Disc Brake Reliability: Preventing Spindle Disconnection
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Summary
Problems
Disc brakes in commercial vehicles face operational failures due to worn-out friction linings, as adjusting spindles can become disconnected from the bridge, leading to a loss of braking function, either due to ignored wear sensor signals or sensor failures, resulting in insufficient thickness and mechanical limitations.
Innovation solutions
The introduction of an axial groove in the adjusting spindle with a captive stop mechanism, combined with a synchronizing device using drive wheels and a traction means, ensures the spindle remains connected to the bridge until a predetermined minimum friction lining thickness is reached, ensuring torque transmission and redundancy through a wear sensor integration.
TRIZ Analysis
Specific contradictions:
General conflict description:
Principle concept:
If the adjusting spindle is made adjustable axially to compensate for wear, then the clearance between brake pad and brake disc can be maintained, but the spindle may become disconnected from the bridge when over-adjusted
Why choose this principle:
The axial groove is pre-formed in the adjusting spindle at a specific depth, and the stop element is pre-positioned in the bridge. When the spindle is adjusted, the groove automatically engages the stop element before the spindle can be completely unscrewed, preventing disconnection. This preliminary structural arrangement ensures that the connection is maintained even when wear compensation is exceeded.
Principle concept:
If a wear sensor is installed to detect minimum friction lining thickness, then safety can be improved, but the sensor may fail or be ignored leading to continued operation with insufficient lining
Why choose this principle:
The axial groove and stop element create a mechanical safety buffer that prevents complete spindle disconnection even when wear sensors fail or are ignored. This mechanical cushioning system provides a backup safety mechanism that does not rely on electronic sensors, thereby compensating for sensor limitations without adding complex sensor systems.
Application Domain
Data Source
AI summary:
The introduction of an axial groove in the adjusting spindle with a captive stop mechanism, combined with a synchronizing device using drive wheels and a traction means, ensures the spindle remains connected to the bridge until a predetermined minimum friction lining thickness is reached, ensuring torque transmission and redundancy through a wear sensor integration.
Abstract
The invention relates to a disc brake for a commercial vehicle, comprising a) a brake caliper which extends over a brake disc, b) a clamping device which is arranged in the brake caliper for pressing brake pads against the brake disc, c) at least one adjusting spindle (3) which is rotatably mounted in a bridge (1) by means of a corresponding thread, said clamping device engaging the bridge, and d) an adjusting device which is positioned in the brake caliper and by means of which a wear-induced change of the clearance between the brake pad and the brake disc can be substantially compensated for via an axial movement of the adjusting spindles (3). The disc brake is designed such that e) the adjusting spindle (3) has at least one axial groove (11) on the outside, the length of the groove being limited in the direction of the clamping device, and a stop (10) which is axially fixed relative to the bridge (1) engages into the axial groove in a relatively displaceable manner.