Self-Energizing Disc Brake Pad Wear-Resistant Ramp Insert
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Solution Overview
Problem
Self-energizing disc brakes face challenges in maintaining functional reliability and extending service life due to wear and corrosion issues in their components, particularly in the spread bearing mechanism.
Innovation Solution
Integrating the holder for at least one brake plunger directly into the brake pad, with ramps designed as a separate insert or a one-piece wear-resistant and corrosion-resistant lining pressure plate, ensuring cost-effectiveness and space efficiency, and preventing reuse of components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the holder for brake plunger is integrated directly into the brake pad, then the device complexity is reduced and manufacturing cost is decreased, but the reliability of the spread bearing mechanism may be compromised due to increased wear and corrosion exposure
Solution Approach 1:
The brake pad is segmented into distinct functional components: a holder for the brake plunger, a friction lining, and a separate spread bearing mechanism. This segmentation allows each component to be optimized independently - the holder can be designed for structural integrity while the spread bearing can be designed for wear resistance, resolving the contradiction between simplified integration and maintained reliability.
Solution Approach 2:
The brake pad employs composite material construction with the friction lining made from wear-resistant composite materials bonded to the holder. This composite structure enables the different regions of the brake pad to have tailored properties - the holder provides structural support while the composite lining provides wear resistance and corrosion protection, maintaining reliability despite direct integration.
2Duration of action of stationary object
If the ramps are designed as a separate insert connected to the lining pressure plate, then the wear resistance and corrosion resistance are improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The ramps are pre-formed as a separate insert with precise geometric contours before assembly. This preliminary preparation allows for optimized wear-resistant surfaces to be created independently through specialized manufacturing processes, then the insert is integrated into the brake pad assembly. This approach ensures high service life through pre-engineered wear resistance while managing complexity through modular pre-fabrication.
Solution Approach 2:
The separate insert design allows the ramps to be manufactured as a dedicated wear component that can be replaced independently when worn. This approach uses simpler, more cost-effective materials and manufacturing methods for the insert itself, while the overall brake pad assembly maintains high service life through the replaceable nature of the wear-prone ramp component.
3Ease of manufacture
If the ramps are designed as a one-piece lining pressure plate, then the manufacturing cost and space requirements are reduced, but the wear resistance and corrosion resistance may be compromised
Solution Approach 1:
The one-piece lining pressure plate design utilizes parameter optimization in material selection and heat treatment processes to achieve adequate wear and corrosion resistance without the separate insert. By adjusting material composition parameters and applying surface treatment parameters during manufacturing, the single integrated component achieves sufficient service life while maintaining manufacturing simplicity and cost-effectiveness.
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
Enhances the functional reliability and service life of self-energizing disc brakes by addressing wear and corrosion concerns, while maintaining a compact and cost-effective design.
Implementation Method 1
a bearing ball, which on the one hand rests in a depression provided with ramps that rise from the inside to the outside in the circumferential direction of the brake disc and on the other hand is held in a dome-shaped receptacle of a pressure plate of the brake lining. When braking, i.e. when the brake pad is pressed against the brake disc by means of the clamping device, the brake pad moves in the direction of rotation due to the frictional forces when it is pressed against the brake disc, with the associated ramp simultaneously moving along the bearing ball, increasing the force exerted on the brake disc acting axially aligned braking force.
Implementation Method 2
when the brake pad is pressed against the brake disc by means of the clamping device, the brake pad moves in the direction of rotation due to the frictional forces when it is pressed against the brake disc
Implementation Method 3
When the brake is released, the brake lining is brought into an initial position by means of a return spring
Data Source
Figure 1
AI summary
The brake has an actuating device with a self-servo device and a brake plunger (6) connected to a pad press plate (3) and actuatable by a brake lever (5). An adjuster device compensates pad and/or disk wear. The self-servo device has a pressure pin (4) contacting a front side with an active-sided pad (2) by a split bearing (10) and fixed to a guide plate (9) movably held in a brake carrier (8). The bearing is enclosed by a seal arrangement, when the self-servo device is not working. The bearing has a bearing ball (12) made from hardenable chromium/nickel steel, tungsten carbide or ceramic.