Brake Caliper Guide Structure to Prevent Misassembly and Vibration
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Solution Overview
Problem
Existing brake calipers for commercial vehicles face issues with incorrect installation and accidental disassembly due to movable parts, leading to noise and potential separation during assembly, installation, and operation, which increases the risk of malfunction.
Innovation Solution
A brake caliper design that incorporates a guiding member to limit the movement of the thrust piece relative to the pressure piece in orthogonal directions, along with a lever and pivot bearing, to secure the components in place, reducing the risk of incorrect installation and ensuring proper alignment, thus simplifying assembly and reducing the risk of malfunction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the thrust piece and pressure piece are pre-assembled before installing in the brake caliper, then the assembly process is simplified, but the parts are not secured in their position relative to each other, increasing the risk of incorrect installation
Solution Approach 1:
The guiding member is pre-installed on the pressure piece before the thrust piece is assembled. This preliminary action creates a positioning structure that guides the thrust piece into the correct position during assembly, ensuring proper alignment and preventing incorrect installation while simplifying the overall assembly process.
Solution Approach 2:
The guiding member acts as an intermediary element between the pressure piece and the thrust piece. It provides a positioning interface that ensures correct relative positioning of the two main components during assembly, thereby improving installation correctness without complicating the assembly process.
2Adaptability or versatility
If the thrust piece is made movable inside the brake caliper to transmit braking force, then the braking function is enabled, but the parts tend to vibrate during assembly, installation and transportation resulting in noise emission and separation
Solution Approach 1:
The guiding member provides preliminary guidance and constraint to the thrust piece in directions orthogonal to the thrust direction, preventing unwanted lateral movements and vibrations during assembly, installation, and transportation. This preliminary anti-action eliminates noise and separation risks while maintaining the necessary movability for braking force transmission along the thrust direction.
3Reliability
If the guiding member limits the movement of the thrust piece in orthogonal directions, then the position and alignment are secured, but the device complexity increases
Solution Approach 1:
The guiding member is designed to perform multiple functions: it provides positioning guidance for the thrust piece, prevents lateral vibrations, ensures correct alignment during assembly, and maintains the thrust piece's movability in the braking direction. This multi-functionality achieves reliable position security without significantly increasing device complexity.
Data Source
AI summary
A brake caliper (1, 1′) for a vehicle brake, in particular a disc brake of a commercial vehicle, includes a pressure piece (110, 110′), a thrust piece (120, 120′) configured to move axially relative to the pressure piece (110, 110′) in a thrust direction (A) to transmit a braking force and a guiding member (130a,b, 130′a,b) configured to limit the movement of the thrust piece (120, 120′) relative to the pressure piece (110, 110′) in at least one direction orthogonal to the thrust direction (A). The brake caliper (1, 1′) may further include a lever (140) pivotally supported between the thrust piece (120, 120′) and the pressure piece (110, 110′), wherein the guiding member (130a,b, 130′a,b) is configured to limit the movement of the lever (140) relative to the pressure piece (110, 110′) and/or the thrust piece (120, 120′) in at least one direction orthogonal to the thrust direction (A).