Disk Brake Gap Adjustment Mechanism for Fixed Calipers
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Solution Overview
Problem
Existing disk brake devices with adjustable mechanisms can over-adjust gaps, leading to excessive wear and heat generation due to friction, and are challenging to implement in fixed caliper types, which complicates size and weight reduction.
Innovation Solution
A gap adjustment mechanism that includes tappet driving means, transmission members, and clutch members to adjust gaps between friction pads and a disk rotor at predetermined surface pressures, allowing for one-way rotation and preventing excessive adjustment, suitable for both floating and fixed caliper types.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a floating caliper type is used with clearance for sliding, then the caliper can move freely to apply brake force, but the caliper rattles during vehicle travel and requires additional space and vibration suppression structures
Solution Approach 1:
The invention transitions from a static fixed caliper to a dynamic system where the caliper can slide during brake application but is constrained during normal operation. The guide rod mechanism enables controlled movement only when brake force is applied, eliminating rattling while maintaining brake functionality.
2Weight of stationary object
If a fixed caliper is employed to eliminate rattling, then the overall size and weight are reduced, but it becomes difficult to provide drive sources for moving both friction pads to the disk rotor side
Solution Approach 1:
The invention divides the brake system into two independent adjustment mechanisms: one for the inner friction pad and one for the outer friction pad. Each mechanism has its own tappet member and adjustment structure, allowing independent gap adjustment without requiring complex coordinated drive sources.
Solution Approach 2:
Instead of moving both friction pads toward the disk rotor from opposite sides (which would require complex dual drive sources), the invention allows the disk rotor to slide axially when pushed by the inner pad, and uses this motion to indirectly adjust the outer pad position through the guide rod mechanism.
3Manufacturing precision
If the adjustment mechanism operates until the gap is completely disappeared, then the friction pads are pushed to maximum contact, but this leads to excessive wear and extra heat development
Solution Approach 1:
The invention incorporates feedback through the guide rod mechanism that senses when the disk rotor contacts the outer friction pad. This feedback signal stops the adjustment process, preventing over-adjustment. The system automatically halts when optimal contact is achieved, avoiding excessive wear and heat generation.
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
The mechanism automatically adjusts gaps to maintain optimal contact, preventing excessive wear and heat, and can be applied to fixed caliper types, reducing device size and weight while maintaining reliability in high-temperature and high-vibration environments without the need for electric control systems.
Implementation Method 1
a tappet member which is free to rotate in only one rotation direction (33), and a piston member (34) screwed to the tappet member (33)
Implementation Method 2
a brake is applied to rotation of the disk rotor by a resulting frictional force generated between the friction pads and the disk rotor
Data Source
Figure 1
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AI summary
A gap adjustment mechanism (40) for a disk brake device (1) according to the present invention adjusts a gap between an inner pad (11) and a disk rotor (10) due to wear on the inner pad (11), by displacing an inner piston (34) to the disk rotor (10) side relative to an inner tappet (33) until the inner pad (11) is brought into contact with the disk rotor (10) at a predetermined surface pressure after being displaced to the disk rotor (10) side by an amount corresponding to a first gap, and adjusts a gap between an outer pad (12) and the disk rotor (10) due to wear on the outer pad (12), by displacing an outer piston (77) to the disk rotor (10) side relative to an outer tappet (76) until the disk rotor (10) is brought into contact with the outer pad (12) at a predetermined surface pressure after being displaced to the outer pad (12) side by an amount corresponding to a second gap.