Brake Caliper Adjuster Assembly for Reliable Gearwheel Positioning
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Solution Overview
Problem
Existing brake calipers for commercial vehicles face challenges in assembly complexity and safety risks due to incorrect positioning of the gearwheel, leading to potential failures in torque transmission and brake performance.
Innovation Solution
The gearwheel is axially fixed relative to the brake caliper, with the adjuster nut and gearwheel in an axially slidable engagement, allowing for correct positioning during assembly and disassembly, and a snap-fit connection with a bracket for secure torque transmission, reducing the risk of incorrect installation and simplifying manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the gearwheel is fixed on the adjuster nut such that the gearwheel is moving axially with each actuation, then the adjuster unit can control the air clearance, but the exact positioning of the gearwheel is needed to ensure proper torque transmission from the adjuster motor
Solution Approach 1:
The adjuster unit is divided into separate components: the gearwheel is mounted on the brake caliper housing while the adjuster nut is mounted on the brake pad. This segmentation allows each component to be positioned and assembled independently, eliminating the need for precise relative positioning between the gearwheel and adjuster nut, thus reducing assembly complexity while maintaining torque transmission reliability.
Solution Approach 2:
The brake caliper housing acts as an intermediary structure that carries the gearwheel and provides the mounting framework. By using the housing as the reference structure for gearwheel positioning rather than fixing the gearwheel directly to the moving adjuster nut, the system achieves reliable torque transmission without requiring precise positioning between moving parts.
2Reliability
If the gearwheel is axially fixed relative to the brake caliper, then position deviations are prevented and torque transmission is ensured, but the adjuster nut must be correctly positioned with respect to the gearwheel during assembly
Solution Approach 1:
The system is segmented into a stationary gearwheel mounted on the brake caliper housing and a movable adjuster nut mounted on the brake pad. This segmentation allows the gearwheel to be axially fixed for position stability while the adjuster nut can be independently positioned and assembled, improving assembly ease without compromising position stability.
3Ease of operation
If the gearwheel and adjuster nut are in axially slidable engagement, then the adjuster nut can be axially moved for assembly and disassembly, but the gearwheel must maintain precise axial position to transfer torque
Solution Approach 1:
The adjuster unit is segmented into a stationary gearwheel mounted on the brake caliper housing and a movable adjuster nut mounted on the brake pad. This segmentation allows the gearwheel to maintain precise axial position for accurate torque transfer while the adjuster nut can be freely moved axially during assembly and disassembly, resolving the contradiction between assembly ease and position precision.
4Reliability
If the gearwheel is mounted to be axially fixed relative to the brake caliper, then failure due to position deviations is avoided, but the assembly complexity increases due to mounting requirements
Solution Approach 1:
The gearwheel is merged with the brake caliper housing structure, utilizing the existing housing as the mounting base. This integration reduces the need for separate mounting mechanisms and simplifies the overall assembly, achieving reliable axial positioning without significantly increasing 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
This configuration ensures reliable torque transfer, prevents brake caliper failure due to position deviations, and simplifies assembly, enhancing safety and manufacturing efficiency while maintaining accurate positioning and energy efficiency in torque transmission.
Implementation Method 1
an adjuster nut operatively coupled with the gearwheel and configured to be operatively coupled with one of the brake pads, such that the rotational movement of the gearwheel in the first direction is converted by the adjuster nut into an axially movement of the brake pad towards the disc
Implementation Method 2
the adjuster nut and the gearwheel are in an axially slidable engagement with respect to one another
Data Source
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AI summary
The invention comprises to a brake caliper (1, 1') for a vehicle brake, in particular an air disc brake of a commercial vehicle, the vehicle brake having a pair of brake pads configured to be coupled to the brake caliper (1, 1') and a disc positioned in between the brake pads, wherein the brake caliper (1, 1') has an adjuster unit (10, 10') mounted to the brake caliper (1, 1'), the adjuster unit comprising: a gearwheel configured for being rotary driven in a first direction, and an adjuster nut operatively coupled with the gearwheel and configured to be operatively coupled with one of the brake pads, such that the rotational movement of the gearwheel in the first direction is converted by the adjuster nut into an axially movement of the brake pad towards the disc. The invention further suggests that the gearwheel (200) is mounted in the brake caliper (1, 1') such that the gearwheel (200) is axially fixed relative to the brake caliper (1, 1'), while the adjuster nut (220) and the gearwheel (200) are in an axially slidable engagement with respect to one another.