Brake Caliper Transfer Mechanism for Low-Drag Pad Alignment
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Solution Overview
Problem
Existing disc brake systems face issues with drag torque due to uneven wear and misalignment of brake pads, which can lead to reduced braking efficiency and increased energy consumption.
Innovation Solution
The brake assembly features a transfer mechanism driven by an actuating member, such as a bridge member, that actively moves the brake caliper and second brake pad simultaneously with the first brake pad, ensuring balanced contact with the brake disc and reducing drag torque.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a free sliding caliper is used to allow pad clearance adjustment, then the brake pad clearance can be automatically adjusted, but drag torque is generated due to uneven pad contact with the brake disc
Solution Approach 1:
The caliper is designed to be movable along the brake disc axis, transitioning from a static position to a dynamic adjustable position. The caliper guidance enables the caliper to slide axially, allowing the brake pads to be repositioned for optimal contact with the brake disc, thereby eliminating drag torque while maintaining automatic clearance adjustment capability
Solution Approach 2:
The brake system uses the braking force itself to center the caliper and adjust pad clearance. During braking operation, the reaction forces automatically position the caliper in the correct axial location, eliminating the need for separate adjustment mechanisms and ensuring uniform pad contact without generating drag torque
2Object-generated harmful factors
If spreading elements are fixed to axle fixated part to centre the caliper, then drag torque can be avoided, but the restoring forces are limited due to limited adjustment force
Solution Approach 1:
The caliper is extracted from the fixed mounting and given mobility along the brake disc axis through the caliper guidance. This allows the caliper to self-center during operation without relying on fixed spreading elements, thereby avoiding drag torque while enabling sufficient restoring forces through the axial movement capability
Solution Approach 2:
The caliper guidance acts as an intermediary mechanism between the fixed brake assembly and the movable caliper. It enables controlled axial movement of the caliper, allowing the system to achieve both drag torque elimination and adequate restoring forces through the guided motion
3Manufacturing precision
If the relative position of the brake disc varies more than the running clearance, then one pad may be permanently in contact with the disc, but the initially set clearance cannot be maintained
Solution Approach 1:
The caliper's axial mobility allows it to dynamically adapt to variations in brake disc position. Instead of being fixed at an initial clearance setting, the caliper can slide to accommodate position variations, ensuring both pads maintain proper clearance even when disc position varies beyond the original clearance tolerance
Solution Approach 2:
The system changes the parameter of caliper position from fixed to variable. By allowing the caliper to move axially along the brake disc, the system can adjust the effective clearance in real-time to compensate for manufacturing tolerances and position variations, maintaining proper pad clearance under varying conditions
Data Source
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AI summary
The present invention relates to a brake assembly (100, 100ʺʺ), comprising: at least one first brake pad (22a) and at least one second brake pad (22b), wherein the at least one first brake pad (22a) and the at least one second brake pad (22b) each comprising a braking surface arranged opposed to each other and facing each other, a brake caliper (24) operatively connected to the at least one first brake pad (22a) and the at least one second brake pad (22b), wherein the respective operative connections are configured to cause a movement of the brake caliper (24) to move the at least one second brake pad (22b) toward the at least one first brake pad (22a) in response to a movement of the at least one first brake pad (22a) toward the at least one second brake pad (22b) in a braking direction, a brake caliper guidance (7) configured to guide a relative movement of the brake caliper (24) in the braking direction, and an actuating member (1, 20, 26) operatively connected to the at least one first brake pad (22a) and configured to move the at least one first brake pad (22a) into a braking direction by being translationally or rotationally driven, wherein the operative connection between the brake caliper (24) and the first brake pad (22a) comprises at least one transfer mechanism (10) configured to move the brake caliper (24) in an opposite direction of the moving direction of the at least one first brake pad (22a) in the braking direction, wherein the at least one transfer mechanism (10) is operatively connected to the brake caliper guidance (7) for a relative movement of the brake caliper (24) with respect to the brake caliper guidance (7), and wherein the actuating member (1, 20, 26) is configured to drive the transfer mechanism (10) for an opposite movement of the brake caliper (24) along the brake caliper guidance (7) with respect to the at least one first brake pad (22a) being moved in the braking direction.