Air Disc Brake Caliper Retraction Using a Deformable Friction Ring
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Solution Overview
Problem
Air disc brake systems experience brake drag due to the caliper failing to completely release the brake pads after braking, leading to premature wear and overheating of brake components.
Innovation Solution
An air disc brake system with a deformable friction ring and guide pin interface that automatically retracts the caliper and brake pads, utilizing a sliding mechanism and friction ring to bias the caliper back to the non-braking position, reducing the likelihood of brake drag.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the caliper is designed to engage the brake pad firmly during braking, then braking effectiveness is improved, but the caliper may fail to completely release the brake pad after braking, causing brake drag
Solution Approach 1:
The friction ring is designed to be deformable, changing its configuration from first to second state during braking to provide dynamic adjustment of the retractive force. This allows the system to adapt between strong engagement during braking and complete release during non-braking, resolving the contradiction between braking effectiveness and brake drag prevention
Solution Approach 2:
The friction ring's physical state changes between two configurations based on operational demands. During braking, the ring deforms to a second configuration that allows firm engagement, while during non-braking it returns to a first configuration that provides complete release. This parameter change enables the system to eliminate brake drag while maintaining reliable braking
2Ease of operation
If traditional return springs are used to retract the caliper, then the caliper can release the brake pad, but the system requires additional components that increase complexity and potential failure points
Solution Approach 1:
The friction ring serves dual functions: it provides the retractive force to release the brake pad and simultaneously seals the interface between the caliper and guide pin. This self-service approach eliminates the need for separate return springs and seals, reducing component complexity while maintaining the caliper release function
Solution Approach 2:
The friction ring is designed to perform multiple functions simultaneously: it provides friction-based retractive force, seals the caliper-guide pin interface, and accommodates thermal expansion. This multi-functionality replaces what would traditionally require multiple separate components, reducing system complexity
3Device complexity
If the caliper and brake pads remain in contact after braking, then the system is simple, but this leads to premature wear and overheating of brake components
Solution Approach 1:
The deformable friction ring acts as an intermediary mechanism between the caliper and guide pin, providing a controlled retractive force that ensures complete separation of the brake pads from the rotor. This intermediary enables automatic release without complex additional mechanisms, reducing wear while maintaining system simplicity
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 system effectively reduces brake drag by maintaining a retractive force on the brake pads, even as they wear, and provides a seal against contamination, potentially eliminating the need for return springs and reducing component wear.
Implementation Method 1
The friction ring is deformable from a first configuration when the caliper is in the non-braking position to a second configuration when the caliper is in the braking position. The friction ring biases the caliper from the braking position to the non-braking position.
Data Source
AI summary
An air disc brake system includes a carrier and a guide pin mounted to the carrier. A caliper is slidably mounted on the guide pin. The caliper has an annular groove extending radially outwardly from an inner circumferential surface. The caliper is moveable relative to the guide pin from a non-braking position to a braking position. A friction ring is disposed in the annular groove and is deformable from a first configuration when the caliper is in the non-braking position to a second configuration when the caliper is in the braking position. The friction ring biases the caliper from the braking position to the non-braking position. Methods of using and assembling the air disc brake system are also provided.