Self-Erecting Threaded Spindle Module for Blind Brake Assembly
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Solution Overview
Problem
The existing threaded spindle modules in wheel brake actuators face challenges in precise alignment and cost-effective assembly due to blind assembly requirements, leading to potential misalignment and increased production complexity, especially in large-scale manufacturing.
Innovation Solution
A self-aligning threaded spindle module with a convex, three-dimensional design and a lowered center of gravity, incorporating the physical properties of a capsizing-resistant yacht, automatically adjusts to a stable, vertically aligned position, eliminating the need for precise manual alignment and ensuring efficient coupling with the actuator interface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional threaded spindle modules are used with standard assembly methods, then assembly can be performed with conventional equipment, but alignment precision deteriorates and manual adjustment is required increasing complexity
Solution Approach 1:
The threaded spindle module employs asymmetric mass distribution with a lowered center of gravity positioned offset from the geometric center. This asymmetric design creates a self-aligning mechanism where gravity generates a restoring moment that automatically centers the spindle in the receptacle, eliminating the need for precise manual alignment while maintaining high alignment precision
Solution Approach 2:
The module utilizes its own weight and gravitational force to achieve self-alignment and self-centering during assembly. The asymmetric mass distribution enables the spindle to automatically correct its own positioning errors without requiring external alignment tools or manual intervention, thereby reducing assembly complexity while improving precision
2Extent of automation
If blind assembly is performed without visual indication, then automation is enabled, but assembly reliability deteriorates due to misalignment risks
Solution Approach 1:
The threaded spindle module performs self-alignment through its asymmetric mass distribution and gravitational self-righting mechanism. This self-service capability ensures that even during blind automated assembly without visual feedback or alignment tools, the spindle automatically achieves correct positioning, thereby maintaining high assembly reliability while enabling full automation
Solution Approach 2:
The invention changes the physical parameter of mass distribution within the spindle module, creating an asymmetric density profile with lowered center of gravity. This parameter change transforms the assembly process from one requiring precise control to one where gravity naturally guides the spindle into the correct position, ensuring reliability during automated assembly
3Ease of manufacture
If the threaded spindle module has uniform density distribution, then manufacturing is simplified, but alignment capability deteriorates due to lack of self-aligning properties
Solution Approach 1:
The module deliberately employs asymmetric mass distribution rather than uniform density, creating a lowered center of gravity positioned offset from the geometric center. This asymmetric design provides the self-aligning capability through gravitational restoring moments while remaining manufacturable through conventional casting or machining processes with controlled material distribution
4Stability of the object's composition
If the center of gravity is lowered in the threaded spindle module, then self-aligning stability is improved, but manufacturing complexity increases due to precise center of gravity coordination
Solution Approach 1:
The design employs asymmetric mass distribution with the center of gravity lowered and positioned offset from the geometric center. This creates a stable equilibrium position where the spindle naturally aligns vertically during assembly. The asymmetric design achieves high self-aligning stability through gravitational restoring moments while remaining compatible with conventional manufacturing processes
Solution Approach 2:
The invention changes the mass distribution parameter within the spindle module, creating a lowered and offset center of gravity. This parameter change fundamentally improves self-aligning stability by enabling automatic centering through gravity-driven restoring moments, while the modification can be integrated into existing manufacturing workflows
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 simplifies and automates the assembly process, reducing the risk of assembly errors and production standstills, enabling cost-effective, efficient production of motor vehicle brake components by ensuring automatic self-alignment and stability without the need for additional image-processing or data processing systems.
Implementation Method 1
the threaded spindle module, with gravity drive, or as a control-related response to a disturbance variable, or an intervention or deflection, automatically exhibits a monostable equilibrium position
Implementation Method 2
the threaded spindle module is designed in relation to its joint, in the direction of gravity (i.e., with its center of gravity lowered, meaning at the lowest possible height h3), such that the restoring forces on the threaded spindle module are maximized
Data Source
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AI summary
Threaded spindle module (1) comprising a threaded spindle (8) which extends along a longitudinal axis A and has an external thread (15) at an output-side end (13), and has, offset with respect to the external thread (15), a drive-side end (14) with a pin (10) for coupling fixedly to an actuator interface so as to rotate with it, and with a threaded nut (9) which is screwed onto the external thread (15), and wherein a support (12) of the threaded nut (9), which support (12) is curved in a joint-like manner, as a pivoting joint of the threaded spindle module (1) is provided with a pivoting joint centre (16) in relation to an associated seat (11). The threaded spindle module (1) is provided designed as a convex three-dimensional body with a homogeneous, uniform density distribution in such a way that the threaded spindle module (1) is erected in each case in an automatic/self-acting manner into a monostable equilibrium position by way of gravity, or as a response to a fault, or an intervention or deflection, and wherein the monostable equilibrium position places the drive-side end (14) of the threaded spindle module (1) vertically at the top and the output-side end (13) of the threaded spindle module (1) vertically at the bottom.