Disc Brake Pad Carrier Alignment for Controlled Frame Movement
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Solution Overview
Problem
Conventional disc brake friction pad carriers experience relative movement with respect to the anchor plate, leading to misalignment of guide pins and performance degradation due to deformation and excessive shear forces, which increases maintenance costs.
Innovation Solution
A friction pad carrier design incorporating alignment pins and strategically positioned fasteners that allow controlled movement (surge, sway, and yaw) while maintaining alignment, using alignment pins to inhibit movement and ensure proper alignment of guide pins.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If fasteners are used to couple the carrier to the anchor plate, then the carrier is prevented from separating from the anchor plate, but the carrier is permitted to move relative to the anchor plate in various directions causing misalignment
Solution Approach 1:
The coupling system is segmented into two distinct functional components: fasteners that provide separation prevention and alignment pins that provide positioning precision. This segmentation allows each component to specialize in one function, resolving the contradiction between strong coupling and precise alignment.
Solution Approach 2:
Alignment pins act as intermediary elements between the carrier and anchor plate, mediating the coupling relationship by providing precise positioning while working together with fasteners to achieve both strength and alignment precision.
2Adaptability or versatility
If the carrier is allowed to move relative to the anchor plate, then deformation and shear force accommodation are possible, but guide pin alignment is compromised and performance degrades
Solution Approach 1:
The system dynamically balances movement accommodation and alignment maintenance by allowing controlled movement through fastener flexibility while maintaining guide pin alignment through rigid alignment pins, enabling the system to adapt to deformation while preserving brake performance.
Data Source
AI summary
A friction pad carrier for a vehicle disc brake includes a frame having an aperture through which a portion of a rotor rotating about a rotational axis extends. The frame mounts friction pads on opposite sides of the rotor. The frame includes lugs proximate each end that receive fasteners coupling the frame to an anchor plate mounted on an axle of the vehicle. The fasteners permit some amount of surge movement and sway movement between the frame and the anchor plate in a plane at the interface between the frame and the anchor plate and yaw movement about an axis perpendicular to the plane. A first alignment pin between one of the lugs and the anchor plate inhibits the amount of surge movement and sway movement and a second alignment pin between one of the lugs and the anchor plate inhibits the amount of yaw movement.