Arc-Shaped Caliper Shells Absorb Braking Forces
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Solution Overview
Problem
Fixed calipers in disc-brakes experience substantial deformation and distortion due to complex three-dimensional loads during braking, leading to overloading of the suspension and uneven wear of friction linings, as they must be oversized to manage these forces effectively.
Innovation Solution
A fixed caliper design featuring arc-shaped or arc-aligned connecting shells with a slenderness ratio less than 17/100, integrated with the side walls, which absorb the entire clamping and braking forces, providing a shell-type connecting structure that enhances rigidity and reduces size while maintaining structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the caliper body is oversized to prevent deformation under three-dimensional loads, then the resistance to deformation is improved, but the weight and size of the caliper increase
Solution Approach 1:
The patent employs arc-shaped connecting bridges with optimized curvature radii (R1, R2, R3) that allow the structure to efficiently distribute and absorb complex three-dimensional loads. The curved geometry provides superior structural performance compared to straight bridges, enabling the caliper to resist deformation with reduced material usage and weight.
Solution Approach 2:
The patent optimizes specific geometric parameters including the curvature radii of the connecting bridges (R1 between 15-30mm, R2 between 20-40mm, R3 between 10-25mm) and the thickness of the bridges (e1, e2 between 3-8mm). These parameter optimizations allow the caliper to achieve adequate deformation resistance with a lighter, more compact design.
2Stability of the object's composition
If the caliper body is oversized to contain deformation within limits, then the stability is improved, but the device complexity increases
Solution Approach 1:
The arc-shaped connecting bridges with optimized curvature radii provide efficient load distribution and deformation control. The curved geometry naturally accommodates the complex stress states during braking, allowing the caliper to maintain stability with a more compact and simpler overall structure.
Solution Approach 2:
By optimizing the curvature radii (R1, R2, R3) and bridge thickness parameters (e1, e2), the patent achieves effective deformation control within a compact caliper design, avoiding the need for an oversized structure.
3Strength
If the connecting bridges are made thicker to resist bending moments, then the strength is improved, but the weight and volume of the caliper increase
Solution Approach 1:
The arc-shaped connecting bridges with optimized curvature radii provide enhanced resistance to bending moments generated during braking. The curved geometry efficiently distributes the bending stresses, allowing the bridges to maintain adequate strength with reduced thickness and volume compared to straight bridge designs.
Solution Approach 2:
The patent optimizes the thickness parameters (e1, e2 between 3-8mm) and curvature radii of the connecting bridges to achieve the necessary bending moment resistance with minimal material usage, thereby reducing the overall caliper volume.
Data Source
AI summary
A caliper for a disc-brake includes two side walls at a distance from each other which delimit a space to accommodate a portion of a brake disc. The side walls are connected to each other by a connecting structure which straddles the disc space. Each of the side walls delimits at least one seating capable of accommodating a pad. The caliper comprises a thrust to clamp the pads against the brake disc. The thrust is secured to the side walls in such a way that the side walls absorb the entire clamping force and the seatings are capable of securing the pads so that the side walls also absorb the entire braking moment. The connecting structure comprises arc-shaped shells, connected so as to be integral with both the side walls. The slenderness of the shells expressed as the ratio of thickness to circumferential extension relative to an axis of rotation of the brake disc is less than 17/100.