Modular Vehicle Brake Actuator Assembly Design
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Solution Overview
Problem
Existing actuator assemblies for vehicle brakes are complex and costly to manufacture, requiring intricate assembly processes and numerous external interfaces, which complicates their installation and increases production time.
Innovation Solution
A modular actuator assembly design featuring separate control and drive assemblies housed in a common, compact plastic or metal shell, with a brushless DC motor and spindle drive, allowing for parallel production and simplified installation, reducing external interfaces and manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If actuator assemblies are manufactured as integrated units, then functional reliability is improved, but manufacturing complexity and production time increase
Solution Approach 1:
The actuator assembly is divided into separate modular sub-assemblies (control assembly and drive assembly) that can be manufactured independently and then combined. This segmentation allows parallel production of components, reducing overall manufacturing complexity and time while maintaining functional reliability through standardized connection interfaces.
2Stability of the object's composition
If actuator assemblies are manufactured as integrated units, then structural stability is improved, but production time and cost increase
Solution Approach 1:
Individual sub-assemblies are pre-manufactured and pre-tested separately before final assembly. This preliminary action allows for optimized production schedules, quality control at each stage, and parallel manufacturing processes, significantly reducing total production time while ensuring structural stability through standardized connection designs.
3Adaptability or versatility
If numerous external interfaces are provided for installation, then functional versatility is improved, but installation complexity and effort increase
Solution Approach 1:
The actuator assembly employs standardized universal interfaces and connection elements that can accommodate multiple mounting configurations and vehicle types. This universality provides functional versatility while simplifying installation procedures, as the same interface design can be used across different applications, reducing installation complexity and training requirements.
Data Source
AI summary
An actuator assembly for a vehicle brake is described, which comprises a control assembly, which can be installed as a separate sub-unit and has a partition panel and a circuit board fastened to said partition panel. The actuator assembly furthermore has a drive assembly (14), which can be installed as a separate sub-unit and which comprises a carrier assembly on which an electric motor, a spindle drive and a gear unit are mounted, which gear unit drivingly couples the electric motor and the spindle drive. The control assembly and the drive assembly are arranged in a common housing. A method for manufacturing an actuator assembly for a vehicle brake is furthermore presented.