Brake Caliper Mounting Assembly Angular Positioning
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Solution Overview
Problem
Existing brake caliper mounting systems lack flexibility in positioning and often result in a heavier and less compact wheel end assembly due to the use of torque plates, which restricts the angular alignment of the brake caliper with the steering knuckle.
Innovation Solution
A brake caliper mounting assembly that includes a steering knuckle with multiple sets of block mounting holes, allowing the first and second blocks to be fastened in various angular positions, thereby enabling the brake caliper to be 'clocked' and securely attached to the steering knuckle using a combination of threaded and unthreaded fasteners, reducing weight and increasing compactness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If torque plates are used to mount the brake caliper to the steering knuckle, then the brake caliper can be securely attached, but the wheel end assembly becomes heavier and less compact
Solution Approach 1:
The patent removes the torque plate component from the mounting system entirely. Instead of using a torque plate to attach the brake caliper to the steering knuckle, the invention directly fastens the brake caliper to the steering knuckle through multiple sets of mounting holes, thereby eliminating unnecessary weight while maintaining secure attachment
Solution Approach 2:
The patent divides the mounting system into multiple discrete mounting points (first set, second set, and third sets of mounting holes) rather than using a single torque plate structure. This segmentation allows for direct attachment of the brake caliper to the steering knuckle at multiple locations, reducing the need for a heavy intermediate torque plate component
2Strength
If torque plates are used for mounting, then the brake caliper can be attached to the steering knuckle, but the angular alignment flexibility is reduced
Solution Approach 1:
The patent provides multiple sets of mounting holes (first set, second set, and third sets) arranged at different angular positions on the steering knuckle, allowing the brake caliper to be mounted at various angular alignments. This dynamic configuration enables flexible angular adjustment while maintaining secure attachment through multiple fastening points
Solution Approach 2:
By dividing the mounting system into multiple discrete sets of mounting holes at different angular positions, the patent allows selective use of different mounting configurations. This segmentation provides angular alignment flexibility while maintaining secure attachment through the distributed mounting points
3Adaptability or versatility
If multiple sets of block mounting holes are provided, then the brake caliper can be positioned at multiple angular positions, but the steering knuckle design becomes more complex
Solution Approach 1:
The multiple sets of mounting holes on the steering knuckle serve multiple functions: they enable angular alignment flexibility, provide alternative mounting positions for different brake caliper configurations, and maintain structural integrity. This multi-functional design achieves positioning versatility without proportionally increasing complexity
Data Source
AI summary
A brake caliper mounting assembly that includes a steering knuckle, a brake caliper, and first and second mounting blocks. The first and second mounting blocks are mounted to the steering knuckle. The brake caliper is mounted on the first and second blocks.