Disc Brake Carrier Structure for Lower Weight and Rigidity
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Solution Overview
Problem
Existing brake carriers for disc brakes have a high weight due to strength requirements and constrained construction space, which limits further optimization for weight reduction and cost efficiency, particularly in commercial vehicle applications.
Innovation Solution
The brake carrier design features a disc-encompassing portion with a triangular configuration on its radial outer side, reducing material usage while maintaining sufficient rigidity. This design includes widened frame portions, reinforcement ribs, and strategically placed apertures to optimize weight reduction and stress distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the brake carrier is designed with sufficient material and conventional geometry to meet strength requirements, then the structural integrity is ensured, but the weight increases
Solution Approach 1:
The brake carrier is divided into functionally optimized segments: bridge struts for primary load bearing, frame portions for structural support, and reinforcement ribs for localized strengthening. This segmentation allows material to be concentrated where needed and reduced where less critical, resolving the contradiction between strength and weight.
Solution Approach 2:
Different regions of the brake carrier are given different material distributions and geometric characteristics tailored to their specific functional requirements. The reinforcement ribs provide localized strengthening at critical stress points, while other areas use optimized triangular geometries to minimize weight. This local differentiation allows the structure to meet strength requirements without excessive overall weight.
2Volume of moving object
If the construction space is constrained to fit vehicle specifications, then the compactness is achieved, but the weight optimization potential is limited
Solution Approach 1:
The frame portions are extended in the axial direction (perpendicular to the disc plane) to create a three-dimensional triangular configuration. This dimensional approach allows the structure to achieve both compactness in the radial direction (fitting constrained space) and weight optimization through the spatial efficiency of the triangular geometry in the axial dimension.
3Stability of the object's composition
If reinforcement ribs are added to increase structural strength, then the rigidity is improved, but the weight increases
Solution Approach 1:
Reinforcement ribs are strategically positioned only at critical stress concentration points and load transfer paths within the brake carrier structure. This localized reinforcement approach provides necessary rigidity and structural stability while minimizing the additional material required, thus limiting weight increase to only what is absolutely necessary for structural performance.
Data Source
AI summary
A one-piece brake carrier for a vehicle disc brake is provided. The brake carrier has a frame-like disc wrap-around element which has two mutually parallel bridge struts, and two frame sections arranged parallel to a brake disc rotation axis and connecting the bridge struts. The brake carrier further has a securing flange by which the brake carrier is fixable to an axle flange. One or both of the frame sections, starting from a side of the brake carrier away from the securing flange widens toward an outer edge of the securing flange.