Brake Caliper Lever Layout for Tight Wheel-Space Packaging
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Solution Overview
Problem
Existing braking systems for commercial vehicles face significant space constraints due to their current arrangement, requiring large axial and radial installation spaces, especially when incorporating a parking brake function, and often collide with wheel rims or axle bodies, limiting lever size and geometry flexibility.
Innovation Solution
A braking system design with a rotatory braking element and stationary braking element, utilizing a lever with a pivot axis parallel to the rotational plane and actuator axes oriented parallel to the horizontal caliper plane, allowing for separate main and auxiliary brake actuators on different sides, and incorporating a transfer element to optimize space usage and reduce dynamic loads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the actuator axis is oriented perpendicular to the disc center plane (radial brake configuration), then the braking system can be mounted in certain positions, but the parking brake portion collides with the road surface and significant radial installation space is required
Solution Approach 1:
The patent reorients the actuator axis from a radial configuration (perpendicular to disc center plane) to an axial configuration (parallel to disc center plane and horizontal caliper plane). This dimensional change allows the braking system to be mounted in positions that avoid collision with the road surface while reducing the radial installation space required.
2Volume of stationary object
If the actuator axis is oriented parallel to the disc center plane (axial brake configuration), then radial installation space is reduced, but the braking system consumes significant axial installation space
Solution Approach 1:
The patent employs an asymmetric lever design where the pivotal axis is oriented at an angle (e.g., 45°) relative to the actuator axis. This asymmetric configuration optimizes the distribution of forces and moments, allowing the system to achieve the required braking function with reduced axial installation space compared to symmetric configurations.
3Power
If the maximum size of the eccentric lever is increased, then the brake mechanism performance is improved, but the lever collides with the wheel rim or axle bodies due to space constraints
Solution Approach 1:
The patent changes the orientation of the lever's pivotal axis from a radial configuration to an axial configuration (parallel to the disc center plane). This reorientation allows the lever to operate in a different spatial dimension, increasing its effective size and leverage for improved brake mechanism performance while avoiding collision with the wheel rim or axle bodies.
4Adaptability or versatility
If the service brake portion and parking brake portion are separated and arranged on different sides of the eccentric lever, then functional independence is improved, but collision with wheel rim or axle bodies occurs
Solution Approach 1:
The patent reorients the entire braking system, including the separated service brake portion and parking brake portion, to an axial configuration where the actuator axis is parallel to the disc center plane. This dimensional change allows both brake portions to be arranged on different sides of the lever with functional independence while positioning them in space to avoid collision with wheel rim or axle bodies.
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 new design reduces installation space requirements, avoids collisions, and enhances flexibility in lever geometry, optimizing the brake mechanism's ratio, progression, and hysteresis while accommodating both main and auxiliary brake functions.
Implementation Method 1
a lever (32) that is configured such that it transfers a force exerted by the brake actuator to the stationary brake element, wherein a pivot axis (326) of the lever (32) is in parallel with a rotational plane of the rotatory braking element
Implementation Method 2
a brake actuator (5, 380, 400) that is configured to actuate the stationary braking element such as to press the stationary braking element towards the rotatory element
Implementation Method 3
the braking pads and the caliper generate a clamping force that acts on the brake disc such that relative movement, in particular relative rotation between the brake disc and the braking pads are slowed down by friction between the brake disc and the braking pads
Data Source
AI summary
A braking system and method of providing a braking system includes: a rotatory braking element that is fixedly connected to a wheel or wheel hub in a manner to rotate conjointly with the wheel, a stationary braking element that is fixedly connected to a vehicle chassis, a brake actuator that is configured to actuate the stationary braking element so as to press the stationary braking element towards the rotatory element, a lever that is configured so as to transfer a force exerted by the brake actuator to the stationary brake element, wherein a pivot axis of the lever is in parallel with a rotational plane of the rotatory braking element and perpendicular to a horizontal caliper plane that is a plane that is oriented tangentially of the rotatory brake element, and an actuator axis is in parallel with the rotational plane and the horizontal caliper plane.