Inhaul cable operated disc brake system

Abstract

The present invention relates to a cable operated disc brake system (100) designed to address performance and cost differences between drum brakes and hydraulic disc brakes. With a floating caliper design, the system (100) enables one brake pad engagement to trigger the caliper (101) to float and engage the other brake pad. Through components such as a brake caliper (101), a caliper cover (102), a cam lever (103), an upper cam (104), a lower cam (105), a spherical roller (106), an adjuster (107), a piston (108), a spring (109), a plurality of mounting bolts (110) and a dust cover (111) of the system, the system combines mechanical advantages and control cable technology to provide enhanced braking performance at a more economical cost than a hydraulic disc brake. The mechanical braking system provides a promising solution for filling the gap of the braking technology in the aspects of performance and cost.

Description

Technical Field

[0001] The present invention relates to a braking device designed for a two-wheeled vehicle. The present invention particularly relates to a cable operated disc brake system (Cable Operated Disc Brake System) that utilizes a mechanical mechanism operated by a control cable. The innovative system produces a variable output force, thereby providing efficient braking for a two-wheeled vehicle. Background Art

[0002] Braking systems are essential to ensure safety and control of two-wheeled vehicles. There are many types of braking systems, including electromagnetic brakes, friction brakes, hydraulic brakes, air brakes, drum brakes, and disc brakes. These systems usually work by absorbing energy from the moving system through friction, thereby stopping the movement. Disc brakes and drum brakes are the two main classifications based on the working principle. Disc brakes are directly connected to the front wheel, while drum brakes are installed on the rear wheel. Although traditional drum brakes are cost-effective, they lack ideal performance and response speed. In contrast, hydraulic disc brakes have superior performance but tend to be more expensive, making them difficult to enter the wider market.

[0003] Among the different braking systems, hydraulic disc brakes are widely used. A hydraulic disc brake system consists of a brake rotor and brake pads that rotate with the wheel under the pressure clamping of a piston. By utilizing an incompressible fluid such as brake fluid, the hydraulic brake system transmits force to force the brake pads against the rotor, thereby effectively slowing the vehicle down.

[0004] However, hydraulic disc brake systems have certain limitations. One of these drawbacks is the potential mess associated with managing the hydraulic fluid. If a leak occurs, it can be difficult to deal with and can even create a fire hazard. Additionally, hydraulic systems can be expensive to maintain due to the complexity and numerous parts involved.

[0005] To overcome the shortcomings of existing systems, several technologies have been developed over the decades to provide improved performance braking systems that are lower maintenance and more cost-effective.

[0006] Patent application TWI545052B entitled "Brake system and apparatus" discloses a brake system comprising a brake pad connected to a slider assembly capable of linear motion in a guide. The slider assembly and the guide are linked to a first brake. In addition, a second brake actuator is connected to the slider assembly, the guide, and the second brake. When the first brake is engaged, the slider assembly is pressed against a rotating braking surface. Therefore, the friction between the brake pad and the rotating braking surface causes the slider assembly to move in the guide, subsequently activating the second brake actuator. The second brake actuator then engages the second brake. Conversely, when the first brake is released, the slider assembly disengages from the rotating braking surface, causing the second brake actuator to release and subsequently disengage from the second brake.

[0007] Patent application US9126653B2, entitled "Straddle type vehicle brake system and straddle type vehicle", discloses a device linking a front disc and a rear drum to improve the braking performance and safety of a two-wheeled vehicle. The device includes a housing, a brake connecting rod, a rear cable, a front cable, a steering rod, a balancer, and a connecting rod. The device effectively distributes the braking force between the front disc brake and the rear drum brake, thereby improving braking efficiency and shortening the braking distance. The device also helps to reduce vehicle skidding and drifting, thereby maintaining the center of gravity during braking. This improves overall driving safety and reduces the reliance on advanced driving skills.

[0008] Patent CN201124920Y, entitled "Hydraulic Combined Braking System for Motorcycles", discloses a hydraulic combined braking system designed specifically for motorcycles. This advanced system includes various key components, including left and right brake master pump assemblies, brake distribution delay valve assemblies, front and rear brake caliper assemblies, and brake oil pipes. By effectively controlling the initial braking time of the front and rear wheels, this innovative system ensures a well-balanced distribution of braking force. It does this by sensing the input pressure from the brake master pump via a valve. Since the system optimizes the coordination between the front and rear brake mechanisms, it greatly improves the braking stability of the motorcycle and enhances safety.

[0009] None of the prior art offers any solution to bridge the gap between the limitations of traditional drum brakes and the high costs associated with hydraulic disc brakes. Therefore, an innovative approach is needed to address the challenges faced by manufacturers and end users. The goal is to develop a practical and cost-effective braking system that provides optimal performance while ensuring accessibility to a wide range of users. Summary of the invention

[0010] The present invention relates to a cable-operated disc brake system, which includes multiple components that cooperate with each other to achieve effective and reliable braking. The system includes a floating caliper, which houses the internal mechanism and monitors the reaction force during braking. The caliper cover provides additional protection and safety for the internal components. The system includes a cam rod, an upper cam and a lower cam for transmitting load and stroke, adjusting the mechanical advantage and converting the rotary motion into linear motion. A plurality of spherical rollers in the upper cam and the lower cam enable fine adjustment of the braking system. The adjuster enables precise adjustment of the piston position to compensate for brake pad wear. The piston transmits the load to engage the brake pad with the brake disc rotor, and the spring helps the piston to retract after the brake is released. A plurality of mounting bolts ensure the secure connection of the caliper and the caliper cover, while the dust cover prevents any water or dust from entering the system. These interconnected components together facilitate the operation of the cable-operated disc brake system, thereby converting the applied force into an effective braking system.

[0011] When the brakes are applied, the front brake lever is depressed and the braking force is transmitted to the cam lever via the control cable. The rotation of the cam lever engages the upper cam, which pushes the lower cam axially. This movement, synchronized with the piston, brings one brake pad into contact with the brake disc rotor, generating clamping force for effective braking. When the brakes are released, the spring retracts the piston. A dust cover protects the system from dust and debris. This process helps to effectively convert the force applied by the user into the necessary movement and clamping force for reliable braking. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] Figure 1a-1k A cross-sectional view showing different components of a system according to an embodiment of the invention is shown.

[0013] Figure 2 A cross-sectional view of a system according to an embodiment of the present invention is shown.

[0014] Description of Reference Numerals

[0015] 100 systems

[0016] 101 brake caliper

[0017] 102 Brake caliper cover

[0018] 103 Cam lever

[0019] 104 upper cam

[0020] 105 lower cam

[0021] 106 Spherical roller

[0022] 107 Regulator

[0023] 108 Piston

[0024] 109 Spring

[0025] 110 Mounting Bolts

[0026] 111 dust cover DETAILED DESCRIPTION

[0027] In order to describe and point out the claimed inventive subject matter, the following definitions are provided for certain terms that will more clearly and concisely be used in the following written description.

[0028] Figure 1a-1k 1 shows a cross-sectional view of various components of a system 100 for operating a disc brake according to various embodiments of the present invention. The system 100 includes Figure 1a A brake caliper 101 is shown which houses all components within the mechanism and monitors the reaction force during braking.

[0029] In addition, the system 100 includes an additional component referred to as a brake caliper cover 102, such as Figure 1b As shown, it is specially designed to enclose and protect the mechanism located in the brake caliper. By safely enclosing the mechanism, the brake caliper cover 102 ensures the service life and optimal performance of the cable-operated disc brake.

[0030] In addition, if Figure 1c As shown, the system 100 is also equipped with another important component, namely, a cam rod 103. The cam rod 103 is used as a mechanism to transfer the load and stroke from the control cable to the brake system. Through its design, the cam rod 103 multiplies the load and stroke to a predetermined value, thereby effectively enhancing the force applied to the brake pad to achieve effective braking.

[0031] In addition, the system 100 includes Figure 1d The upper cam 104 shown in the figure cooperates with the cam rod 103. The upper cam 104 converts the rotational motion generated by the cam rod 103 into the linear axial motion of the lower cam 105. Figure 1e As shown. To achieve variable mechanical advantage (MA), the upper cam 104 features a variable contact radius. This variability enables precise adjustment and optimization of the braking force applied to the brake disc rotor. The lower cam 105 cooperates with the upper cam 104 to convert rotary motion into linear motion by utilizing three wedges. Similar to the upper cam 104, the lower cam 105 is provided with variable radius grooves along its wedge surface, thereby providing variable mechanical advantage (MA) throughout its operation. This adjustability ensures that the brake system can adapt to different braking requirements.

[0032] like Figure 1f As shown, another key component of the system 100 assembled between the upper cam and the lower cam wedge is a plurality of spherical rollers 106. The spherical rollers 106 move in the grooves of the upper cam 104 and the lower cam 105, thereby changing the contact radius. By adjusting the contact radius, the spherical rollers 106 can achieve fine-tuning of the braking system, thereby achieving precise control and adjustment of the braking force.

[0033] The system 100 further includes: Figure 1g The regulator 107 shown and Figure 1h The piston 108 is shown. The adjuster 107 is specifically designed to adjust the position of the piston 108 in relation to brake pad wear. Over time, as the brake pad wears, the adjuster 107 can make precise adjustments to compensate for changes in brake pad thickness. By ensuring optimal positioning of the piston 108, the adjuster 107 helps maintain consistent braking performance and increases the overall life of the brake system.

[0034] The piston 108 plays a vital role in the cable operated disc brake system 100 by transferring the load from the cam to the brake pad. When engaged, the piston 108 applies the necessary force to bring the brake pad into contact with the brake disc rotor, thereby achieving effective braking.

[0035] like Figure 1i As shown, the system 100 is provided with a spring 109 which assists in returning the piston 108 after the brake is released. When the brake is no longer applied, the spring 109 assists in restoring the original position of the piston 108. By applying force in the reverse direction, the spring 109 ensures that the brake pads are disengaged from the brake disc rotor, thereby achieving smooth rotation and preventing any undesirable friction. The action of the spring 109 during the retraction process contributes to the overall efficiency and function of the cable-operated disc brake.

[0036] like Figure 1j As shown, the system 100 further includes a plurality of mounting bolts 110 to ensure structural integrity and secure connection of the components. The mounting bolts 110 are specifically designed to join the brake caliper 101 and the brake caliper cover 102 together. By securely connecting these components, the mounting bolts 110 provide stability and strength to the brake assembly. Their presence ensures that the brake caliper 101 and the brake caliper cover 102 remain firmly fixed, thereby achieving stable and reliable operation of the cable-operated disc brake system 100.

[0037] like Figure 1kAs shown, the system 100 further includes a protective component referred to as a dust cover 111. The dust cover 111 plays a vital role in protecting the brake mechanism from potential damage caused by the ingress of water and dust. By preventing the ingress of external elements, the dust cover 111 helps maintain the integrity of the internal components. By reducing the risk of contamination and potential wear and cracking, the dust cover 111 helps to improve the long-term reliability and performance of the system 100. In addition, the dust cover 111 ensures that the system 100 remains well protected and operates optimally under various environmental conditions.

[0038] Now refer to Figure 2 , depicts a cross-sectional view of a cable-operated disc brake system 100, wherein the system 100 includes interconnected components that work in a seamless manner to facilitate the operation of the cable-operated disc brake. A floating caliper 101 houses the mechanism and monitors the reaction force, while a caliper cover 102 encloses and protects the internal components. A cam rod 103 transmits load and stroke, which is further converted to linear axial motion of a lower cam 105 by an upper cam 104, thereby adjusting the mechanical advantage through a variable contact radius and groove. Spherical rollers 106 within the upper cam 104 and lower cam 105 vary the contact radius, while an adjuster 107 adjusts the precise position of a piston 108 to compensate for brake pad wear. The piston 108 effectively transmits the load to engage the brake pad with the brake disc rotor, while a spring 109 assists in retracting the piston after the brake is released. A plurality of mounting bolts 110 ensure a secure connection between the caliper 101 and the caliper cover 102, and a dust cover 111 provides water and dust protection to maintain the integrity of the brake mechanism. Together, these interconnected components work in a coordinated manner to enable reliable and efficient operation of the cable operated disc brake system 100 .

[0039] In an embodiment, when a user applies the brakes using the cable-operated disc brake system 100, the front brake lever is depressed, thereby starting to transmit the braking force and travel through the control cable. The cam rod 103 is activated by this movement, causing it to rotate. As the cam rod 103 rotates, the cam rod 103 engages with the upper cam 104, which then pushes the lower cam 105 axially. The axial movement of the lower cam 105 is synchronized with the movement of the piston 108. As a result, one of the brake pads is brought into contact with the brake disc rotor. When the force is transmitted to the brake pad, the clamping force required for effective braking is then generated, allowing the brake pad to firmly clamp the brake disc rotor. When the brake is released, the spring 109 promotes the piston 108 to retract to the initial position. In addition, the dust cover 111 fixed to the cam rod 103 protects the system 100 from dust and debris, thereby ensuring optimal performance. Through this process, the cable-operated disc brake system 100 effectively converts the force applied by the user into the movement and clamping force required for reliable braking.

[0040] The present invention discloses a system 100 that effectively converts the force applied by the user into the precise movement and clamping force required for reliable braking. This effective conversion ensures that the braking mechanism operates effectively, thereby providing the required performance level and safety. In addition, the design goal of the system 100 is to maintain optimal performance and extend the service life of the braking system by effectively preventing the ingress of dust and debris.

Claims

1. A cable-operated disc brake system (100), comprising: A cam rod (103) is rigidly connected to an upper cam (104), wherein the upper cam (104) is connected to a lower cam (105), wherein the lower cam (105) is characterized by having a plurality of grooves of variable radius along the wedge-shaped surface of the lower cam (105), and a plurality of spherical rollers (106) located in the grooves form an interconnection mechanism for converting the rotational motion of the cam rod (103) into the linear axial motion of the lower cam (105).

2. The system (100) according to claim 1, wherein: The cam lever (103) is linked to a user-operated brake lever via a control cable for facilitating the transfer of a braking force from the user-operated brake lever to the cam lever (103) each time the user-operated brake lever is depressed.

3. The system (100) of claim 1, wherein: The internal components of the system (100) are housed within a floating brake caliper (101), which is further protected by a caliper cover (102) to prevent corrosion and erosion from external substances.

4. The system (100) of claim 1, wherein: The variable contact radius of the plurality of spherical rollers (106) on the variable radius groove of the lower cam (105) facilitates adjustment and optimization of the braking force applied to the brake disc rotor, thereby enabling the system (100) to achieve variable mechanical advantage (MA) throughout operation.

5. The system (100) of claim 1, wherein: The lower cam (105) moves axially together with a piston (108) disposed between the lower cam (105) and the brake pad, thereby transferring load from the cam rod (103) to the brake pad to promote effective engagement of the brake pad with the brake disc rotor and ensure effective braking.

6. The system (100) of claim 1, wherein: The plurality of variable radius grooves between the lower cam (105) and the upper cam (104) are designed to accommodate the movement of a plurality of spherical rollers (106), thereby enabling fine tuning of the system (100) and facilitating control of braking force.

7. The system (100) of claim 1, wherein: In response to brake pad wear, an adjuster (107) assembled with the lower cam (105) adjusts the position of the piston (108) using a fastening mechanism for maintaining a contact gap between the brake disc rotor and the brake pad, thereby enabling the system (100) to achieve optimal braking force.

8. The system (100) of claim 1, wherein: After the brake pad is released, the piston (108) is retracted by means of a spring (109) assembled between the piston (108) and the brake caliper (101), thereby promoting the brake pad to be disengaged from the upper position of the brake pad rotor to achieve smooth rotation and helping the piston (108) to return to its initial position.

9. The system (100) of claim 1, wherein: The structural integrity of the system (100) is ensured by fixedly connecting the floating brake caliper (101) and the brake caliper cover (102) using a plurality of mounting bolts (110).

10. The system (100) of claim 1, wherein: The system (100) includes a dust cover (111) as a protective device to protect the brake mechanism from corrosion and erosion by foreign substances.

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