Disc Brake Anchor Bracket Shoulder Design
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Solution Overview
Problem
Existing disc brake assemblies face challenges in securely attaching the anchor bracket to non-rotatable vehicle components like knuckles and axle flanges, leading to potential movement and slippage during braking, which can affect braking torque transmission and stability.
Innovation Solution
The proposed disc brake assembly design features an anchor bracket with specific shoulder configurations and conical surfaces on fasteners and components, ensuring secure attachment by preventing relative movement between the anchor bracket and non-rotatable vehicle components through complementary shoulder surfaces and conical contact points.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional fastening methods are used to attach the anchor bracket to non-rotatable vehicle components, then the assembly process is simple, but relative movement and slippage occur during braking affecting stability
Solution Approach 1:
The patent employs conical surfaces on the fasteners that engage with complementary conical surfaces on the anchor bracket and non-rotatable vehicle component. This curved geometric interface prevents relative movement and slippage during braking by distributing loads across the conical contact surfaces, thereby enhancing attachment reliability without requiring complex additional structures.
Solution Approach 2:
The anchor bracket features asymmetric shoulder configurations with different geometries on different sides. These asymmetric shoulders engage with corresponding features on the non-rotatable vehicle component to prevent rotation and movement in specific directions, providing stable attachment while maintaining a relatively simple overall bracket structure.
2Manufacturing precision
If simple fastening structures are used, then manufacturing is easier, but braking torque transmission consistency deteriorates due to movement and slippage
Solution Approach 1:
The anchor bracket and non-rotatable vehicle component are designed with pre-configured shoulders and conical surfaces that automatically align the fasteners during assembly. This preliminary geometric configuration ensures precise alignment and consistent braking torque transmission without requiring complex alignment procedures or additional adjustment mechanisms during manufacturing.
3Strength
If conventional attachment methods are used, then the design is simpler, but slippage occurs affecting braking torque transmission
Solution Approach 1:
Conical surfaces are incorporated on the fasteners and corresponding engagement surfaces on the anchor bracket and vehicle component. This curved geometry increases the contact area and distributes fastening loads more effectively, enhancing fastening strength and preventing slippage during braking while maintaining a relatively simple fastener design.
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A disc brake assembly comprises an anchor bracket having a pair of arms, a caliper supported on the bracket and a non-rotatable vehicle component having a pair of lugs, each of the lugs provided with a non-threaded opening formed therethrough. The non-threaded openings receive fasteners installed in threaded openings of the bracket to secure the vehicle component to the bracket. The bracket includes on at least one of the arms a first shoulder at a transition between the first and second portions thereof. The vehicle component includes on at least one of the lugs a second shoulder having a shape which is generally complimentary to the shape of the first shoulder. When the vehicle component and bracket are secured together, selected surfaces of the first and second shoulders contact each other to substantially prevent movement of the bracket relative to the vehicle component.