Brake Caliper Structural Optimization with Face Orientation Constraints
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Solution Overview
Problem
Existing brake calipers experience uneven wear, noise, and increased brake fluid absorption due to elastic deformation during brake activation, which complicates structural optimization and leads to non-optimal designs regarding weight and performance.
Innovation Solution
A method for structurally optimizing brake calipers using a computer-implemented model with a boundary condition that maintains the orientation of brake caliper faces relative to the piston movement axis under load, allowing for weight reduction and improved deformation behavior through generative manufacturing methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If the brake caliper structure is optimized to reduce weight, then the weight is reduced, but the elastic deformation increases causing uneven wear and performance issues
Solution Approach 1:
The patent applies parameter changes by modifying the boundary conditions in the optimization model - specifically constraining the orientation of caliper faces to remain constant under load. This parameter constraint allows the optimization algorithm to find designs that achieve weight reduction while preventing the face deformation that causes uneven brake pad wear and performance instability.
2Weight of moving object
If traditional structural optimization methods are used, then weight reduction is achieved, but the faces of the brake caliper deform unevenly under load
Solution Approach 1:
The patent implements preliminary action by pre-defining the boundary condition that constrains face orientation before the actual structural optimization process begins. This preliminary constraint ensures that during the weight optimization iterations, the faces maintain their orientation relative to the piston movement axis, preventing uneven deformation while achieving weight reduction.
3Weight of moving object
If the brake caliper faces are allowed to deform under load, then weight can be reduced, but brake fluid absorption increases
Solution Approach 1:
The patent uses parameter changes by imposing a boundary condition that limits the deformation of the hydraulic chamber volume. By constraining the face orientation and limiting volume change parameters during optimization, the method achieves weight reduction while preventing the excessive brake fluid absorption that would otherwise occur due to uncontrolled elastic deformation.
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
The method prevents uneven deformation of brake caliper faces, achieving weight reduction and improved stiffness while maintaining optimal brake performance and minimizing brake fluid absorption.
Implementation Method 1
During brake activation, large forces act on the brake caliper. The brake caliper may thus elastically deform or, put differently, elastically deflect.
Data Source
AI summary
The invention concerns a method for the structural optimization of a brake caliper (10), the brake caliper (10) having a first face (24) and a second face (26) that are spaced apart from one another along a piston movement axis (A), wherein the first and second face (24, 26) are connected by a bridge section (22) of the caliper (10), wherein the method is performed based on a computer-implemented model (30) of the brake caliper (10), caliper model, the method comprising:prescribing a boundary condition according to which an orientation of the first face (24) and the second face (26) relative to one another and/or to the piston movement axis (A) remains constant even under load;performing a structural optimization of the caliper model (30) taking into account said boundary condition.Also disclosed is a brake caliper (10).