rotary-to-linear conversion mechanisms is used, then the braking output is expanded, but the device complexity increases
Solution Approach 1:
The patent makes both rotary-to-linear conversion mechanisms serve dual functions: the first mechanism generates braking force while the second mechanism recovers energy during braking. This multi-functionality allows the system to expand braking output without proportionally increasing device complexity, as each mechanism contributes to multiple system objectives.
Solution Approach 2:
The patent merges the braking force generation and energy recovery functions into a unified dual-mechanism system. By combining these functions in parallel rather than sequentially, the system achieves expanded braking output while maintaining manageable complexity through shared control and coordinated operation.
3Volume of moving object
If the reduction mechanism size is reduced for downsizing, then the device volume is decreased, but the braking force generation capability is reduced
Solution Approach 1:
The patent segments the braking force generation into two parallel pathways, each using a compact rotary-to-linear conversion mechanism. This segmentation allows the system to maintain high total braking force while using smaller individual components, thereby reducing overall device volume without sacrificing braking capability.
Solution Approach 2:
The patent changes the system's architectural parameters from a single high-ratio reduction mechanism to two lower-ratio mechanisms operating in parallel. This parameter change enables the use of smaller, more compact components while maintaining or enhancing the total braking force through combined output from both mechanisms.
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 design allows for a compact electric disk brake that can generate large braking force, reduces the load on the electric motor, and enables continued operation even if one of the rotary-to-linear conversion mechanisms fails, contributing to downsizing and energy saving.
Implementation Method 1
a reduction mechanism that transfers the rotary output to one side and reaction force to the other, utilizing a planetary gear mechanism or differential deceleration mechanism
Implementation Method 2
a pair of rotary-to-linear conversion mechanisms to which rotation of the electric motor is transferred; a pair of pressing member that presses at least one brake pad toward a disk rotor by means of each of the rotary-to-linear conversion mechanisms
Implementation Method 3
a single electric motor; a pair of rotary-to-linear conversion mechanisms to which rotation of the electric motor is transferred
Data Source
AI summary
An electric disk brake includes a single electric motor, a pair of rotary-to-linear conversion mechanisms to which rotation of the electric motor is transferred, a pressing member that presses a brake pad toward a disk rotor by each of the rotary-to-linear conversion mechanisms and a reduction mechanism interposed between the electric motor and the pair of rotary-to-linear conversion mechanisms. The reduction mechanism transfers rotation output, where input of the electric motor is expanded, to one side of the pair of rotary-to-linear conversion mechanisms and transfers reaction force of the rotation output to the other side of the pair of rotary-to-linear conversion mechanisms.