EMB Actuator Frame Structure for Brake Load Transfer
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Solution Overview
Problem
Existing carrier assemblies for brake actuators struggle to optimally absorb and distribute operational forces such as vibrational forces, torque, and reaction forces during braking, leading to potential structural weaknesses and reduced durability.
Innovation Solution
A frame and housing design for the actuator assembly that integrates a single, unitary metal frame with projections and interfaces for direct fastening, allowing for robust load transfer and reduced assembly complexity by eliminating separate fasteners and seals, while maintaining high stiffness and alignment of components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional carrier assemblies are used to secure brake actuator components, then assembly and disassembly are simplified, but the ability to absorb and distribute operational forces such as vibrational forces, torque, and reaction forces is insufficient
Solution Approach 1:
The patent integrates the motor mounting bracket and gear stage carrier into a single unitary carrier assembly. This merging of previously separate components creates a unified structure that can distribute operational forces more effectively throughout the assembly while reducing the total number of parts and assembly steps.
Solution Approach 2:
The carrier assembly is formed from aluminum alloy material that provides high strength-to-weight ratio and excellent durability. The use of this composite material enables the single-piece structure to withstand vibrational forces, torque, and reaction forces during braking operations while maintaining structural integrity.
2Reliability
If multiple separate components are used in the carrier assembly, then manufacturing and assembly are easier, but structural weaknesses and reduced durability occur under operational forces
Solution Approach 1:
The motor mounting bracket and gear stage carrier are merged into a single injection-molded component, eliminating the need for separate manufacturing processes and assembly operations. This unitary construction ensures consistent structural integrity and durability while the molding process efficiently produces the complex geometry.
Solution Approach 2:
The carrier assembly uses aluminum alloy material with specific mechanical properties that provide high strength and durability. The material parameters are optimized to withstand the operational forces encountered during braking, including vibrational forces, torque, and reaction forces, while the injection molding process parameters ensure consistent quality.
3Force
If a robust frame structure is implemented for force distribution, then load transfer efficiency improves, but assembly complexity and manufacturing difficulty increase
Solution Approach 1:
The frame structure is integrated into the unitary carrier assembly, combining the load-bearing function with the component mounting function. This eliminates the need for separate frame structures and fasteners, simplifying assembly while maintaining excellent load transfer efficiency through the molded-in structural features.
Solution Approach 2:
The carrier assembly includes integrated mounting interfaces and attachment features that are segmented into functional zones within the single-piece structure. This segmentation allows for optimized force distribution paths while maintaining a simple assembly process, as the interfaces are built-in rather than requiring separate components.
Data Source
AI summary
A frame is provided for an actuator assembly of a vehicle brake having a housing enclosing a gear stage and a motor for delivering torque to the gear stage. The frame includes a base having a first interface for connecting to the gear stage and a second interface for connecting to the motor. Projections extend outward from the first interface for receiving fasteners to secure the base directly to the housing and transfer loads from the motor to the housing during braking operations.