Brake Pad Adjuster Manual Rewind Torque Limiting
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Solution Overview
Problem
Conventional brake pad adjuster mechanisms are prone to damage from excessive manual de-adjustment, leading to operational failures and the need for frequent component replacement, as they lack effective torque management to prevent damage without compromising safety factors.
Innovation Solution
A manual rewind apparatus with a transmission path that includes a clutch or tolerance ring configured to slip at a predetermined torque, preventing damage to components and allowing for safe operation without the need for replacement after torque exceeding the predetermined level, thereby reducing manufacturing costs by lowering the safety factor of brake components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a weakness or rupture is provided in the adjuster shaft to prevent damage from excessive torque, then damage to the adjuster mechanism is prevented, but the shaft must be replaced requiring stripping and re-building of the adjuster
Solution Approach 1:
The adjuster system is divided into separable components: the adjuster mechanism housed in a caliper, and a separate protective element (cap or adaptor) that can be removed and replaced independently. When the protective element fails due to excessive torque, only that element needs replacement, not the entire adjuster mechanism, thus resolving the contradiction between preventing damage and ease of repair.
Solution Approach 2:
A protective cap or adaptor is introduced as an intermediary element between the tool and the adjuster shaft. This intermediary absorbs the excessive torque through controlled failure (shearing or deforming), protecting the adjuster mechanism from damage. The intermediary can be replaced without affecting the adjuster mechanism, solving both the damage prevention and ease of repair requirements.
2Reliability
If a shearable or deformable element is provided to prevent excessive torque application, then damage to the adjuster mechanism is reduced, but the element must be replaced after deformation
Solution Approach 1:
The protective cap or adaptor serves a dual function: it protects the adjuster mechanism from excessive torque and simultaneously acts as the de-adjustment tool interface. After protective element failure, the same cap/adaptor (when replaced) continues to serve as the tool interface, eliminating the need for separate protective elements and reducing overall device complexity.
Solution Approach 2:
The protective function and the tool interface function are merged into a single component (the cap or adaptor). This consolidation means that when the protective element fails, the replacement component automatically restores both the protective function and the tool interface function, reducing complexity by eliminating separate components.
3Reliability
If components are designed to withstand high manual abuse torque (approximately 100 Nm), then safety is ensured, but manufacturing costs increase due to higher safety factors
Solution Approach 1:
The protective cap or adaptor is designed as a disposable, low-cost component that can withstand excessive torque and fail safely. By using a cheap protective element, the main adjuster mechanism and brake components can be designed with lower safety factors, reducing their manufacturing costs while maintaining overall system safety through the sacrificial protective element.
Solution Approach 2:
The protective cap or adaptor is installed beforehand to cushion against excessive torque application. This pre-installed protective element absorbs the shock of torque overload, allowing the main brake components to be manufactured with lower safety factors and reduced material usage, thereby lowering manufacturing costs while maintaining safety.
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
The solution effectively prevents damage to brake components by limiting torque application, reducing the need for frequent replacements and lowering manufacturing costs while maintaining the safety and functionality of disc brakes.
Implementation Method 1
a clutch configured to slip at a predetermined torque
Implementation Method 2
a tolerance ring configured to slip at a predetermined torque
Data Source
AI summary
An adjuster system for adjusting the position of a brake pad relative to a brake disc so as to maintain a suitable running clearance between the pad and disc in a disc brake. The system comprises a manual rewind apparatus to reset the position of the brake pad when replacement thereof is required. The manual rewind apparatus has a transmission path extending from a rewind tool engaging portion to a brake pad engaging portion of the system. The manual rewind apparatus is configured such that when a rewind torque above a pre-determined torque is applied to the transmission path by a rewind tool no damage is caused to components along the transmission path.