Brake Piston Conical Contact and Stepped End Wall
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Solution Overview
Problem
Existing brake pistons for vehicle disc brakes face challenges in secure positioning and efficient load transfer, particularly when transitioning between hydraulic and electric actuation modes, which can lead to inconsistent braking performance and installation issues.
Innovation Solution
A brake piston design featuring a first and second tubular piston body portion connected by an annular end wall, with a conical surface contact for improved load transfer and a radially inwardly directed floor region to prevent spindle flange contact, allowing for secure positioning and even force distribution across the piston body portions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional brake piston design is used, then the structure is simple, but the positioning is insecure and load transfer is inefficient
Solution Approach 1:
The brake piston is divided into a first piston body portion and a second piston body portion, which are connected via an annular end wall. This segmentation allows the piston to achieve secure positioning and efficient load transfer while maintaining a manageable structural complexity through modular design.
2Reliability
If the brake piston is designed without a radially inwardly directed floor region, then the structure is simpler, but spindle flange contact cannot be prevented
Solution Approach 1:
The radially inwardly directed floor region is designed in advance to prevent harmful contact between the spindle flange and the brake piston. This preliminary anti-action ensures that the harmful contact is prevented before it can occur, guaranteeing consistent braking performance across all actuation modes.
3Strength
If a flat contact surface is used between piston body portions, then manufacturing is easier, but load transfer and centring are insufficient
Solution Approach 1:
The contact surface between the first and second piston body portions is designed with a conical geometry rather than a flat surface. This curvature provides superior load transfer and centring capabilities, while the conical shape can still be manufactured using standard machining processes.
4Reliability
If the end wall is flat without axial steps, then manufacturing is simpler, but spindle flange contact cannot be prevented in all positions
Solution Approach 1:
The axially stepped end wall is designed in advance to create a predetermined distance between the end wall and components of the brake piston drive. This preliminary positioning action ensures that spindle flange contact is prevented in all possible positions of the brake piston, guaranteeing successful installation and bleeding.
Data Source
AI summary
A bake piston, which is arranged on a brake caliper of a disc brake of a vehicle, has a first and a second tubular piston body portion which are connected together at a first axial end of the brake piston via an annular end wall. The second piston body portion forms a receptacle in which a spindle nut of a spindle drive is accommodated so as to be axially displaceable and not rotatable relative to the brake piston, and receives a drive spindle. The first piston body portion has a radially inwardly directed floor region. The end wall is axially stepped towards the outside and has a radially outer portion and a radially inner portion which each have an end face pointing axially away from the brake piston, wherein the end face of the radially inner portion is axially offset relative to the end face of the radially outer portion in the direction towards the second axial end of the brake piston.