Disk Brake Adjustment Mechanism Integrating Thread and Wrap Spring
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Solution Overview
Problem
Existing disk brake systems for commercial vehicles face challenges in maintaining precise adjustment of brake pads due to relative movements between adjustment devices and wear, leading to reduced accuracy and increased assembly effort, with limited flexibility and increased installation space requirements.
Innovation Solution
A disk brake system with an adjustment mechanism that is directly mounted on the actuating spindle, utilizing a wrap spring as a one-way clutch and thread device, allowing for synchronous movement with the actuating spindle and eliminating the need for separate adjustment nuts and caliper mounting, thereby simplifying the design and improving accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the adjustment device is mounted separately in the brake caliper and connected to the actuating spindle via additional components (adjustment nut, pressure collar), then the adjustment mechanism can be positioned remotely, but the assembly complexity increases and installation space requirements expand
Solution Approach 1:
The adjustment device is integrated directly onto the actuating spindle, merging the adjustment function with the actuating mechanism. This eliminates separate components such as adjustment nuts and pressure collars, reducing assembly complexity while maintaining adjustment accessibility during brake maintenance
Solution Approach 2:
The actuating spindle serves dual functions: both actuating the brake pads and housing the adjustment mechanism. This multi-functionality reduces the total component count while ensuring the adjustment device remains accessible for maintenance operations
2Manufacturing precision
If the adjustment device is fixed in position relative to the movable element, then the adjustment geometry remains stable, but the device cannot adapt to wear-induced changes in release clearance
Solution Approach 1:
The adjustment device is designed to move synchronously with the actuating spindle during brake actuation and wear compensation. This dynamic positioning allows the adjustment mechanism to maintain precise geometric relationships while adapting to wear-induced changes in release clearance, combining stability with adaptability
3Reliability
If the adjustment nut and pressure collar are mounted in a fixed manner in the movable element, then the adjustment mechanism remains stable during operation, but the installation space in the axial direction increases
Solution Approach 1:
The adjustment device is nested onto the actuating spindle in a compact axial arrangement. By integrating the adjustment mechanism directly on the spindle rather than mounting separate components in the movable element, the design achieves reliable adjustment stability while minimizing axial installation space
4Ease of manufacture
If separate adjustment components (adjustment nut, pressure collar) are used, then the adjustment mechanism can be designed with modular components, but the assembly and disassembly effort increases
Solution Approach 1:
The adjustment device is combined with the actuating spindle as an integrated unit, eliminating the need to assemble and disassemble separate adjustment nuts and pressure collars. This integration maintains manufacturing simplicity while significantly reducing assembly and disassembly effort during brake maintenance
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 enhances the accuracy and flexibility of brake pad adjustment, reduces assembly complexity, and optimizes installation space, allowing for more generous part dimensions and improved braking performance by enabling adjustments during both braking and release strokes.
Implementation Method 1
utilizing a wrap spring as a one-way clutch
Implementation Method 2
thread device, which, at least in the case of rotation in a second direction of rotation opposite the first direction of rotation, is configured to mesh with the external thread of the actuating spindle and is configured to screw the adjustment mechanism in relation to the actuating spindle
Data Source
AI summary
A disk brake includes a brake disk, a brake caliper, at least one application device lying within the brake caliper on one side of the brake disk, an axially movable device configured to move a brake pad axially toward the brake disk by way of at least one actuating spindle when the brake is actuated, and an adjustment mechanism configured to rotate the actuating spindle because of a rotational coupling acting in the direction of rotation. The adjustment mechanism comprises a thread device, which, at least in the case of rotation in a second direction of rotation opposite a direction of rotation, is configured to mesh with an external thread of the actuating spindle and is configured to screw the adjustment mechanism in relation to the actuating spindle.