Brake Pad Mounting Grooves for Rotation Control
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Solution Overview
Problem
Conventional air-operated disc brakes in commercial vehicles require labor-intensive and costly brake pad replacement processes, with brake pads prone to rotation and vibration, leading to increased wear and reduced caliper fatigue life due to space constraints and the need for tall mount horns to prevent rotation.
Innovation Solution
A brake pad mounting and retention arrangement featuring narrow vertical grooves and lateral grooves in the caliper mount horns allows for easy installation and removal of brake pads without caliper disassembly, with the grooves limiting pad rotation and vibration, enabling a thicker caliper design for increased strength and fatigue life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional brake pad retention mechanisms are used, then brake pads are retained during operation, but brake pad replacement requires labor-intensive disassembly and removal of the brake caliper
Solution Approach 1:
The brake pad is segmented from the retention mechanism through the lateral projections that engage with grooves in the mount horns. This allows the brake pad to be independently removed by pulling it laterally outward without disturbing the caliper mounting structure, enabling quick replacement while maintaining a simple integrated retention system
Solution Approach 2:
The retention function is extracted from the caliper assembly and embedded directly into the mount horns through grooves. This allows the brake pad to be removed by simply pulling it laterally outward from the mount horns without requiring disassembly of the caliper or removal of the caliper from the vehicle, significantly reducing replacement time and labor
2Stability of the object's composition
If tall mount horns are used to prevent brake pad rotation, then pad rotation is reduced, but caliper thickness is reduced and fatigue life is reduced
Solution Approach 1:
The solution moves from controlling pad rotation vertically (through tall mount horns) to controlling it laterally (through grooves in the mount horns that receive lateral projections). By changing the dimension of control from radial height to lateral engagement, the caliper can be thinner while still preventing rotation, as the grooves constrain the pad's lateral movement that would lead to rotation
Solution Approach 2:
The grooves are strategically positioned in specific locations on the mount horns to provide rotation prevention only where needed, rather than requiring the entire mount horn structure to be tall. This localized engagement allows the caliper to be thinner in non-critical areas while maintaining adequate strength in high-stress regions
3Area of stationary object
If space constraints are accommodated with limited radial clearance, then brake pads can be installed, but brake pads are prone to rotation and vibration during operation
Solution Approach 1:
The lateral projections and grooves create a dynamic retention system that allows the brake pad to move axially toward and away from the brake disc during normal operation, while simultaneously constraining lateral movement that would cause rotation. This dynamic design accommodates the limited radial clearance while maintaining stability through selective freedom of movement
Data Source
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Figure 4a~4c
AI summary
A system and method are provided for mounting, removing and retaining brake pads in disc brakes, such as air-operated disc brakes utilized on commercial vehicles, in a manner which does not require the use of separate brake pad retaining devices while providing positive retention of the brake pad. A preferred embodiment includes a brake caliper mount having brake pad abutment surfaces having radially-oriented and lateral grooves which permit a brake pad with corresponding projections on is lateral sides to be inserted through, an opening of the brake caliper into the radially-oriented grooves until the backing plate projections are aligned with the lateral groove, and advancing the brake actuator behind the brake pad to place the brake pad in an operating position in which the actuator prevents the brake pad from realigning with the radially-oriented grooves until the actuator is retracted to permit brake pad extraction.