Disc Brake Coupling Ring With Integrated Bearing and One-Way Clutch
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Solution Overview
Problem
The existing adjustment devices for vehicle disc brakes are complex, costly, and require many components, which complicates assembly and increases the risk of tilting, affecting precision and reliability.
Innovation Solution
A simplified clutch ring design with a steel ring slidably supported against a cylindrical bearing section, featuring a rotary coupling with non-rotatable coupling parts and a wave spring for axial movement, along with a one-way clutch mechanism using teeth with alternating flanks for precise adjustment and protection against unintended reset.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional adjusting device with multiple components is used, then the adjustment function is achieved, but the device complexity and assembly difficulty increase
Solution Approach 1:
The patent combines the cardan pivot bearing and coupling ring into a single integrated component. The coupling ring is formed as one piece with the cardan pivot bearing, eliminating the need for separate assembly of these two components. This merging reduces the total number of parts while maintaining the adjustment precision and reliability through the integrated design that ensures proper alignment and functional coordination between the bearing and coupling elements.
2Adaptability or versatility
If multiple separate components are used in the adjusting device, then the functions are distributed, but the assembly process becomes more complex and time-consuming
Solution Approach 1:
The integration of the cardan pivot bearing and coupling ring into a single component directly addresses the assembly complexity issue. By combining these functions into one molded part, the assembly process is simplified - fewer parts mean fewer assembly steps, less fastening work, and reduced assembly time. The functional distribution is maintained within the integrated component itself, where different sections of the coupling ring perform different functions (cardan pivot support, coupling teeth, axial movement guidance).
Solution Approach 2:
The coupling ring is designed as a multi-functional component that simultaneously serves as the cardan pivot bearing housing, the coupling element with toothing for axial movement control, and the support structure for the adjusting device. This multi-functionality reduces the need for separate specialized components while maintaining all necessary adjustment functions.
3Ease of manufacture
If a simple coupling ring design is used, then the manufacturing cost is reduced, but the friction and wear resistance may be compromised
Solution Approach 1:
The coupling ring is manufactured from a composite material consisting of a sintered metal powder mixture, primarily iron with additional components like copper, nickel, and binding agents. This composite structure provides both cost-effectiveness through a relatively simple sintering process and superior wear resistance through the heterogeneous material composition that combines the advantages of different metals and ceramics in a single engineered material system.
4Device complexity
If the steel ring is directly supported against the shaft, then the structure is simplified, but the friction and wear increase
Solution Approach 1:
The coupling ring acts as an intermediary element between the cardan pivot bearing and the shaft. Instead of direct contact between the steel ring and shaft, the coupling ring is positioned between them, providing a controlled interface that reduces friction through its specific geometric design and material properties. The coupling ring's cylindrical inner contour and sliding bearing surface create an optimized contact interface that minimizes wear while maintaining structural simplicity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design reduces component count, enhances precision and reliability by providing a cost-effective, low-friction, and wear-resistant adjustment mechanism that simplifies assembly and ensures accurate brake pad alignment while preventing accidental resets.
Implementation Method 1
An axially acting spring element can be arranged between the clutch ring and the cardan pivot bearing. A wave spring is particularly suitable as a spring element here.
Implementation Method 2
The inner surfaces of the arms together form a cylindrical inner contour, with which the arms are supported over a flat area on the cylindrical bearing section of the shaft, resulting in a relatively large sliding bearing surface and thus particularly low-friction and wear-resistant sliding of the surfaces involved.
Data Source
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AI summary
A coupling ring (52) for an adjusting device for a vehicle disc brake is proposed. The adjusting device compensates for operational wear on the brake pads and brake disc. The coupling ring (52) has an annular opening, an end-face annular surface (62), and at least one further annular surface (74) provided with coupling structures in the form of ramps (71) evenly distributed around its circumference. The further annular surface (74) is conically shaped with respect to the axis (A) of the ring. The annular opening has alternating first circumferential sections (56) projecting radially towards the axis (A) and second circumferential sections (57) projecting inwards, respectively.