Brake Pad Distance Adjuster With Low-Friction One-Way Locking
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Solution Overview
Problem
Current brake adjustment mechanisms in pneumatic disk brakes are complex, leading to increased production costs, higher failure rates, and reduced part life due to excessive parts and friction, which causes overheating and premature wear.
Innovation Solution
A simplified brake adjustment mechanism using pin ball bearings and a reduced number of parts, eliminating conical clutching and incorporating a steel press spring for one-way rotation and locking, which reduces friction and wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional brake adjustment mechanism with multiple parts (including conical clutching) is used, then the brake pads can be adjusted, but the number of parts increases production cost and complexity
Solution Approach 1:
The patent combines multiple functions into a single integrated adjustment mechanism. The adjustable support leg incorporates both the adjustment function and the support function in one component, eliminating the need for separate conical clutching mechanisms and reducing the total number of parts while maintaining adjustment capability
Solution Approach 2:
The support leg is designed to perform multiple functions: it provides structural support, enables brake pad adjustment, and maintains positioning. This multi-functional design replaces what would traditionally require multiple specialized components, thereby reducing complexity and part count
2Reliability
If more parts are used in the brake adjustment mechanism, then the adjustment function can be achieved, but the production cost increases
Solution Approach 1:
By merging the adjustment mechanism and support structure into a single integrated component, the patent reduces the number of parts that need to be manufactured, assembled, and quality-checked. This integration directly lowers production costs while preserving the adjustment function
Solution Approach 2:
The patent extracts and eliminates unnecessary components from the traditional design, such as the conical clutching mechanism. By removing these extraneous parts, the design achieves the same adjustment function with fewer components, thereby reducing production cost
3Reliability
If conical clutching and multiple elements are used for locking operation, then the mechanism can lock, but friction increases causing heat and wear
Solution Approach 1:
The patent replaces the conical clutching mechanical locking system with an alternative locking mechanism that generates less friction. This substitution maintains the locking function while reducing harmful thermal effects and wear on the brake components
Solution Approach 2:
The design converts the potential harm of friction-induced heat into a benefit by using a locking mechanism that minimizes friction during normal operation. The locking function is achieved through a different mechanical principle that avoids excessive heat generation, thereby protecting the brake pads from premature wear
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 solution decreases production costs, extends part life, and prevents overheating, resulting in a more reliable and cost-effective brake adjustment mechanism with reduced maintenance needs.
Implementation Method 1
incorporating a steel press spring for one-way rotation and locking
Implementation Method 2
reduces friction and wear
Implementation Method 3
Conduct of locking operation by use of only ball bearings
Implementation Method 4
pressing onto brake disk during braking and thus converting kinetic energy into heat energy
Implementation Method 5
converting kinetic energy into heat energy
Data Source
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AI summary
A novelty for reduction of wearing and number of parts in brake adjustment mechanism in Pneumatic Disk brakes located in calliper and used for adjustment of pre-use distance between brake pads and pressing onto brake disk during braking and thus converting kinetic energy into heat energy, providing slowing down and stop of vehicle and automatically adjusting distance differences arising from wearing in the brake pads during period of use.