Disc Brake Caliper Gearbox Layout for Reduced Axial Width
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Solution Overview
Problem
Existing disc brake caliper designs are cumbersome due to their large axial dimensions, particularly in motorcycles, where reduced width and maneuverability are constrained by the side-by-side arrangement of the piston and worm-nut screw assembly and gearbox, which cannot be effectively minimized.
Innovation Solution
Integration of gearbox components with the thrust device, using a single thrust bearing to support both the worm and gearbox, eliminating unnecessary components and simplifying the assembly by directly transmitting motion from the gearbox to the worm, thereby reducing the axial footprint.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the piston and worm-nut screw assembly with gearbox are arranged side-by-side, then the braking function is achieved, but the axial dimensions of the caliper become large and cumbersome
Solution Approach 1:
The patent merges the gearbox and thrust device into a single integrated assembly where the gearbox is positioned concentrically around the worm-nut screw assembly. The planet gears of the gearbox engage directly with the worm gear, eliminating the need for separate mounting and reducing axial space requirements while maintaining both the braking and motion transmission functions.
Solution Approach 2:
The gearbox is nested concentrically around the thrust device, with the planet gears positioned within the outer diameter of the worm-nut screw assembly. This nested arrangement allows the gearbox output shaft to be coaxial with the worm axis, significantly reducing the axial footprint of the overall assembly while preserving all functional requirements.
2Ease of manufacture
If separate components are used for thrust device and gearbox, then manufacturing and assembly are simplified, but the overall assembly becomes more complex and occupies more space
Solution Approach 1:
The patent combines the gearbox and thrust device into a single integrated assembly where the gearbox is positioned concentrically around the worm-nut screw assembly. The planet gears of the gearbox engage directly with the worm gear, eliminating the need for separate mounting and reducing axial space requirements while maintaining both the braking and motion transmission functions.
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 significantly reduces the axial dimensions of the caliper, achieving a more compact design that was not possible with previous solutions, while simplifying the assembly process and enhancing the caliper's structural integrity.
Implementation Method 1
a screw thrust bearing (12) supporting said worm (10) in a rotatable manner and applying by said worm (10) an axial reaction mainly along said axial direction (A-A)
Data Source
AI summary
A brake caliper of a disc brake has a caliper body straddling a brake disc and having a thrust device housing accommodating a thrust device operatively connected to a translating screw nut. The translating screw nut is operatively connected to a worm. The worm is operatively connected to a gearbox and rotatably supported by a screw thrust bearing configured to apply for the worm an axial reaction. At least one part of the gearbox is rotatably supported by a gearbox thrust bearing configured to apply for the at least one part of the gearbox a radial reaction. The thrust bearing has at least one radially inner slewing ring and the gearbox has an epicyclic gear having a fixed gear or an internally toothed body cooperating with at least one planet gear rotatably supported about at least one planet gear pin connected to the at least one radially inner slewing ring to transmit action of the gearbox to the worm by the at least one radially inner slewing ring.