Disc Brake Caliper Pin Attachment Rigidity
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Solution Overview
Problem
Existing caliper designs for disc brakes require expensive and complex solutions to ensure the necessary rigidity of support pins, which are complicated to produce and mount, and are prone to loosening due to vibrations.
Innovation Solution
A caliper design featuring support pins with an attachment portion and a support portion, where the attachment portion is secured within a support hole with a screw, eliminating the need for bushings and incorporating anti-rotation mechanisms to prevent loosening, ensuring secure and rigid attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional support pins are used to ensure necessary rigidity, then the attachment rigidity is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The support pin is divided into two distinct parts: a support portion that contacts the pad and a attachment portion that receives the screw. This segmentation allows each part to be optimized for its specific function, achieving rigidity where needed while simplifying the overall attachment mechanism
Solution Approach 2:
The attachment portion is designed to be inserted into a support hole in the caliper body, creating a nested structure where the pin fits within the caliper body. This nesting eliminates the need for separate mounting brackets or complex external attachment mechanisms, reducing device complexity while maintaining rigidity
2Strength
If traditional support pins are used, then the attachment is achieved, but the ease of manufacture and mounting deteriorates
Solution Approach 1:
The support hole is pre-formed in the caliper body with the correct geometry to receive the attachment portion. This preliminary preparation allows the pin and screw to be easily assembled without requiring complex machining or fitting operations during final assembly, improving manufacturing ease while ensuring secure attachment
Solution Approach 2:
The screw threads directly into the attachment portion of the pin, creating a self-contained fastening system. This self-service mechanism eliminates the need for additional fasteners, clips, or complex locking mechanisms, making the attachment both secure and easy to manufacture and assemble
3Ease of operation
If traditional support pins are used, then the support function is provided, but the reliability deteriorates due to loosening from vibrations
Solution Approach 1:
The screw creates a pre-tensioned connection between the attachment portion and the caliper body, establishing a rigid, vibration-resistant connection before any loosening can occur. This preliminary anti-action counteracts the loosening effect of vibrations, maintaining reliability while preserving the ease of the support function
Data Source
Figure 1~2a
Figure 2b
Figure 3a~5b
AI summary
A caliper for a disc brake having a pair of half-bodies (16,20) and comprising at least one pin (44) which overhangs from at least one half-body (16,20) towards the brake disc, the pin (44) having a support portion (48) and an attachment portion (52), the support portion (48) being able to support the pad. At least one screw (68) engages with the attachment portion (52) to attach the pin (44) to the half-body. The attachment portion (52) is at least partially lodged inside the support hole and the support portion (48) reaches its final position against the half-body (16,20) at the first access aperture of the support hole (60) from the side of the associable pad (24).