Sliding Disc Brake Caliper Locking for Pad Clearance Control
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Solution Overview
Problem
Existing brake assemblies for heavy commercial vehicles face issues with brake pads unintentionally contacting the rotor due to uneven wear and vibrations, leading to reduced efficiency, increased fuel consumption, and premature wear of friction material.
Innovation Solution
A disc brake assembly with an actuating arrangement that locks or inhibits the sliding of the caliper relative to the brake carrier, maintaining a desired clearance between the brake pads and rotor, and dampening vibrational effects, using a linear actuator to apply forces that ensure consistent engagement across varying wear conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the caliper is allowed to slide freely on guide pins relative to the brake carrier, then the brake pads can be easily positioned during braking operations, but the brake pads may unintentionally contact the brake rotor due to vibrations or cornering forces
Solution Approach 1:
The system dynamically transitions between two states: a first configuration where the caliper can slide freely on guide pins during braking operations, and a second configuration where the caliper is locked relative to the brake carrier to prevent unintended contact. The actuating arrangement enables this dynamic switching based on operational requirements.
Solution Approach 2:
The actuating arrangement changes the positional parameter of the caliper relative to the brake carrier by moving the caliper transverse to the first longitudinal axis. This parameter change locks or inhibits the sliding capability of the caliper, thereby preventing unintended pad contact while maintaining the ability to slide when needed.
2Reliability
If existing positive pad retraction systems are used to push brake pads away from the rotor, then pad retraction is improved, but the system cannot account for differential wear between inboard and outboard brake pads and rotor surfaces
Solution Approach 1:
The actuating arrangement performs multiple functions: it locks the caliper to prevent unintended contact, dampens vibrations, and maintains optimal clearance. By moving the entire caliper assembly transverse to the first longitudinal axis, it simultaneously addresses both inboard and outboard pad positioning, accommodating differential wear between brake pads and rotor surfaces.
3Reliability
If the caliper and brake carrier are locked to prevent unintended contact, then pad clearance is maintained, but the system becomes more complex with additional actuating mechanisms
Solution Approach 1:
The actuating arrangement is integrated into the existing brake assembly structure, with the actuator mounted to either the caliper or brake carrier and engaging with corresponding engagement portions. This extraction approach adds the locking function without requiring a completely separate system, minimizing the increase in overall device complexity.
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
Prevents unintended contact between brake pads and rotor, reducing wear, improving efficiency, and extending the life of brake components by maintaining optimal clearance and controlling frictional forces.
Implementation Method 1
the actuating arrangement may also act to dampen undesirable vibrational effects, such as a rattling sound caused by components of the disc brake assembly abutting against each other
Data Source
AI summary
A disc brake assembly having brake pads, a brake carrier, a caliper, and an actuating arrangement. The caliper is slidable with respect to the brake carrier for clamping and release of a rotor by the brake pads. The actuating arrangement is configured to selectively move the caliper and the brake carrier relative to each other generally transverse to a first longitudinal axis so as to lock or inhibit sliding of the caliper relative to the carrier.