Floating-Calliper Brake Guide Layout for Compact High-Power Packaging

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Solution Overview

Problem

Existing electromechanically operated floating-calliper brakes face challenges in terms of installation space and weight, particularly when requiring high braking power for front wheel brakes or large passenger cars, such as SUVs.

Innovation Solution

The design optimizes installation space by utilizing a single connecting portion for each guide assembly, allowing for the placement of an electric motor, gearbox, and other components close to the floating calliper, thereby reducing bearing forces and accommodating additional components like brake covers and dust collectors.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If electromechanical drives are used to actuate the actuator piston, then high braking power can be achieved, but the installation space requirement increases

Engineering Contradiction:

Improvebraking powerVSAvoidinstallation space

Core Design Contradiction:

PowerVSArea of stationary object

Solution Approach 1:

The guide assemblies are arranged radially outward from the brake disc center plane, utilizing the radial dimension rather than only axial space. This allows the electromechanical drive components to be positioned in the radial direction, effectively using three-dimensional space around the brake disc to reduce the axial installation space requirement.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The guide elements are disposed within guide ducts that are enclosed by the brake carrier, creating a nested arrangement where the guide elements fit inside the guide ducts. This nesting allows compact positioning of multiple components in limited space while maintaining their functional relationships.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Power

If electromechanical drives are used to actuate the actuator piston, then high braking power can be achieved, but the weight increases

Engineering Contradiction:

Improvebraking powerVSAvoidbrake system weight

Core Design Contradiction:

PowerVSWeight of stationary object

Solution Approach 1:

The patent replaces traditional hydraulic actuation systems with electromechanical drives that use electric motors and gearboxes to actuate the actuator piston. This substitution eliminates the need for hydraulic fluid, reservoirs, and complex piping, thereby reducing overall system weight while maintaining high braking power capability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Area of stationary object

If guide assemblies are arranged close to the brake disc center plane, then installation space is reduced, but bearing forces between brake carrier and floating calliper increase

Engineering Contradiction:

Improveinstallation spaceVSAvoidbearing forces

Core Design Contradiction:

Area of stationary objectVSForce

Solution Approach 1:

Instead of arranging guide assemblies only in the axial direction close to the center plane, the patent positions them radially outward at optimized distances from the center plane. This spatial reconfiguration reduces the lever arm and moment forces acting on the brake carrier-float calliper interface, thereby reducing bearing forces while still achieving compact installation.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

4Adaptability or versatility

If additional components such as brake covers or brake dust collectors are accommodated, then functionality is improved, but installation space requirement increases

Engineering Contradiction:

Improvecomponent accommodation capabilityVSAvoidinstallation space

Core Design Contradiction:

Adaptability or versatilityVSArea of stationary object

Solution Approach 1:

The brake carrier is designed to serve multiple functions: it houses the guide ducts for the guide assemblies, provides structural support for the floating calliper, and accommodates additional components such as brake covers and brake dust collectors. This multi-functional design allows various components to be integrated into the same spatial envelope without proportionally increasing installation space requirements.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS20250027543A1Floating-calliper brake

Publication Date: 2025.01.23 ZF ACTIVE SAFETY GMBH

AI summary

The disclosure relates to a floating-calliper brake a piston region is situated on a brake disc first side, in an axial direction, that can be accommodated in a brake disc chamber, and a finger region is situated on a brake disc second side. A first guide assembly is arranged on a third side running congruently with a brake disc rotational axis that can be accommodated in the chamber and extends along a first guide axis running in the axial direction and parallel to the rotational axis. A second guide assembly is arranged on a fourth side, opposite the third side and extends along a second guide axis running in the axial direction and parallel to the rotational axis. The first guide assembly has a first guide duct enclosed by the brake carrier, a first guide element is guided displaceably in the axial direction in the first guide duct and has a first guide shaft and a first fastening end, and only one first connecting portion that is connected to the floating calliper. The first guide element is fixedly connected to the first connecting portion by its first fastening end. The first connecting portion is situated at the level of the finger region in the axial direction and/or at least partially on the second side.