Brake Caliper Assembly with Spring Clip Adjuster
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Solution Overview
Problem
Existing vehicle brake assemblies, particularly air actuated disc brakes for heavy vehicles, face challenges in assembly complexity and time consumption due to the numerous components required, which can be cumbersome and inefficient.
Innovation Solution
A vehicle brake assembly with a brake caliper, cover plate, and actuator assembly that includes an adjuster mechanism with an adjuster shaft fixed by a clip arrangement, allowing for easier assembly by creating a subassembly that can be mounted within the caliper housing, where the clip arrangement, such as a spring clip, secures the adjuster shaft to the cover plate and biases it away, preventing movement and facilitating assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple components are assembled into the caliper housing, then the brake assembly functionality is complete, but the assembly process becomes time-consuming and complex
Solution Approach 1:
The brake assembly is divided into separate modules: the actuator assembly with adjuster mechanism can be pre-assembled as a subassembly, then installed as a unit into the caliper housing. This segmentation allows parallel assembly processes and reduces the sequence-dependent time consumption of traditional multi-component assembly.
Solution Approach 2:
The adjuster mechanism is pre-assembled with the actuator components before installation into the caliper housing. This preliminary assembly of subcomponents allows for quality control and adjustment calibration to be performed beforehand, reducing on-site assembly time and ensuring proper functionality before final installation.
2Reliability
If multiple components are assembled into the caliper housing, then the brake assembly functionality is complete, but the assembly complexity increases
Solution Approach 1:
By segmenting the brake assembly into modular components (actuator assembly, adjuster mechanism, caliper housing), the complexity of managing multiple small components is reduced. Each module can be assembled, tested, and maintained independently, simplifying the overall system management and reducing assembly complexity.
3Stability of the object's composition
If the adjuster shaft is secured with a clip arrangement, then the adjuster shaft is prevented from moving, but the assembly complexity increases
Solution Approach 1:
The clip arrangement uses simple, inexpensive retaining clips that can be easily installed and removed. These clips are designed for single-use or limited-life applications, allowing quick assembly and disassembly of the adjuster mechanism without requiring complex fastening systems, tools, or specialized procedures.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design simplifies the assembly process by allowing the subassembly to be assembled remotely and then integrated into the caliper housing, reducing the complexity and time needed for assembly while maintaining the functionality of the brake system.
Implementation Method 1
The clip arrangement, such as a spring clip, secures the adjuster shaft to the cover plate and biases it away, preventing movement
Data Source
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AI summary
A vehicle brake assembly (100) including a brake caliper defining a caliper housing (107) and defining a plane of rotation of a brake disc, the housing having an opening (108) facing the plane of rotation of a brake disc, a cover plate (128) for closing the opening (108) and an actuator assembly (117, 118) at least partially mounted in the housing, wherein the actuator assembly includes at least one piston (117, 118) for moving a friction element into contact with a brake disc, an adjuster mechanism (119) for adjusting the effective length of the at least one piston (117, 118), the adjuster mechanism (119) including an adjuster shaft (121), the adjuster shaft (121) being fixed to the cover plate (128) by a spring clip arrangement (320).