Commercial Vehicle Axle Disc Brake Caliper Mounting
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Commercial vehicle axles with disc brakes are too heavy and large, failing to meet the requirements of space-optimized and light commercial vehicles, particularly due to the need for a brake carrier that occupies significant space and weight.
Innovation Solution
A commercial vehicle axle with a direct connection of the brake caliper to the wheel carrier via pin guides, eliminating the need for an additional brake carrier, which reduces weight and space requirements, and incorporates sealed bolt guides to prevent dirt ingress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a brake carrier is used to mount the disc brake on the wheel carrier, then the brake pads are properly supported and guided, but the overall weight and installation space increase significantly
Solution Approach 1:
The patent merges the brake carrier functions with the wheel carrier by integrating the guide pins directly into the wheel carrier structure. The wheel carrier now directly provides the mounting and guidance functions previously requiring a separate brake carrier, eliminating redundant components and reducing overall weight while maintaining brake pad support and guidance functionality.
Solution Approach 2:
The patent extracts the essential guidance function from the brake carrier and transfers it to the wheel carrier through integrated guide pins. By taking out the guidance function from the separate brake carrier component and embedding it in the wheel carrier, the design eliminates the need for the additional brake carrier while preserving the necessary brake pad guidance and support.
2Reliability
If a brake carrier is used to mount the disc brake on the wheel carrier, then the brake pads are properly supported and guided, but the installation space required increases
Solution Approach 1:
The patent merges the brake carrier mounting functions with the wheel carrier structure. By combining the mounting and guidance functions into the existing wheel carrier, the design eliminates the need for additional brake carrier components and their associated mounting space, thereby reducing the overall installation space required for the disc brake assembly.
Solution Approach 2:
The patent extracts the mounting and guidance functions from the separate brake carrier and transfers them to the wheel carrier. This extraction eliminates the need for the additional brake carrier component and its associated mounting space, reducing the overall installation space while maintaining proper brake pad support and guidance.
3Ease of manufacture
If open bolt guides are used in the brake caliper, then the structure is simple and manufacturing is easy, but dirt and contaminants can ingress and affect brake performance
Solution Approach 1:
The patent uses sealing elements (thin film barriers) to close the bolt guides, preventing dirt and contaminant ingress while maintaining the simple cast structure. The sealing elements act as flexible barriers that block harmful factors from entering the bolt guide openings, protecting the internal components without requiring complex sealed structures.
Solution Approach 2:
The patent converts the potential harm of open bolt guides (dirt ingress) into a benefit by using simple casting to create the bolt guide structures, then adding sealing elements to prevent contamination. The simple cast structure provides manufacturing ease, while the sealing elements prevent the harmful effects, turning a potential weakness into a strength.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to a commercial vehicle axle with a disc brake, wherein the disc brake comprises a brake caliper and brake pads for clamping the brake disc, and wherein the brake caliper has a first interior space with an opening on the side facing a brake disc for receiving a clamping device, and the brake caliper has a second interior space for receiving the brake disc. The object of the invention is to provide a cost- and space-optimized commercial vehicle axle with a disc brake, wherein the disc brake can be easily mounted on a commercial vehicle axle.