Electro-mechanical Brake Actuator Nesting for Reliability
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Solution Overview
Problem
Conventional electro-mechanical brake systems are susceptible to external damage due to the actuator being positioned outside the caliper, leading to unstable parking brake forces and reduced operation reliability.
Innovation Solution
The electro-mechanical brake device positions the driver and gears within the caliper body, utilizing a worm gear system and a moving nut mechanism to generate a stable parking brake force, with the driver being an electrical motor positioned above the caliper body, and integrating the second worm wheel gear, gear support, and rotating gear bar to reduce external shock and maintain a stable parking force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the driver and gears are positioned outside the caliper body, then the structure is simpler and easier to manufacture, but the parking brake force becomes unstable and the system is susceptible to external damage
Solution Approach 1:
The driver and gear system are nested inside the caliper body, with the driver positioned in the caliper and the gear system integrated within the same housing. This nesting arrangement protects the actuator components from external damage while maintaining a compact structure, directly resolving the contradiction between reliability and device complexity.
2Reliability
If the driver is positioned above the caliper body, then the risk of external damage is reduced, but the structural complexity increases
Solution Approach 1:
The driver is nested within the caliper body housing, positioned in a protected space above the piston assembly. The caliper body serves as a protective enclosure that shields the driver from external shocks and damage, while the nested arrangement minimizes the increase in structural complexity.
3Reliability
If a worm gear system is used, then the parking brake force is stabilized, but the device complexity increases
Solution Approach 1:
The worm gear system is extracted as a distinct functional module within the caliper body, with the worm gear engaged with the gear bar to provide mechanical advantage and self-locking capability. This extraction allows the complex gear system to be designed as a specialized subsystem that stabilizes parking brake force while being integrated into the overall compact structure.
Solution Approach 2:
The gear system performs multiple functions: it provides mechanical advantage through the worm gear mechanism, ensures self-locking to maintain parking brake force, and integrates with the moving nut mechanism to convert rotational motion into linear piston movement. This multi-functionality reduces the need for separate components, managing device complexity while achieving reliable parking brake force stabilization.
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 configuration reduces the risk of external damage, stabilizes the parking brake force, and enhances vehicle operation reliability by positioning critical components within the caliper body, thereby improving the reliability and reducing maintenance costs.
Implementation Method 1
The first gear may include a first worm gear which is installed outside the output shaft and extended in a horizontal direction. The second gear may include: a first worm wheel gear engaged with the first gear and configured to rotate with the first gear
Implementation Method 2
a second worm gear extended to the bottom of the connection member and having a screw thread formed thereon so as to be engaged with the third gear
Implementation Method 3
a moving nut engaged with the third gear and configured to move linearly. The third gear may include... a rotating gear bar installed in parallel to the output shaft and configured to rotate with the output shaft
Implementation Method 4
a piston installed in a shape covering an outside of the moving nut, and pushed by the moving nut so as to pressurize a brake pad
Implementation Method 5
The electro-mechanical brake device may further include: a bearing member installed on a first side of the gear support so as to reduce a frictional force
Data Source
AI summary
An electro-mechanical brake device may include: a driver configured to generate rotary power; a first gear connected to an output shaft of the driver, and the first gear configured to rotate with the output shaft; a second gear installed in a direction crossing the first gear, engaged with the first gear, and configured to rotate with the first gear; a third gear engaged with the second gear and configured to rotate with the second gear, the third gear having a rotating gear bar installed in parallel to the output shaft and configured to rotate with the output shaft; a moving nut engaged with the third gear and configured to move linearly; and a piston installed in a shape covering an outside of the moving nut, and pushed by the moving nut so as to pressurize a brake pad.