Two-Part Brake Carrier Design for Commercial Vehicle Axles
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Solution Overview
Problem
Existing brake carriers for disc brakes on commercial vehicles are expensive to produce due to the need for precise machining of struts between brake carrier horns and contact surfaces, which can lead to distortion and increased production costs.
Innovation Solution
A two-part brake carrier design where the brake carrier parts are fastened to a vehicle axle part via angled receiving grooves and webs, eliminating the need for struts and reducing machining complexity, while ensuring stability through mounting on the vehicle axle part.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If brake carriers are manufactured as one-piece castings with struts, then stability is achieved, but manufacturing precision and production cost deteriorate due to complex machining requirements
Solution Approach 1:
The brake carrier is divided into multiple separate components: a base body and individual struts. The struts are no longer integrated into the brake carrier but are separate elements that connect to the base body and vehicle axle part. This segmentation eliminates the need for complex machining of integrated struts, reducing manufacturing precision requirements while maintaining structural stability through the assembled configuration.
2Strength
If struts are machined precisely to avoid distortion, then structural integrity is improved, but production cost and manufacturing complexity increase
Solution Approach 1:
By separating the struts from the brake carrier into independent components, each part can be manufactured more simply. The base body requires less complex machining, and the struts can be produced as separate, simpler elements that are then assembled. This reduces overall manufacturing cost while maintaining structural integrity through proper connection design.
Solution Approach 2:
The vehicle axle part serves as an intermediary element that connects the brake carrier base body to the vehicle axle. The struts connect to both the base body and the vehicle axle part, distributing forces and maintaining structural integrity without requiring complex integrated machining of the brake carrier itself.
3Stability of the object's composition
If brake carrier parts are positively attached to vehicle axle part, then stability is maintained, but device complexity increases
Solution Approach 1:
The attachment mechanism is merged into the vehicle axle part itself. The vehicle axle part includes integrated connection elements (such as mounting surfaces, holes, or attachment features) that directly receive and secure the brake carrier base body and struts. This eliminates the need for separate, complex attachment mechanisms while maintaining stable positive attachment.
Data Source
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AI summary
The invention relates to a brake carrier (100) of a disc brake on a vehicle axle of a commercial vehicle, wherein the brake carrier (100) has a fixing region (114, 124) for fastening the brake carrier (100) on the vehicle axle, respective contact surfaces (113, 123) for radially supporting at least one brake lining and respective carrier lugs (112, 122) on the inlet side and outlet side, on which the at least one brake lining inserted between a carrier lug (112, 122) on the inlet and outlet side can be supported, wherein the brake carrier (100) is formed in at least two parts from a first brake carrier part (110) disposed on the inlet side and a second brake carrier (120) disposed on the outlet side, wherein the at least two brake carrier parts (110) are fastened to a vehicle axle part (130) and are connected to one another by means of the vehicle axle part (130). The invention further relates to a brake carrier and to a disc brake.