Brake Caliper Locking Assembly for Running Clearance Stability
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Solution Overview
Problem
Existing brake systems for heavy commercial vehicles experience unintentional contact between brake pads and the rotor due to uneven wear and engine vibrations, leading to reduced efficiency, increased fuel consumption, and premature wear of brake pads.
Innovation Solution
A brake assembly with a lock arrangement that includes a friction element and a retaining cage, allowing selective inhibition of relative sliding between the caliper and brake carrier, preventing unintended contact and dampening vibrational effects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the caliper is allowed to slide freely on guide pins relative to the brake carrier, then the brake pads can move relative to the brake carrier during braking operation, but the brake pads may contact the brake rotor unintentionally outside of braking operations due to engine vibration or cornering forces
Solution Approach 1:
The guide pin assembly transitions from a static free-sliding design to a dynamic system that can switch between locked and unlocked states. The lock arrangement with friction element provides dynamic control over the guide pin's ability to allow caliper movement, enabling the system to adapt between braking operation mode (unlocked, free sliding) and idle mode (locked, preventing unintended contact).
Solution Approach 2:
The lock arrangement acts as an intermediary mechanism between the guide pin and caliper. It controls the interaction between these components by selectively enabling or disabling the sliding capability, serving as a mediator that prevents direct unintended contact while allowing intended movement during braking.
2Reliability
If a lock arrangement is introduced to inhibit relative sliding between the caliper and brake carrier, then unintended brake pad contact is prevented, but the device complexity increases
Solution Approach 1:
The lock arrangement is merged with the existing guide pin assembly structure. The friction element is integrated into the guide pin's interaction with the caliper, combining the locking function with the existing guidance mechanism rather than adding a completely separate locking system.
Solution Approach 2:
The friction-based lock arrangement provides self-locking capability through the inherent friction between the guide pin and caliper components. The system uses its own operational forces and friction characteristics to maintain the locked state, reducing the need for additional active locking mechanisms or control systems.
3Reliability
If the guide pin abuts against the caliper due to engine vibration, then the caliper position is maintained, but undesirable vibrational effects and rattling sounds occur
Solution Approach 1:
The lock arrangement converts the harmful vibrational effects and rattling sounds into a beneficial controlled frictional connection. By introducing the friction element, the system transforms the problematic loose abutment into a controlled, damped connection that maintains position stability while reducing noise and vibration.
Solution Approach 2:
The friction element provides beforehand cushioning by creating a controlled frictional connection that dampens vibrations before they can cause harmful rattling sounds. The friction-based connection acts as a cushion that absorbs and dampens vibrational energy in advance.
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 solution effectively prevents brake pad contact with the rotor outside of braking operations, ensuring even wear and reducing fuel consumption and maintenance costs by maintaining a desired running clearance and dampening vibrations.
Implementation Method 1
the lock arrangement comprising a friction element. The lock arrangement is operable to selectively apply a force to the friction element in order to increase friction between the guide sleeve and the guide bore
Implementation Method 2
the lock arrangement may also act to dampen undesirable vibrational effects, such as a rattling sound caused by the guide pin abutting against the caliper
Data Source
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AI summary
A brake assembly (100) for a heavy commercial vehicle, the brake assembly (100) comprising: a caliper (102) comprising a guide bore (122a); a brake carrier (101) arranged to receive a brake pad (103a, 103b); a guide pin (124a) comprising a guide sleeve (128a) secured to the brake carrier (101), the guide pin (124a) defining an axial direction and being received within the guide bore (122a) of the caliper (102) such that the caliper (102) is slideable relative to the brake carrier (101) along the guide sleeve (128a); and a lock arrangement (142) at least partially interposed between the guide bore (122a) and the guide sleeve (128a), the lock arrangement (142) comprising a friction element, wherein the lock arrangement (142) is operable to selectively apply a force to the friction element in order to increase friction between the guide sleeve (128a) and the guide bore (122a) and inhibit relative sliding between the caliper (102) and the brake carrier (101).