Brake Caliper Mid-Plane Mounting for Balanced Warping
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Solution Overview
Problem
Conventional brake caliper mounting on the inboard side leads to uneven deflection and distortion, resulting in inefficient braking and uneven pad wear, particularly in high-performance vehicles.
Innovation Solution
A brake caliper mounting system with points at either end of the bridge section, close to the brake disc mid-plane, utilizing a fixed leading mount and a floating trailing mount to balance warping between the inboard and outboard sections, maintaining piston perpendicularity and reducing lift.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the brake caliper is mounted on the inboard side only, then the mounting structure is simple, but uneven deflection and distortion occur between inboard and outboard sections
Solution Approach 1:
The caliper mounting system is segmented into two separate mounting points: a fixed leading mounting point on the inboard side and a floating trailing mounting point on the outboard side. This segmentation allows each mounting point to independently manage the deflection characteristics of its respective caliper section, preventing the uneven deflection that occurs with single-sided mounting while maintaining structural simplicity.
2Stability of the object's composition
If the brake caliper is mounted close to the brake disc mid-plane, then warping between sections is balanced, but the mounting points must be positioned at specific locations
Solution Approach 1:
The mounting system employs asymmetric positioning where the fixed leading mounting point is located on the inboard side and the floating trailing mounting point is located on the outboard side, both positioned close to the brake disc mid-plane. This asymmetric yet balanced configuration optimizes the distribution of mounting points to balance warping between sections while accommodating the specific length requirements of the caliper structure.
3Manufacturing precision
If a floating link is used at the trailing mounting point, then piston perpendicularity is maintained, but the mounting system becomes more complex
Solution Approach 1:
The trailing mounting point incorporates a floating link mechanism that allows dynamic adjustment and movement. This floating connection maintains piston perpendicularity by accommodating thermal expansion, brake torque-induced distortion, and manufacturing tolerances, while the simplicity of the floating link design prevents excessive complexity in the overall mounting system.
Data Source
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AI summary
A braking system comprising a support member, a brake disc defining a disc mid-plane line, and a brake caliper comprising a bridge section, an inboard section and an outboard section. The brake caliper is connected to the support member such that the joint there-between is close to the brake disc mid-plane so as to balance warping between the inboard caliper section and the outboard caliper section.