Brake Caliper Worm-Gear Bearing Layout for Reduced Axial Size
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Solution Overview
Problem
Existing disc brake caliper designs are cumbersome due to their significant axial extension, which restricts the reduction of axial dimensions, particularly in applications like motorcycles where space and maneuverability are critical.
Innovation Solution
The integration of gearbox components with the thrust device and the use of a single thrust bearing that supports both the worm and gearbox, eliminating unnecessary components and simplifying the assembly, allows for a significant reduction in axial dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate thrust bearing and gearbox support bearing are used, then reliability is improved, but axial dimension increases
Solution Approach 1:
The patent combines the thrust bearing and gearbox support bearing into a single integrated bearing component. This merging eliminates the need for separate bearings while maintaining all necessary support functions, thereby reducing the axial dimension of the caliper without compromising reliability
Solution Approach 2:
The integrated bearing is designed to perform multiple functions simultaneously: it acts as both a thrust bearing for the worm and a support bearing for the gearbox. This multi-functionality allows a single component to replace what would traditionally require two separate bearings, reducing overall assembly size
2Ease of manufacture
If multiple separate components are used for worm support and gearbox support, then ease of manufacture is improved, but device complexity increases
Solution Approach 1:
The patent merges the worm support bearing and gearbox support bearing into a single integrated bearing component. While this may slightly increase the complexity of manufacturing the integrated bearing itself, it significantly reduces the overall assembly complexity by eliminating the need for multiple separate components and their associated mounting operations
3Volume of moving object
If axial dimension is reduced, then space efficiency is improved, but manufacturing precision requirements increase
Solution Approach 1:
The integrated bearing is designed with nested functional zones that accommodate both the worm thrust support and gearbox support functions within a compact axial footprint. This nesting arrangement optimizes space utilization while maintaining manufacturability through standardized bearing design practices
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 achieves a substantial reduction in axial caliper size, enhancing space efficiency and simplifying assembly processes, addressing the limitations of previous designs by integrating motion transmission components directly into the worm support bearing.
Implementation Method 1
said worm being rotatably supported by a thrust bearing adapted to support said worm and gearbox in rotatable manner
Data Source
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AI summary
The present invention relates to a brake caliper of a disc brake (1) comprising: - a caliper body (2) adapted to straddle a brake disc (3) to apply a braking action on a vehicle; - said brake disc (3) defining an axial direction (A-A) directed either along or parallel to the rotation axis (X-X) of said brake disc (3); a radial direction (R- R) orthogonal to said axial direction (A-A) and a circumferential direction (C-C) orthogonal to said axial (A-A) and radial (R-R) directions, as well as a tangential direction (T-T) locally orthogonal to said axial direction (A-A) and said radial direction (R-R) and tangent to said circumferential direction (C-C); - said caliper body (2) comprising at least one thrust device housing (4) which accommodates a thrust device (5) adapted to apply a bias on at least one brake pad (6) to abut said at least one brake pad (6) against the braking surfaces (7, 8) of said brake disc (3); wherein - said thrust device (5) is operatively connected to a translating screw nut (9); operatively connected to a worm (10); said translating screw nut (9) is operatively connected to a worm (10); said worm (10) is operatively connected to a gearbox (11); and wherein - said worm (10) is rotatably supported by a screw thrust bearing (12) adapted to support in rotatable manner said worm (10) and to apply for said worm (10) an axial reaction, i.e. a direct reaction prevalently along said axial direction (A- A); - at least part of said pressure gearbox (11) placed near and operatively connected to said worm (10) is rotatably supported by at least one gearbox thrust bearing (12) adapted to support in rotatable manner said at least one part of said reduction gear (11) and apply for said at least one part of said reduction gear (11) a radial reaction, that is a direct reaction prevalently along said radial direction (R-R); and wherein said screw thrust bearing and said gearbox thrust bearing are the same thrust bearing (12).