Brake Disc Guard Scraper for Off-Road Caliper Dirt Protection
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Solution Overview
Problem
Off-road vehicle brake devices face issues with increased weight due to metal caliper bracket modifications for dirt removal, requiring high accuracy for proper clearance, and dirt entry into the caliper remains a problem.
Innovation Solution
A brake device with a resin cover member that includes a scraper projecting towards the rim, integrated with a flange to cover the disc and caliper, reducing the need for a metal radial projection and ensuring accurate clearance without high precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a radial projection is formed at the end portion of the caliper bracket to remove dirt from the space between the rim and flange, then dirt removal function is improved, but the caliper bracket size increases causing weight increase
Solution Approach 1:
The radial projection is extracted from the metal caliper bracket and transferred to the resin cover member. This allows the dirt removal function to be maintained while preventing the metal bracket from increasing in size and weight. The resin cover member with integrated radial projection performs the scraping function without adding significant weight to the braking system.
Solution Approach 2:
The invention uses a composite structure where a resin cover member with integrated radial projection is combined with the metal caliper bracket. The resin material provides the necessary scraping function with minimal weight penalty compared to adding a metal projection to the bracket, effectively combining the benefits of both materials.
2Object-affected harmful factors
If a radial projection is formed at the end portion of the caliper bracket to ensure proper clearance, then dirt removal function is improved, but high manufacturing precision is required
Solution Approach 1:
The radial projection is extracted from the precision-critical metal caliper bracket and implemented on the resin cover member instead. This transfer allows the projection to be formed with less stringent precision requirements, as the resin cover member can accommodate larger tolerances without affecting the overall brake system performance or clearance specifications.
3Ease of operation
If the caliper is exposed without covering by the brake disc guard, then accessibility is maintained, but dirt entry into the caliper cannot be prevented
Solution Approach 1:
The flange on the resin cover member serves multiple functions: it covers the outer circumference of the disc to prevent dirt entry, and its integrated radial projection provides dirt removal capability. This multi-functional design protects the caliper area from dirt accumulation while maintaining the overall accessibility of the brake system for maintenance and operation.
Data Source
AI summary
A brake disc guard is provided inside of a rim of a front wheel and mounted on a knuckle. A caliper is located in a cutout portion formed at a front portion of the brake disc guard. The caliper is supported through a caliper bracket to the knuckle. A large-diameter portion is formed at an upper front end portion of the brake disc guard. The large-diameter portion extends so as to cover the upper side of the caliper bracket and the caliper. A scraper is formed at the front end of the large-diameter portion so as to be bent radially outwardly. The spacing a between the rim and the scraper is set to be the smallest. The dirt deposited on the rim is scraped off by the scraper, so that the dirt separated from the rim is prevented from falling onto the caliper.