Brake Caliper Support Connections for Rigidity
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing brake caliper assemblies experience undesirable movement, bending, bowing, and deformation during brake application, leading to increased brake fluid displacement, uneven wear, and a spongy brake feel, due to inadequate rigidity between the caliper body and support member, which is not effectively addressed by existing solutions without increasing size, weight, complexity, or cost.
Innovation Solution
Increasing the number of support connections and mounting positions between the caliper body and support member to enhance stiffness, reducing moment arms and movement, thereby stabilizing the caliper body and brake pistons, and improving the connection to minimize brake pedal stroke and wear issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the number of support connections between caliper body and support member is increased, then rigidity and stability are improved, but device complexity and assembly complexity increase
Solution Approach 1:
The support member is divided into multiple mounting positions (first, second, third, and fourth positions) with separate support connections. This segmentation allows each connection point to independently contribute to rigidity while maintaining modular assembly, resolving the contradiction between stability improvement and complexity increase.
2Manufacturing precision
If support connections are added to reduce moment arm effects, then caliper body deformation is reduced, but manufacturing complexity and cost increase
Solution Approach 1:
The support connections are positioned asymmetrically at different locations on the caliper body (inboard and outboard walls) rather than symmetrically. This asymmetric arrangement optimizes the distribution of support forces to minimize moment arm effects and deformation while maintaining manufacturing simplicity through standard mounting procedures.
3Reliability
If the connection between caliper body and support member is strengthened, then brake system responsiveness is improved, but weight and packaging space increase
Solution Approach 1:
The support member incorporates adjustable mounting positions that allow optimization of connection parameters (location, orientation, and number of connections). By adjusting these parameters, the system achieves improved responsiveness through better force distribution while controlling weight increases through efficient use of existing structural capacity.
Data Source
AI summary
A brake caliper assembly that includes a caliper body and a support member. The caliper body includes an inboard wall; an outboard wall; and a transverse wall connecting the inboard wall and the outboard wall. The support member is adapted to connect the brake caliper assembly to a vehicle. The support member is connected to the inboard wall at more than two support connections.