Brake Caliper Support Assembly With Elastic Displacement Sensing

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Solution Overview

Problem

Existing brake caliper systems face challenges in reliably and accurately quantifying braking action, particularly due to non-linear deformations and variable friction conditions, leading to residual braking torque, noise, and maintenance issues, especially in hydraulically actuated systems and brake-by-wire vehicles.

Innovation Solution

A caliper and support assembly that connects the caliper body to a supporting structure via a fixed portion and an elastically deformable constraining element, allowing displacement during braking, with a detecting device measuring displacement or constraining element deformation to quantify braking action.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If the caliper body is rigidly constrained to the supporting structure, then stability and positioning accuracy are improved, but residual braking torque and noise are generated due to inability to accommodate deformation

Engineering Contradiction:

Improvecaliper body positioning stabilityVSAvoidresidual braking torque and noise

Core Design Contradiction:

Stability of the object's compositionVSObject-generated harmful factors

Solution Approach 1:

The constraint system is divided into multiple constraining elements (first and second constraining elements) that can independently deform, allowing the caliper body to be constrained in multiple directions simultaneously while accommodating deformation through segmented elastic elements

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The constraining elements are designed with specific elastic properties and deformation characteristics, changing the rigidity parameter from rigid to elastically deformable, allowing the system to accommodate caliper body deformation while maintaining constraint functionality

Inventive Principle:

Principle #35Parameter changes

2Object-generated harmful factors

If the caliper body is allowed to displace freely during braking, then residual torque is reduced, but measurement accuracy and positioning control are compromised

Engineering Contradiction:

Improveresidual braking torqueVSAvoidbraking action quantification accuracy

Core Design Contradiction:

Object-generated harmful factorsVSMeasurement precision

Solution Approach 1:

A detection device is integrated to measure the deformation of constraining elements or displacement of caliper body, providing feedback information that enables accurate quantification of braking action while the caliper body is allowed to deform elastically

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The rigid mechanical constraint is replaced with elastically deformable constraining elements that can accommodate movement while providing measurable deformation signals for braking action quantification

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If multiple constraining elements are added to prevent deformation, then braking action quantification reliability is improved, but device complexity increases

Engineering Contradiction:

Improvebraking action quantification reliabilityVSAvoidcaliper assembly complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The constraining elements serve multiple functions: they constrain the caliper body in specific directions, accommodate deformation through elastic behavior, and provide measurable deformation signals for braking action quantification, eliminating the need for separate measurement devices

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The constraint function and measurement function are merged into a single integrated system where the deformable constraining elements themselves serve as the measurement mechanism, reducing overall device complexity

Inventive Principle:

Principle #5Merging (Combining)

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 enables simple, repeatable, and reliable quantification of braking action, reducing residual torque and wear, improving braking control, and maintaining standard brake configurations.

Implementation Method 1

a constraining element (9) configured to connect the caliper body (5) to a second fixing portion (8) of the supporting structure (4) along said predetermined direction P-P, so as to prevent said displacement of the caliper body (5) in the absence of a braking action; wherein during the braking action, the constraining element (9) elastically deforms

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Data Source

PatentUS20250020178A1Caliper and support assembly, and method

Publication Date: 2025.01.16 FRENI BREMBO SPA

AI summary

A caliper and support assembly has a brake caliper having a caliper body, and a supporting structure connected to the caliper body and having a first fixing portion and a second fixing portion for connecting with a vehicle, and a connecting portion for connecting the caliper body to the first fixing portion along a direction parallel to an axial direction or a direction parallel to a radial direction. The connecting portion allows a free movement of the caliper body relative to the supporting structure along a predetermined direction incident to the axial and radial directions or to directions parallel thereto. A constraining element connects the caliper body to the second fixing portion preventing the free movement of the caliper body and during a braking action elastically deforms determining a displacement of the caliper body relative to the supporting structure. A detecting device detects the displacement of the caliper body.