Gear Assembly Axle Contour Rolling for Brake Noise Reduction
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Solution Overview
Problem
Gear assemblies in electrically operable brakes for motor vehicles produce noise due to local excess loads and deformations, leading to unfavorable engagement of intermeshing teeth and increased wear, which affects the longevity of components.
Innovation Solution
The gear assembly features intermeshing toothed wheels with axially outwardly curved and straight circumferential surfaces that allow for rolling motion, enabling the axle element and toothed wheel to maintain an inclined position, thereby compensating for deformations and minimizing changes in tooth engagement, thus reducing noise and wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the support structure is rigid and fixed, then structural stability is improved, but deformation under high forces causes inclined position of axle elements and unfavorable engagement of intermeshing teeth, leading to noise and increased wear
Solution Approach 1:
The patent applies the dynamics principle by making the toothed wheel adjustable in its position relative to the axle element. The toothed wheel can dynamically adapt its inclination angle to compensate for deformations in the support structure, maintaining optimal engagement of intermeshing teeth even under high forces. This dynamic adjustment prevents the inclined position that would otherwise cause noise and unfavorable engagement.
Solution Approach 2:
The patent implements parameter changes by allowing the inclination angle of the toothed wheel to vary. The system changes the positional parameter of the toothed wheel relative to the axle element, enabling adaptation to deformation conditions. This parameter adjustment ensures consistent engagement of teeth while accommodating support structure deformation under load.
2Manufacturing precision
If the toothed wheels are fixed in position, then manufacturing precision is improved, but deformation of components causes changes in tooth engagement, increasing wear and reducing component lifetime
Solution Approach 1:
The patent applies dynamics by enabling the toothed wheel to adjust its position dynamically in response to component deformations. This movement capability allows the system to maintain proper tooth engagement despite changes in component geometry due to wear or deformation, thereby extending component lifetime while preserving engagement precision.
Solution Approach 2:
The system implements self-service through the automatic adjustment mechanism that compensates for deformations without external intervention. The toothed wheel self-adjusts its position to maintain optimal engagement, effectively compensating for wear and deformation of other components, thereby extending the operational life of the gear assembly.
3Stability of the object's composition
If the axle elements are held firmly in position, then positional stability is improved, but deformation of support structure causes inclined position and unfavorable engagement, promoting noise production
Solution Approach 1:
The patent applies dynamics by allowing the toothed wheel to move relative to the firmly held axle element. While the axle element remains fixed in position, the toothed wheel can adjust its orientation and position to compensate for support structure deformation, maintaining proper tooth engagement and preventing noise from unfavorable engagement conditions.
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 minimizes noise production and extends the lifespan of components by maintaining consistent tooth engagement and reducing wear, ensuring a more stable operation of the gear assembly.
Implementation Method 1
the circumferential surfaces roll relative to each other on the contours in order to bring the at least one toothed wheel and the axle element into an inclined position relative to each other
Data Source
AI summary
The gear assembly can be operatively connected on the input side to a drive machine and on the output side preferably to an actuating element of the electrically operable brake and comprises at least one gear stage. The at least one gear stage comprises at least two intermeshing gear wheels, of which at least one gear wheel is rotatably mounted on an axle element by engagement of the axle element in a receptacle of the at least one gear wheel. The receptacle and the axle element have mutually corresponding peripheral surfaces, of which, in the axial direction, at least one peripheral surface has an outwardly curved contour and the other peripheral surface has a contour designed such that the peripheral surfaces roll against one another on the contours in order to bring the at least one gear wheel and the axle element into an oblique position relative to one another.