Symmetrical Brake Actuator Gear Layout for Left-Right Mountability
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Solution Overview
Problem
Conventional brake actuators have asymmetrical shapes and structures, leading to interference with vehicle components, reduced mountability, increased manufacturing costs, and decreased durability due to varying wheel positions, necessitating separate designs for left and right wheels.
Innovation Solution
An actuator design with a symmetrical housing and gear assembly, featuring a bearing between gear units to stabilize load absorption and symmetric mounting parts, along with a method of manufacturing that includes press-fitting and injection molding to simplify structure and reduce costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the actuator has an asymmetrical shape to accommodate internal gear structure, then the gear assembly can be configured, but the mountability and applicability to vehicle are degraded due to interference with surrounding components
Solution Approach 1:
The patent applies asymmetry principle by configuring the gear assembly with specific asymmetric gear arrangements (worm gear, bevel gear, and pinion gear in a particular configuration) while maintaining an overall symmetrical housing shape. This allows the internal gear structure to function properly while the external symmetrical shape ensures uniform mountability on both left and right wheels.
2Adaptability or versatility
If different actuators are designed for left and right wheels to avoid interference, then interference problems are solved, but production efficiency decreases and manufacturing cost increases
Solution Approach 1:
The patent applies universality principle by designing a symmetrical housing with symmetrically arranged mounting parts that can be uniformly installed on both left and right wheels. The gear assembly internally accommodates the necessary asymmetric configurations through proper gear arrangement, allowing a single actuator design to serve both wheels without requiring different designs, thereby maintaining high production efficiency and reducing manufacturing costs.
3Device complexity
If the actuator has an asymmetrical shape, then the gear elements can be configured, but the durability is degraded due to position-dependent wear
Solution Approach 1:
The patent applies asymmetry principle within the internal gear configuration, arranging the worm gear, bevel gear, and pinion gear in a specific asymmetric pattern that ensures proper mechanical function. The symmetrical housing and mounting arrangement ensure that the actuator experiences identical load conditions regardless of whether it is installed on the left or right wheel, thereby improving durability by eliminating position-dependent wear variations.
4Ease of manufacture
If the actuator structure is simplified to improve assemblability, then manufacturing cost is reduced, but the gear assembly functionality may be compromised
Solution Approach 1:
The patent applies segmentation principle by dividing the actuator into distinct functional modules: a symmetrical housing containing the gear assembly, a motor unit, and mounting parts. The gear assembly itself is segmented into separate gear elements (worm gear, bevel gear, pinion gear) that can be manufactured and assembled independently. This modular segmentation simplifies manufacturing and assembly processes while maintaining the necessary gear functionality.
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
Improves mountability, reduces interference, enhances durability, and stabilizes braking power generation regardless of wheel position, while simplifying assembly and lowering production costs.
Implementation Method 1
a bearing provided between the first driven gear and the second driven gear on the gear shaft
Implementation Method 2
the gear assembly includes a driving gear provided on a driving shaft of the motor, a first gear unit connected to the driving gear to transmit a rotational force
Implementation Method 3
a motor configured to provide a driving force
Data Source
AI summary
An actuator may include a motor generating a rotational force, a gear assembly transmitting the rotational force of the motor, and a housing accommodating the gear assembly therein. The gear assembly includes a driving gear provided on a driving shaft of the motor, a first gear unit connected with the driving gear, and a second gear unit connected with the first gear unit to transmit the rotational force transmitted from the first gear unit to a power conversion unit, and the first gear unit includes a gear shaft, a first driven gear provided on one side of the gear shaft and meshed with the driving gear, a second driven gear provided on the other side of the gear shaft and meshed with the second gear unit, and a bearing provided on the gear shaft between the first driven gear and the second driven gear.