Split Inner Race Brake Bearing for Load and Weight Balance
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Solution Overview
Problem
Existing brake assemblies in electro-mechanical brake systems face challenges in efficiently managing load distribution and material utilization in their bearing assemblies, leading to increased costs and potential performance degradation.
Innovation Solution
The brake assembly incorporates a split-type inner race configuration with asymmetrically shaped forward and aft inner race portions, where the forward portion is stronger and larger, while the aft portion is lighter and smaller, optimized for load-bearing and non-load-bearing functions respectively, using different materials and shapes to enhance load capacity and reduce weight and manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a conventional single-piece inner race is used in the bearing assembly, then the structure is simple and manufacturing is straightforward, but the load distribution is inefficient and material utilization is poor leading to increased costs
Solution Approach 1:
The inner race is divided into two separate portions: a forward inner race portion and an aft inner race portion. This segmentation allows each portion to be optimized independently for its specific functional requirements, improving material utilization while maintaining manufacturing feasibility through separate fabrication and assembly processes
Solution Approach 2:
Different portions of the inner race are assigned different material properties and geometries based on local load requirements. The forward portion uses stronger, heavier material for load-bearing regions, while the aft portion uses lighter material for non-load-bearing regions, optimizing overall material efficiency
2Device complexity
If a conventional single-piece inner race is used in the bearing assembly, then the structure is simple, but the load distribution is inefficient leading to performance degradation
Solution Approach 1:
Dividing the inner race into forward and aft portions enables differentiated load management, where each segment can be specifically designed to handle its local loading conditions, thereby improving overall load distribution efficiency and bearing assembly reliability
Solution Approach 2:
The forward and aft inner race portions are designed with asymmetric geometries and material properties tailored to their respective functional requirements, allowing optimal load distribution across the bearing assembly while maintaining reasonable structural complexity
3Strength
If stronger and larger material is used for the entire inner race to ensure load-bearing capacity, then load capacity is sufficient, but weight increases and manufacturing costs rise
Solution Approach 1:
The forward inner race portion that requires load-bearing capacity is made with stronger, larger material, while the aft inner race portion that does not require load-bearing capacity is made with lighter material, thereby reducing overall weight while maintaining sufficient load capacity where needed
Solution Approach 2:
Segmenting the inner race allows differentiation of material properties between load-bearing and non-load-bearing regions, enabling weight reduction in non-critical areas while preserving strength in critical load-bearing areas
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 achieves optimal load distribution, reduces material usage, and lowers manufacturing costs without compromising performance, enabling a more efficient and cost-effective brake assembly.
Implementation Method 1
rollable bodies rollably disposed between the inner race and the outer race
Data Source
AI summary
A brake assembly comprises a rotatable part configured to be rotatable by an actuator and a translatable part operably coupled with the rotatable part and configured to be axially translatable relative to the rotatable part to move the brake pad according to rotation of the rotatable part; and a bearing assembly configured to support the rotatable part. The bearing assembly comprises: an inner race comprising a forward inner race portion and an aft inner race portion; an outer race; and rollable balls. The forward inner race portion located closer to the brake pad than the aft inner race portion is made of a different and/or stronger material from and/or than the aft inner race portion located farther from the brake pad than the forward inner race portion, and/or is smaller than the forward inner race portion located farther from the brake pad than the aft inner race portion.