Torque Distributing Assembly for Brake Piston Load Balancing
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Solution Overview
Problem
Existing brake systems with multiple pistons face challenges in efficiently distributing torque to manage load and resistance differences, leading to uneven braking performance due to factors like brake pad wear, system degradation, and mechanical variations, which existing technologies fail to address effectively with a single motor configuration.
Innovation Solution
A torque distributing assembly that redistributes torque between multiple brake pistons based on load differences by using a single motor and a gear train system, ensuring equal torque distribution until resistance varies, allowing the system to adapt and maintain consistent braking performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of stationary object
If a single motor is used to move multiple brake pistons, then weight, cost, and packaging space are reduced, but torque distribution becomes difficult to manage due to load and resistance differences
Solution Approach 1:
The brake system is divided into multiple independent piston assemblies, each with its own brake pad and rotor contact interface. The single motor's output is segmented through a mechanical linkage system that allows independent torque distribution to each piston, enabling the system to handle load differences while maintaining the benefits of a single motor configuration.
Solution Approach 2:
The mechanical linkage system incorporates dynamic elements that automatically adjust torque distribution based on real-time load conditions. When one brake pad experiences higher resistance (e.g., due to wear), the linkage dynamically redistributes torque to maintain balanced braking force, providing adaptability without requiring multiple motors or complex electronic control.
2Ease of operation
If torque is distributed equally to all brake pistons, then the system is simple to control, but braking performance becomes uneven when load differences occur
Solution Approach 1:
The mechanical linkage system is designed to automatically sense and compensate for load differences between brake pistons. The system self-adjusts torque distribution based on the mechanical resistance encountered by each brake pad, eliminating the need for complex electronic sensors or control algorithms while maintaining consistent braking performance across varying load conditions.
Solution Approach 2:
The mechanical linkage incorporates passive feedback mechanisms where the physical state of each brake piston (position, resistance) directly influences the torque distribution through mechanical advantage variations. This inherent feedback loop ensures that pistons experiencing higher resistance receive proportionally more torque, maintaining braking consistency without requiring active electronic control.
3Adaptability or versatility
If multiple motors are used to move brake pistons, then torque distribution is easier to control, but weight, cost, and system complexity increase
Solution Approach 1:
The single motor is designed to perform multiple functions: it drives the entire brake system and simultaneously distributes appropriate torque to each piston through the mechanical linkage. This multi-functional design eliminates the need for separate motors at each piston while maintaining the ability to handle load variations, reducing overall system complexity and component count.
Solution Approach 2:
A mechanical linkage system serves as an intermediary between the single motor and multiple brake pistons. This intermediary mechanism translates the motor's rotational output into coordinated linear motion for each piston, automatically managing torque distribution based on mechanical resistance. The intermediary eliminates the need for direct motor-piston connections, simplifying the system while maintaining control capability.
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 enables a single motor to effectively manage torque distribution across multiple brake pistons, ensuring consistent braking performance even with uneven load conditions, reducing wear and maintaining vehicle control by dynamically adjusting torque supply to each piston.
Implementation Method 1
A torque distributing assembly that redistributes torque between multiple brake pistons based on load differences by using a single motor and a gear train system
Data Source
AI summary
A brake system that includes a brake caliper, a motor, and a torque distributing assembly configured to distribute torque from the motor to a first brake piston and/or to a second brake piston. The torque distributing assembly includes a gear set that includes gears that are configured to rotate about an axis. One of the first brake piston and the second brake piston is configured to move along the same axis during a brake apply or a brake release.