Annular Disk Brake Force Amplification via Cam Interfaces
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Solution Overview
Problem
Annular disk brakes face challenges in generating sufficient clamping force within limited space, particularly when integrated with pneumatic systems, requiring innovative designs to enhance braking efficiency and compactness.
Innovation Solution
The design incorporates a main support, rotor disk, casing, brake pads, an axially-guided brake pad carrier, and an actuator assembly with a force-transmitting arrangement featuring cam interfaces to amplify the clamping force, allowing for increased braking torque and friction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a conventional actuator design is used in an annular disk brake, then the brake can be mounted within or close to a vehicle wheel, but the clamping force generated is insufficient for effective braking
Solution Approach 1:
An intermediary member is introduced between the actuator and the brake pad carrier. This intermediary member includes cam surfaces that convert the actuator's linear motion into rotational motion of the brake pad carrier, providing mechanical advantage to amplify the clamping force applied to the rotor disk
Solution Approach 2:
The brake pad carrier is designed to rotate about a radial axis rather than move purely axially. This dimensional change from linear to rotational motion allows the cam surfaces to leverage the actuator force more effectively, generating higher clamping force on the brake pads
2Force
If the actuator size is increased to generate sufficient clamping force, then braking efficiency improves, but the brake assembly occupies more space within the wheel well
Solution Approach 1:
The brake pad carrier is designed as a rotating component that dynamically converts linear actuator motion into rotational motion. This dynamic mechanism allows a compact actuator to generate high clamping force through mechanical advantage, eliminating the need for a large actuator
Solution Approach 2:
The cam surfaces on the intermediary member act as a force amplifier, converting the actuator's limited force into high clamping force on the brake pads. This intermediary mechanism allows sufficient braking force to be generated with a compact actuator design
3Ease of manufacture
If the brake design is simplified to reduce manufacturing complexity, then production cost decreases, but the ability to generate sufficient clamping force in limited space is compromised
Solution Approach 1:
The brake assembly is segmented into distinct functional components: a fixed actuator, a rotating brake pad carrier, and an intermediary member with cam surfaces. This segmentation allows each component to be optimized for its specific function while maintaining overall manufacturing simplicity
Solution Approach 2:
The rotational motion of the brake pad carrier about a radial axis creates mechanical advantage through the cam surfaces, enabling high clamping force generation without complex multi-stage actuation mechanisms
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
This configuration effectively amplifies the clamping force and braking torque, enhancing the braking efficiency while maintaining a compact design, suitable for various vehicle types and applications.
Implementation Method 1
a force transmitting arrangement comprising a first cam interface between the axially-actuated member and an intermediary member located between the axially-actuated member and the inboard side of the brake pad carrier, the intermediary member being coaxially disposed with reference to the central axis and pivoting in a radial plane, the arrangement further comprising a second cam interface between the intermediary member and the inboard side of the brake pad carrier, the brake pad carrier axially moving when the intermediary member pivots, whereby the arrangement creates a force increasing amplification
Implementation Method 2
A braking friction and heat are generated when the fixed and the movable brake pads are in a clamping engagement with the sides of the rotor disk
Data Source
AI summary
The annular disk brake comprises a rotor disk and at least one brake pad provided on each side of the rotor disk. The brake pad or pads on one side are connected to a substantially axially-guided brake pad carrier. The brake has a force transmitting arrangement creating a force increasing amplification between an axially-actuated member and the carrier. This arrangement can increase the brake compactness and provide an even distribution of the braking force around the circumference of the rotor disk. A method of increasing a brake pad clamping force is also disclosed.