Disk Brake Plunger Assembly for Tool-Free Thrust Piece Replacement
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Solution Overview
Problem
The existing disc brake systems in commercial vehicles face challenges in easily replacing the pressure piece without the use of special tools, due to its difficult access and the risk of damaging components during the process.
Innovation Solution
A brake stamp design with a set spindle, a pressure piece, and a slide sleeve that allows for easy assembly and disassembly of the pressure piece, enabling manual operation without tools, and incorporating features like a groove for axial fixation and feather arms for snap protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If the pressure piece is rigidly secured to the adjusting spindle using traditional methods (caulking or shoulder), then axial securing is achieved, but replacement requires special tools and risks component damage
Solution Approach 1:
The pressure piece is divided into multiple parts: a pressure piece body and a separate retaining ring. The retaining ring can be independently removed to release the pressure piece from the adjusting spindle, enabling tool-free replacement without complex securing mechanisms.
Solution Approach 2:
The retaining ring is extracted as a separate removable component from the pressure piece assembly. This allows the retaining ring to be taken out for maintenance or replacement independently, facilitating easy access and replacement of the pressure piece without special tools.
2Adaptability or versatility
If the sealing element is made extremely elastic to accommodate rotational movement, then rotational freedom is achieved, but the sealing element becomes a wear part requiring replacement
Solution Approach 1:
The sealing element is designed with dynamic characteristics, being extremely elastic to accommodate the rotational movement of the threaded tube relative to the brake caliper. This elasticity allows the sealing element to flex and maintain sealing during the wear path traversal, though it does become a wear part requiring periodic replacement.
3Device complexity
If the groove for axial fixation is positioned far from the end face of the threaded tube, then axial securing is achieved, but the overall length of the threaded tube unit increases
Solution Approach 1:
The groove is positioned in a different spatial dimension - close to the end face of the threaded tube rather than far from it. This dimensional repositioning allows axial fixation to be achieved while minimizing the overall length of the threaded tube unit, as the groove utilizes the end face area efficiently.
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
A brake plunger (1) of a disk brake of a utility vehicle has an actuating spindle (6), with a threaded tube (61) and with an actuating spindle head (62) which projects out of an end surface (66) of the threaded tube (61), and has a thrust piece (7), which is seated on the actuating spindle head (62) so as to be secured axially in relation to a longitudinal axis of the actuating spindle (6) and which has a receiving opening (72) for receiving the actuating spindle head (62), wherein a sliding sleeve (9) is arranged between the thrust piece (7) and the actuating spindle head (62), wherein the sliding sleeve (9) or the thrust piece (7) is secured axially in a groove (64, 68) of the actuating spindle (6). Also described is a disk brake of a utility vehicle having at least one such brake plunger (1).