Brake Rotary Lever Segmented Insert Design
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Solution Overview
Problem
Existing rotary brake levers for disc brakes in motor vehicles face challenges in adapting to various drive tasks and torque requirements, as they often require a solid design to transmit high drive torques, limiting their versatility and ease of assembly.
Innovation Solution
A rotary brake lever design featuring a driven section with a non-rotatably connected insert element that can be easily adapted by inserting and fastening different output elements, such as gear wheel segments or pins, made from materials like plastic or high-strength metals, allowing for axial or radial drives and enabling the transmission of both small and high torques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a solid design is used to transmit high drive torques, then reliability is improved, but adaptability deteriorates
Solution Approach 1:
The rotary brake lever is divided into a base body and separate insert elements that can be independently selected and combined. The insert elements (such as gear wheel segments or pins) can be removed and replaced depending on the specific drive task, while the main body remains constant. This segmentation allows the lever to maintain structural integrity for reliability while adapting to different applications through element replacement.
Solution Approach 2:
The rotary brake lever base body is designed as a universal component that can accommodate multiple types of output elements (gear wheel segments, pins, etc.) through standardized receptacles. This universal design enables a single base body to serve multiple functions and drive different mechanisms (wear adjusters, sensors, etc.) by simply changing the insert elements, thereby achieving both reliability through a proven base design and adaptability through element interchangeability.
2Strength
If a solid design is used to transmit high drive torques, then strength is improved, but ease of manufacture deteriorates
Solution Approach 1:
The rotary brake lever is segmented into a base body and separate insert elements. The base body can be manufactured using standard processes with consistent geometry, while the insert elements can be produced using appropriate methods for their specific materials (plastic injection molding, sintering, or metal machining). This segmentation allows each component to be optimized for its manufacturing process, improving overall ease of manufacture while maintaining the strength required for high torque transmission through the robust base body design.
Solution Approach 2:
The rotary brake lever employs composite construction by combining a base body (typically metal) with insert elements made from different materials such as plastic, sintered material, or high-strength metal. This composite approach allows each material to be selected for its optimal properties: the base body provides structural strength, while the insert elements can be made from materials that are easier to manufacture or better suited for specific functions (e.g., plastic for low-friction applications, sintered material for porous filtration). The combination achieves both high strength and ease of manufacture.
Data Source
Figure 1
Figure 2
AI summary
A brake rotary lever (2) of a disc brake (1) has an output section (14, 17), which is attached to at least one axial end face of the brake rotary lever (2) and has in each case one output element (15, 18). The at least one output section (14, 17) is non-rotatably connected to the brake rotary lever (2). At least one output element (15, 18) of one of the output sections (14, 17) is configured as an inlay part. A disc brake (1) is equipped with the brake rotary lever (2).