Brake Caliper Pull Rod Layout for Lower Weight and Space
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Solution Overview
Problem
Existing pull rod devices in brake calipers for rail vehicles are heavy, occupy excessive installation space, and require unnecessary components, limiting cost savings and performance improvements.
Innovation Solution
A pull rod device arrangement comprising separate pull rod top and bottom parts connected by vertical rods, eliminating the need for a vertical pull rod rib, allowing for reduced weight and compact design while maintaining functionality through the transfer of vertical forces and bending moments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a single-piece pull rod device with vertical pull rod rib is used, then structural integrity and force transfer are maintained, but weight and installation space increase
Solution Approach 1:
The pull rod device is divided into separate components: pull rod top, pull rod bottom, and vertical rods. This segmentation eliminates the need for the heavy vertical pull rod rib while maintaining structural integrity through the combination of these lighter separate parts.
Solution Approach 2:
The vertical pull rod rib is removed from the design entirely. Its force transfer function is replaced by the vertical rods connecting the pull rod top and bottom, achieving weight reduction without sacrificing structural capability.
2Area of stationary object
If a single-piece pull rod device with vertical pull rod rib is used, then force transfer capability is ensured, but installation space and device complexity increase
Solution Approach 1:
By segmenting the pull rod device into separate components (pull rod top, pull rod bottom, vertical rods), the overall installation space is reduced as these parts can be arranged more compactly compared to the monolithic single-piece design with its required vertical rib space.
Solution Approach 2:
The vertical rods serve multiple functions: they connect the pull rod top and bottom, transfer forces between them, and replace the structural role of the removed vertical pull rod rib. This multi-functionality reduces the need for additional components.
3Ease of manufacture
If separate pull rod top and bottom parts are used, then weight and space are reduced, but connection complexity and manufacturing difficulty increase
Solution Approach 1:
The pull rod top and bottom are manufactured separately, allowing for simplified production processes for each component. This segmentation enables easier manufacturing compared to producing a single complex piece, despite requiring assembly of multiple parts.
Solution Approach 2:
The separate pull rod top, pull rod bottom, and vertical rods are combined through straightforward connections to form the complete pull rod device. This merging process, while adding assembly steps, uses simple connection methods that offset the increased assembly complexity.
Data Source
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AI summary
A pull rod device (3) arrangement of a brake caliper (1), comprising a pull rod top (30), a pull rod bottom (31), and two vertical rods (5, 5'), wherein the pull rod top (30) and the pull rod bottom (31) of the pull rod device (3) are connected to each other. The pull rod top (30) and the pull rod bottom (31) of the pull rod device (3) are designed as separate parts. A brake caliper (1) comprises said pull rod device (3).