Brake Caliper Replaceable Wear Inserts
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Solution Overview
Problem
The brake caliper of disc brakes in commercial vehicles experiences abrasive wear due to its exposed position, leading to reduced service life and operational reliability, as the wear cannot be replaced and affects the tension struts' functionality.
Innovation Solution
The implementation of replaceable protective elements made of wear-resistant materials, such as metal, specifically designed as shaped sheet metal parts for the tension strut and lever dome, which can be easily attached using screws, to absorb external wear and extend the service life of the brake caliper.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If the brake caliper is designed as a cast part for long service life, then the initial strength and durability are improved, but the wear-resistant areas cannot be replaced when worn
Solution Approach 1:
The brake caliper is divided into a permanent cast base structure and replaceable wear-resistant inserts. The inserts are separate components that can be independently replaced when worn, while the main caliper body remains intact. This segmentation allows the durable cast structure to be preserved while enabling replacement of worn surfaces.
Solution Approach 2:
Instead of making the entire brake caliper replaceable or using uniform material throughout, wear-resistant inserts with specialized material properties are applied only to the specific areas subject to wear (brake pad contact surfaces). This local application of enhanced material quality extends service life where needed without requiring replacement of the entire component.
2Ease of operation
If the brake caliper is positioned in an exposed area for functional operation, then the braking function is improved, but abrasive wear from dirt and weather increases
Solution Approach 1:
Wear-resistant inserts act as intermediary elements between the brake caliper and the harsh external environment. These inserts are positioned at the surfaces exposed to dirt and weather, serving as a protective mediator that absorbs the abrasive effects before they can damage the main caliper structure.
Solution Approach 2:
The wear-resistant inserts are designed as consumable components that can be easily replaced when worn out. Rather than protecting the entire expensive cast caliper, these relatively simple inserts are sacrificed periodically, providing continuous protection to the main structure at low cost.
3Reliability
If the tension struts are dimensioned for high tensile load capacity, then the operational reliability is improved, but the wear-related weakening leads to breakage
Solution Approach 1:
Wear-resistant coatings or inserts are applied to the tension strut surfaces before wear can significantly reduce their cross-sectional area and strength. This preventive measure cushions against the gradual strength reduction that would otherwise lead to sudden breakage under tensile load.
Data Source
Figure 1
Figure 2
AI summary
The invention relates to a brake caliper (1) of a disk brake for a utility vehicle, comprising two tension braces (4), which are arranged substantially parallel and at a distance from each other, bridge a brake disk perpendicularly to the rotational direction of the brake disk in the assembled position, and connect receptacles for functional parts arranged on both sides of the brake disk to one another, wherein one receptacle forms a caliper back (3) and the other receptacle forms a housing (2) having a lever dome (5) formed thereon. The brake caliper (1) is designed in such a way that respective replaceable protective elements (8, 13) are fastened at each potential area of wear caused by operation.