Brake Adjusting Device With Limited Rotation Angle
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Solution Overview
Problem
Existing adjusting devices for pneumatically actuated disc brakes face challenges in manual restoration, requiring high force and additional components, and are costly due to complex design measures needed to overcome the 100% blocking action of the freewheel during pad replacement.
Innovation Solution
An adjusting device with a ball ramp clutch and cone clutch system, featuring a limited working angle of rotation and a stationary stop, prevents the drive-output-side clutch ring from rotating, allowing for easy manual turning back and eliminating the need for additional components, while maintaining automatic adjustment functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a freewheel mechanism is used to prevent backward rotation during automatic adjustment, then automatic adjustment functionality is maintained, but manual restoration requires high force and additional components
Solution Approach 1:
The clutch ring is designed with a limited working angle of rotation (αA) defined by stationary stops, allowing dynamic control of rotational movement. During automatic adjustment, the clutch ring rotates within the defined angle, while during manual restoration, the limited angle prevents excessive rotation and enables easy turning back without overcoming 100% blocking action
Solution Approach 2:
The system changes the operational parameters of the clutch ring by limiting its working angle of rotation. This parameter limitation allows the clutch ring to function differently in automatic adjustment mode (rotating within angle αA) versus manual restoration mode (prevented from rotating by stationary stop), thereby resolving the contradiction between maintaining automatic adjustment and enabling easy manual restoration
2Ease of operation
If additional components are added to enable manual turning back of the freewheel, then manual restoration becomes easier, but device complexity and cost increase
Solution Approach 1:
The clutch ring serves multiple functions: it transmits rotational movement during automatic adjustment, limits the working angle through stationary stops, and prevents rotation during manual restoration. This multi-functionality eliminates the need for additional components specifically designed for manual turning back, thereby reducing device complexity while maintaining ease of operation
Solution Approach 2:
The stationary stops on the clutch ring provide self-service by automatically limiting the working angle and preventing rotation during manual restoration. The system uses its own structural elements (clutch ring and stationary stops) to control its operation, eliminating the need for external components or additional 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 design reduces the force required for manual restoration, eliminates the need for additional components, and simplifies production through non-cutting shaping technology, enabling cost-effective and efficient manual retraction of the adjusting mechanism.
Implementation Method 1
an adjusting device with a ball ramp clutch and cone clutch system, featuring a limited working angle of rotation and a stationary stop, prevents the drive-output-side clutch ring from rotating
Implementation Method 2
A cone clutch is arranged between the drive-output-side clutch ring and a spring sleeve for a cylindrical spring
Data Source
AI summary
A wear adjustor adjusts the wear of brake pads and a brake disc of a pneumatic disc brake having a rotary lever brake application device. The wear adjustor is insertable into an adjusting spindle and attached to a caliper of the disc brake by a bearing disc. An axial bearing is formed axially on a side of a drive ring, and a ball ramp coupling with a freewheel function is formed axially on the opposite side of the drive ring. The ball ramp coupling includes balls and a drive socket which is arranged axially, on the drive side, between the axial bearing and the balls thereof, a cone coupling being arranged between the coupling ring on the output side and an elastic sleeve for a cylinder spring. The output-side coupling ring is designed for a working rotational angle defined by at least one fixed abutment.