Brake Friction Lining Assembly With Wear-Adaptive Restoring Spring
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Solution Overview
Problem
Existing friction lining assemblies with sheet-metal restoring springs fail to maintain a constant release clearance as the friction material and brake disk wear, leading to increased brake pedal travel and residual braking torques, and are complex to produce and assemble.
Innovation Solution
A friction lining assembly with a restoring spring that features a hammer-head-shaped claw and a spring arm capable of controlled plastic deformation under wear, ensuring a consistently dimensioned release clearance by engaging in a defined position and adapting to wear through deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a sheet-metal restoring spring is fixed on the friction lining assembly to adjust release clearance, then residual braking torques are avoided, but the release clearance increases with wear leading to extended pedal travel
Solution Approach 1:
The spring arm is designed to be movable relative to the spring body, allowing it to shift position automatically in response to wear. The spring arm can move along the spring body between a first position (when new) and a second position (when worn), dynamically adjusting the release clearance to maintain it within a target range throughout the service life of the friction lining assembly
Solution Approach 2:
The invention changes the geometric parameters of the spring arm position relative to the spring body based on wear. By allowing the spring arm to move to different positions along the spring body, the effective length and leverage of the spring arm changes, which compensates for wear and maintains constant release clearance
2Reliability
If the spring arm makes contact in the same way throughout wear, then residual braking torques are avoided, but the release clearance increases with wear
Solution Approach 1:
The spring arm is designed to dynamically change its contact position along the spring body as wear progresses. This dynamic adjustment allows the system to maintain precise release clearance dimensioning throughout the service life, compensating for wear automatically without requiring complex manufacturing tolerances
3Ease of manufacture
If a separate lining guide element is used to clamp the restoring spring, then protection from stone impact and avoidance of expensive machining is achieved, but the release clearance cannot be kept constant with wear
Solution Approach 1:
The spring arm's ability to move dynamically along the spring body provides the necessary adjustment mechanism for maintaining constant release clearance, eliminating the need for complex positioning mechanisms in the brake holder while preserving the manufacturing advantages of using a separate lining guide element
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 solution maintains a constant release clearance, reducing brake pedal travel and avoiding residual braking torques while simplifying production and assembly, and is robust against contamination and corrosion.
Implementation Method 1
the restoring spring is supported elastically, with an axial spring action, by means of a spring leg on the brake holder
Implementation Method 2
the spring arm of which extends over a hammer-head-shaped claw and is capable of controlled plastic deformation under brake actuation owing to frictional wear of the friction material and/or the brake disk
Data Source
AI summary
A friction lining assembly having a backing plate and a sheet metal restoring spring fixed thereto, for a partially lined sliding-caliper type disk brake having a brake holder fixed with respect to the vehicle, on which friction lining assemblies arranged on both sides of a brake disk are slidably guided. A housing, which extends over the brake disk and the friction lining assemblies, is slidably mounted on the brake holder. The restoring spring is clamped axially between the brake holder and the friction lining assembly by at least one spring leg and applies a release clearance to the friction lining assembly. The spring leg extends over a hammer-head-shaped claw of the backing plate. The spring leg is plastically deformable in a defined manner under braking actuation as a result of a reduction in the friction-material thickness in order to impose a constantly dimensioned release clearance on the friction lining assembly.