Brake Caliper Cable Holder Using Existing Nut for Wear Sensor Routing
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Solution Overview
Problem
The existing disc brake systems for commercial vehicles face challenges in securely and economically routing cables for wear sensors, particularly in retrofitting, due to lack of suitable fastening options and potential damage from improper cable management, which can compromise the strength and integrity of the brake caliper.
Innovation Solution
A detachable, variably adaptable holding device is attached to the screw connection device of the brake caliper using a spring-loaded wire section, allowing for secure and flexible cable routing without requiring additional components or processing, and can be integrated with the existing nut and closure plate for enhanced stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cable clips are pressed into brake caliper housing bores, then cable retention is achieved, but additional cast material expenditure and drilling operations are required which are uneconomical
Solution Approach 1:
The cable holding device utilizes the existing screw connection device (nut) already present on the brake caliper for actuating device mounting. The device serves itself by using the structural elements already provided in the brake caliper design, eliminating the need for separate cable retention mechanisms and their associated manufacturing steps.
Solution Approach 2:
The cable holding device is attached to the screw connection device, making the nut serve dual purposes: securing the actuating device and providing mounting for cable retention. This multi-functional approach eliminates the need for separate cable management components and their associated manufacturing operations.
2Ease of manufacture
If cable ties are used for cable retention, then manufacturing is simpler, but fastening options are inadequate and cables may be improperly fastened leading to high probability of destruction
Solution Approach 1:
The cable holding device acts as an intermediary between the cable and the brake caliper structure. It provides a proper mechanical interface that securely fastens the cable while maintaining manufacturing simplicity, eliminating the inadequacies of direct cable tie attachment to the caliper housing.
Solution Approach 2:
The device utilizes the existing screw connection device for mounting, serving both cable retention and structural mounting functions. This approach maintains manufacturing simplicity while ensuring reliable cable fastening through proper mechanical attachment.
3Reliability
If mechanical machining or complex freeform casting is used for cable routing in car disc brakes, then cable holding is achieved, but the brake caliper strength is compromised or exposed positions are created
Solution Approach 1:
The cable holding device utilizes the existing screw connection device (nut) already present on the brake caliper for actuating device mounting. This approach achieves cable holding without requiring any additional material removal or complex casting operations that would compromise caliper strength.
Solution Approach 2:
The cable holding function is separated from the main caliper structure and implemented as a detachable device mounted on the screw connection device. This segmentation allows cable retention without modifying the caliper housing, preserving its structural integrity and avoiding exposed positions.
4Adaptability or versatility
If a detachable holding device is attached to the screw connection device, then cable routing flexibility and adaptability are improved, but device complexity increases
Solution Approach 1:
The holding device serves multiple functions: cable retention, cable routing guidance, and mounting on the existing screw connection device. By utilizing the existing nut structure, the device achieves adaptability without requiring complex mounting mechanisms or additional components.
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 ensures secure and efficient cable management without increasing the radial space, preventing contact with other vehicle parts and allowing for easy adaptation to both original equipment and retrofitting scenarios, thereby enhancing the reliability and durability of the disc brake system.
Implementation Method 1
a spring-loaded wire section, allowing for secure and flexible cable routing
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
The system has a brake caliper surrounding a brake disk, and a clamping unit arranged on a side of the brake disk in the brake caliper. A cable (K) is attached to a wear sensor for a brake lining, and a cable holder (8) holds the cable in a clamping side region (3) of the brake disk. The cable holder is detachably attached to a nut (7) by clamping unit and includes a resilient clamping wire section for mounting at a screw connection unit. The cable holder is closed in the brake caliper on a side that faces towards the brake disk.