Trailer Disc Brake Screw Actuation for High Braking Force
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Solution Overview
Problem
Existing trailer braking systems, particularly hydraulic and electric drum brakes, are either complex and expensive or lack sufficient braking force, leading to safety risks and accidents, especially when trailers are overloaded or in adverse road conditions, with no effective low-cost alternative available.
Innovation Solution
An electric disc brake system for trailers that converts rotational motion of a threaded shaft into linear motion to engage brake pads against a rotor, using a power screw assembly driven by an electric motor, providing braking force similar to hydraulic systems while incorporating standard components like axles and calipers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If hydraulic disc brake systems are used, then braking force is improved, but device complexity and cost increase
Solution Approach 1:
The patent replaces the hydraulic mechanical system with an electric motor-driven system. Instead of using hydraulic fluid and pistons to generate braking force, the invention uses an electric motor coupled with a power screw assembly to convert rotational motion into linear motion for actuating the brake pads, thereby reducing system complexity while maintaining adequate braking force
Solution Approach 2:
The invention extracts and eliminates the complex hydraulic components (hydraulic fluid, hoses, seals, and hydraulic pistons) from the braking system, retaining only the essential mechanical elements needed for brake actuation. This simplification reduces device complexity while the electric motor provides the necessary actuation force
2Device complexity
If electric drum brakes are used, then device complexity and cost are reduced, but braking force decreases
Solution Approach 1:
The patent changes the actuation mechanism from the traditional electric drum brake configuration to a power screw-based linear actuation system. This parameter change in the mechanical transmission allows for more effective force multiplication and better control over brake pad application, thereby increasing braking force while keeping the system relatively simple
Solution Approach 2:
The invention employs a disc brake configuration with a rotating disc rotor instead of a drum, providing a larger effective braking surface area. The disc geometry allows for more efficient heat dissipation and greater braking force capability compared to the enclosed drum structure, while the power screw mechanism provides precise control over pad engagement
3Device complexity
If no trailer brakes are installed, then cost is reduced, but safety and braking capacity deteriorate
Solution Approach 1:
The braking system is designed to be self-contained and independent, with its own electric motor and power screw assembly that does not rely on the towing vehicle's braking system. This self-service capability ensures that the trailer can provide its own braking force regardless of the towing vehicle's condition or capacity, thereby improving safety while remaining cost-effective
Solution Approach 2:
The system includes a controller that can anticipate braking needs and activate the electric motor in advance. The controller receives signals from the towing vehicle's brake system or operates independently based on speed and distance parameters, ensuring that braking force is applied promptly and effectively when needed, thereby enhancing safety
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 system offers a cost-effective and efficient braking solution that enhances trailer safety by ensuring adequate braking force, reducing the risk of jackknifing and accidents, aligning with safety standards and addressing the limitations of existing brake technologies.
Implementation Method 1
A power screw assembly is attached to the caliper and employs an electric motor coupled to a piston by use of a screw drive. The screw drive converts rotation of the motor into linear motion to push the piston
Implementation Method 2
An inner brake pad is slidably secured to the caliper and juxtapositioned to an inner surface of the rotor. An outer brake pad is slidably secured to the caliper and juxtapositioned to an outer surface of the rotor. A power screw assembly is attached to the caliper and employs an electric motor coupled to a piston by use of a screw drive
Implementation Method 3
The inner and outer brake pads engage the rotor based upon the amount of pressure applied by the piston
Data Source
AI summary
An electric disc brake system for a trailer. The brake system employs a caliper assembly that is attached to the trailer with floating fasteners, wherein the caliper assembly straddles an axle mounted rotor positioning an inner and outer brake pad adjacent to the rotor. A screw drive assembly is attached to the caliper. The assembly includes an electric motor coupled to a piston by a threaded shaft. The screw drive assembly converts rotation of the electric motor into linear motion to movement of the piston, wherein the inner and outer brake pads engage the rotor based upon the amount of pressure applied by the piston. A controller reacts to the pressure applied to a brake pedal to cause the electric motor to rotate in a clockwise or counter-clockwise direction.