Brake Caliper Closure Plate Cable Holder Design
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Solution Overview
Problem
Conventional disc brake cable mounting methods for commercial vehicles are inefficient, leading to potential cable detachment, overheating, and scuffing, especially in narrow wheel rim areas, due to the need for additional cast material and drilling, which complicates both original equipment and retrofit installations.
Innovation Solution
A cable holder integrated into the closure plate of the brake caliper with a positive locking mechanism, allowing for easy installation and thermal protection without altering the cast structure, using stamped and bent sheet metal with openings that protrude radially to secure the cable behind the closure plate, preventing exposure to heat and rotation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cable clips are pressed into housing bores of the brake caliper with frictional engagement, then the cable is retained in a non-destructive manner, but additional cast material and drilling are required which are uneconomical and risk cable detachment or twisting
Solution Approach 1:
The cable holder is separated from the brake caliper housing into a distinct component that attaches to the closure plate. This segmentation eliminates the need for drilling holes in the caliper housing itself, as the cable holder is mounted on the closure plate which already has integrated openings. The cable retention function is segmented from the structural housing into a dedicated holder component.
Solution Approach 2:
The closure plate serves as an intermediary component between the brake caliper housing and the cable holder. Instead of directly drilling into the caliper housing, the closure plate provides a mounting surface with pre-formed openings that receive the cable holder. This intermediary approach avoids compromising the structural integrity of the caliper housing while still providing secure cable retention.
2Ease of manufacture
If cable ties are used to position the cable, then installation is simpler, but fastening options are inadequate and special material breakthroughs are required which entail strength problems
Solution Approach 1:
The cable holder is merged with the closure plate through positive locking engagement. The holder integrates multiple functions: it provides cable retention, structural support, and thermal protection in a single component that attaches to the closure plate. This merged design eliminates the need for separate cable ties and special material breakthroughs, as the holder itself provides all necessary fastening and protective functions.
Solution Approach 2:
The solution employs composite construction where the closure plate (made from sheet metal) and the cable holder (made from plastic or metal) are combined through positive locking. This composite approach allows each component to be optimized for its specific function while maintaining overall structural strength without requiring material breakthroughs in the caliper housing.
3Adaptability or versatility
If the cable is routed in the brake caliper area on the application side, then the wear sensor can monitor brake pad wear, but the cable is exposed to extreme temperatures and risk of overheating or scuffing
Solution Approach 1:
The cable holder is designed to nest within the closure plate structure, with the cable positioned inside the holder which is itself attached to the closure plate. This nested arrangement provides multiple layers of protection: the closure plate shields the holder from direct heat radiation, and the holder material provides additional thermal and mechanical protection to the cable and sensor components.
Solution Approach 2:
The closure plate and cable holder act as intermediary protective barriers between the cable/wear sensor and the harsh thermal and mechanical environment. These intermediaries absorb and redirect heat away from the cable, and provide mechanical shielding against scuffing from the wheel rim and brake components, while still allowing the sensor to function.
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 provides a secure, tool-free cable fixation that protects against heat radiation and rotation, ensuring reliable cable routing and attachment in both original and retrofit scenarios, enhancing the structural integrity and ease of installation without additional cast material or drilling.
Implementation Method 1
the holding device has two legs which can be brought together against an elastic restoring force in order to insert them into the opening and which then widen again, whereby they are supported with their elastic restoring force on the inner contour of the opening
Data Source
Figure 1~2
Figure 3~6
Figure 7~9
AI summary
The disk brake comprises a brake caliper (2) enclosing a brake disk (1), and a brake application device (6) arranged on one side of the brake caliper in the brake caliper. A closure plate (5) is provided for closing the brake caliper on the side facing the brake disk, which comprises a functional opening for the passage of a portion of the application device. A cable is connected to a wear sensor for a brake lining. The closure plate comprises an opening (8), in which a holding unit for holding the cable is fixed by form closure.