Electromagnetic Brake Pad Retraction for Stable Disk Brake Air Gaps
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Solution Overview
Problem
Conventional disk brake retraction mechanisms have insufficient retraction force, leading to instability and uneven brake performance due to varying air gaps caused by dirt accumulation, wear, and temperature changes, resulting in potential vehicle destabilization during braking.
Innovation Solution
A disk brake system utilizing an electromagnet with a coil and ferromagnetic coil core to generate a sufficient retraction force of over 100 newtons, allowing for precise adjustment and centering of the brake caliper relative to the brake carrier, and adaptive air gap control via an electronic control unit, enabling robust and space-optimized design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If conventional spring-based retraction mechanisms are used, then the brake pad can be retracted, but the retraction force is insufficient (only 20-30 newtons) and cannot robustly retract the housing over the lifetime of the brake
Solution Approach 1:
The patent replaces the conventional mechanical spring-based retraction mechanism with an electromagnet system. The electromagnet generates a magnetic field that acts on a ferromagnetic component of the brake pad, producing sufficient retraction force (over 100 newtons) to reliably retract the brake pad and housing throughout the brake's lifetime, overcoming the insufficient force of spring mechanisms.
Solution Approach 2:
The patent changes the physical state and properties of the retraction system by introducing an electromagnet with adjustable electrical parameters. By controlling the current through the coil, the magnetic field strength can be adjusted to generate the required retraction force, and the system can adapt to varying conditions such as dirt accumulation and wear over time.
2Force
If spring-based retraction is used, then the brake pad can be retracted, but the springs are not able to center the housing relative to the disk
Solution Approach 1:
The patent replaces the passive spring-based centering mechanism with an active electromagnet system. The electromagnet can generate directional forces that not only retract the brake pad but also actively center the housing relative to the brake disk, ensuring proper alignment even when the disk is deflected during vehicle operation.
3Device complexity
If no active retraction control is used, then the structure is simple, but the air gap changes over time due to wear and temperature, causing different response times and brake forces
Solution Approach 1:
The patent implements a controlled retraction system where the electromagnet can be activated based on detected conditions such as air gap size, wear level, or temperature. This feedback mechanism allows the system to maintain consistent brake performance by adjusting the retraction force as needed, compensating for changes due to wear and thermal expansion.
Solution Approach 2:
The patent transforms the static spring-based retraction system into a dynamic electromagnet system that can adjust its retraction force in real-time. This dynamic capability allows the system to adapt to changing operating conditions, maintaining optimal air gap and consistent brake response throughout the brake's lifetime.
4Force
If higher retraction force is applied to the outer brake pad, then the pad can be retracted against friction forces, but the floating caliper as a whole must be moved
Solution Approach 1:
The patent replaces the mechanical spring system with an electromagnet that can generate high retraction force (over 100 newtons) without requiring significant mass. The electromagnetic force is generated through the interaction of the magnetic field with the ferromagnetic component, allowing high force output without increasing the moving mass of the floating caliper.
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 provides stable and efficient braking performance by maintaining a consistent air gap, reducing residual slip torques, and allowing rapid braking while minimizing wear and energy consumption, thus enhancing vehicle stability and control.
Implementation Method 1
an electromagnet having a coil and a coil core movably arranged in the coil, wherein the coil core is connected to at least one of the brake pads
Implementation Method 2
an electromagnet having a coil and a coil core movably arranged in the coil, wherein the coil core is connected to at least one of the brake pads
Data Source
AI summary
The disclosure relates to a disk brake comprising a brake caliper, a brake carrier that supports the brake caliper, a brake disk couplable for conjoint rotation with a vehicle wheel, a first brake pad and a second brake pad between which the brake disk is mounted. The brake pads are each spaced apart from the brake disk by a retraction force. A brake piston is connected to a pressure source. The brake piston is sealingly displaceably guided in the brake caliper of the disk brake in order to effect a relative movement between the respective brake pad and the brake disk by an applied force provided by the pressure source, so that the brake pads can be brought into contact with the brake disk. An electromagnet having a coil and a coil core movably arranged in the coil is also provided. The coil core is connected to at least one of the brake pads, for example to the second brake pad arranged on a side of the brake disk that is remote from the brake piston to generate the retraction force acting on the at least one brake pad. The coil is connected to the brake carrier.