Direct-Acting Self-Energizing Brake Caliper Without Wedge Locking
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Solution Overview
Problem
Existing self-energizing brake systems, particularly those using a wedge structure, suffer from complex designs, high manufacturing costs, and self-locking issues, which limit their applicability and productivity, and the braking force generated by electro-mechanical brake calipers may not be sufficient for emergency braking scenarios.
Innovation Solution
A direct-acting self-energizing brake caliper design that eliminates the wedge mechanism, featuring a caliper bracket with first and second caliper arms connected to inboard and outboard brake pads, utilizing a return spring and piston mechanisms to amplify braking force without self-locking, allowing direct application of actuator force to brake pads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a wedge structure is used to amplify braking force, then braking force amplification is achieved, but self-locking occurs and device complexity increases
Solution Approach 1:
The patent removes the wedge structure from the brake caliper system entirely. Instead of using a wedge mechanism to amplify force, the invention employs a direct-acting caliper where the piston directly pushes the brake pads against the rotor. This extraction of the problematic wedge element eliminates self-locking while maintaining braking force through proper mechanical leverage design.
Solution Approach 2:
Rather than using a wedge to convert small piston force into large brake force, the patent inverts the approach by using a direct push mechanism where the piston force is transmitted through properly positioned caliper arms to achieve force multiplication. The caliper arms are positioned such that the piston force creates a mechanical advantage through leverage, achieving force amplification without the self-locking wedge mechanism.
2Force
If a wedge structure is used for self-energizing brake, then braking force is amplified, but manufacturing cost increases
Solution Approach 1:
By removing the complex wedge mechanism, the patent significantly simplifies the manufacturing process. The direct-acting caliper design requires fewer precision-machined components, fewer assembly steps, and eliminates the need for specialized wedge-shaped parts. This results in lower manufacturing costs while maintaining effective braking force through optimized caliper arm positioning and leverage.
3Device complexity
If EMB caliper is used in front-wheel disc brake, then braking system is simplified, but braking force is insufficient for emergency braking
Solution Approach 1:
The patent introduces dynamic force amplification through the caliper arm mechanism. As the brake pads contact the rotor and friction develops, the caliper arms rotate about their pivot points, creating a self-energizing effect where the friction force itself contributes to increasing the clamping force. This dynamic mechanism allows the system to generate sufficient emergency braking force while maintaining a relatively simple EMB structure.
Solution Approach 2:
The caliper arm design creates a self-energizing effect where the friction force between the brake pads and rotor automatically contributes to increasing the braking force. As the pads press against the rotor, the reaction force through the caliper arm geometry amplifies the clamping force without requiring additional actuator force, enabling emergency braking capability in a simplified EMB system.
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
The solution provides a robust and efficient braking system that amplifies braking force effectively, preventing self-locking and reducing manufacturing complexity, thus enhancing braking performance in various braking devices.
Implementation Method 1
At least one of the first caliper arm and the second caliper arm can be connected to the caliper bracket by a return spring
Implementation Method 2
One of the first braking part and the second braking part can comprise a piston which applies a braking force to one of the inboard brake pad and the outboard brake pad
Implementation Method 3
The first caliper arm comprises a first end which is rotatably connected to the caliper bracket with respect to a first rotation axis extending in the radial direction of a wheel
Implementation Method 4
a first braking part applying a braking force to an inboard brake pad and a second braking part applying a braking force to an outboard brake pad
Data Source
AI summary
A self-energizing brake caliper includes a caliper bracket fixed to a body of a braked device; a first caliper arm; and a second caliper arm. The first caliper arm comprises a first end which is rotatably connected to the caliper bracket with respect to a first rotation axis extending in the radial direction of a wheel and a second end which is rotatably connected to the inboard brake pad at a first position with respect to a second rotation axis which is parallel with the first rotation axis. The second caliper arm comprises a first end which is rotatably connected to the caliper bracket with respect to a third rotation axis extending in the radial direction of the wheel and a second end which is rotatably connected to the outboard brake pad at a second position with respect to a fourth rotation axis which is parallel with the third rotation axis.