Disk Brake Shell Assembly Locking Against Collar Deformation
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Solution Overview
Problem
Existing disk brake systems face issues with shell assemblies moving out of their original position due to deformation under constant load, leading to a decrease in locking action and potential failure during frequent braking.
Innovation Solution
A disk brake system with a shell assembly that features a passage formed by deforming the shell material, creating a collar that fits into a bore, and a shaped element inserted into the passage to reinforce the collar and prevent deformation, ensuring a secure locking mechanism.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If tabs are used for positive locking of the shell assembly in the channel, then the shell assembly is initially secured against movement, but the tabs deform under constant load during frequent braking, causing the locking action to decrease and the shell assembly to move out of position
Solution Approach 1:
The locking mechanism is segmented into multiple functional elements: the collar structure divided into first and second portions, the shaped element as a separate reinforcement component, and the bore as a distinct anchoring feature. This segmentation allows each element to perform its specific function optimally while distributing mechanical stresses across multiple points rather than concentrating them in single tabs.
Solution Approach 2:
The locking mechanism combines different structural features (collar, bore, shaped element) that work together as a composite system. The collar provides initial positioning, the bore provides anchoring, and the shaped element provides reinforcement - creating a composite locking system that overcomes the limitations of simple tab-based locking.
2Device complexity
If the shell assembly is designed with simple tab-based positive locking, then the device complexity is low and manufacturing is easy, but the locking mechanism fails under constant load from frequent braking operations
Solution Approach 1:
The collar structure is pre-formed on the shell assembly before installation, creating a ready-to-lock feature that engages with the bore. The shaped element is also pre-formed or pre-positioned to provide immediate reinforcement. This preliminary preparation ensures that the locking mechanism is robust from the start without requiring complex assembly procedures or additional fastening operations.
Solution Approach 2:
The locking mechanism transitions from a two-dimensional tab surface contact to a three-dimensional engagement involving the collar extending into the bore. This dimensional change from surface contact to volumetric engagement significantly increases the locking reliability while maintaining reasonable structural complexity.
3Reliability
If the shell material is deformed to create a passage in the form of a collar, then the collar establishes a positive fit with the bore for locking, but the constant load causes the collar to deform and become loose
Solution Approach 1:
The shaped element is specifically designed to counteract the deforming forces that the collar would experience under constant load. By positioning the shaped element within the collar, it provides preliminary anti-action against the loosening forces, preventing the collar from deforming and becoming loose during frequent braking operations.
4Reliability
If a shaped element is added to reinforce the collar and prevent deformation, then the locking mechanism becomes more reliable under constant load, but the device complexity increases
Solution Approach 1:
The shaped element is integrated with the collar structure, merging the reinforcement function into the existing locking mechanism rather than adding a completely separate component. This merging approach enhances reliability while minimizing the increase in device complexity by combining multiple functions into a unified structural element.
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
The solution provides a long-term improved locking mechanism for the shell assembly, preventing it from moving out of its original position even under constant load, thus enhancing the structural integrity and longevity of the disk brake system.
Implementation Method 1
a shaped element is pressed into the passage once the shell has been inserted into the channel and the collar has been locked inside the bore. The shaped element slightly expands the collar to fix the device in the bore, wherein the shaped element additionally supports the collar with respect to shear forces.
Implementation Method 2
a passage is produced by deformation of the shell material and extends in the form of a collar into the bore and establishes a positive fit between the shell and the channel
Data Source
AI summary
Disk brake including a brake caliper and an application device arranged therein for applying force to the brake pads of the disk brake, wherein a component of the application device is a brake lever which can be actuated by a force element and preferably by a pressure cylinder and is composed of a lever arm against which the force element is supported and an application shaft. The application shaft is supported, on one side, against a pressure piece operating in the direction of the brake pads and, on the other side, with the interposition of a shell, against a channel arranged on the inside of the brake caliper, wherein the curvature of the shell is complementary to the curvature of the channel. In order to develop the disk brake and the shell assembly by constructive measures so as to prevent the shell assembly from moving out of the original position even in the case of long-term use and under frequent load caused by braking, an opening of a bore is located in the channel.