Disk Brake Shell Assembly Locking Against Groove Migration
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Solution Overview
Problem
Existing disc brake shell assemblies are prone to migrating out of their grooves due to high pressure forces during braking, leading to structural integrity issues and potential damage from deformation under continuous load.
Innovation Solution
A shell assembly design featuring a through-hole with a collar and a shaped element, where the shaped element is pressed into the through-hole to reinforce the collar, ensuring a positive lock within the groove, and a support roller is used to reduce manufacturing complexity and enhance stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If tabs are used for positive locking of the shell assembly to the groove, then the shell assembly is secured against migration, but the tabs deform under continuous load leading to weakening of the locking mechanism
Solution Approach 1:
The locking function is segmented into two independent components: the collar providing initial positive locking through its interference fit with the bore, and the shaped element providing reinforcement and load distribution. This segmentation allows each component to be optimized for its specific function, preventing the single-point failure that occurred with the tab design.
Solution Approach 2:
The shaped element acts as an intermediary component pressed into the through-hole to reinforce the collar structure. It mediates between the collar and the bore, distributing loads and preventing deformation of the collar under continuous braking forces, thereby maintaining reliable locking without the deformation issues of tabs.
2Stability of the object's composition
If a support roller is added to the shell assembly, then stability and load distribution are improved, but device complexity increases
Solution Approach 1:
The support roller is integrated with the shell assembly such that it forms a unified structural unit. The roller is positioned within the shell's groove structure, merging the support function into the existing shell geometry rather than adding a completely separate mounting system, thereby limiting the increase in device complexity.
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 design improves the long-term locking of the shell assembly, preventing it from moving out of position, reduces manufacturing effort, and enhances structural integrity and longevity by minimizing material wear and deformation.
Implementation Method 1
a shaped element is pressed into the through-hole after the shell has been inserted into the groove and the collar has been locked in the bore. The shaped element slightly expands the collar and thus fixes the device in the bore, with the shaped element additionally supporting the collar against shear forces.
Data Source
Figure 1~2
Figure 3
AI summary
Described is a disk brake having a brake calliper and a brake application device arranged therein for the application of force to the brake linings of the disk brakes, wherein part of the brake application device is a brake lever which can be actuated by a force element and preferably a pressure cylinder, said brake lever being comprised of a lever arm, against which the force element bears, and a brake application shaft. The latter bears against a pressure piece acting towards the brake linings on one side and against a channel (6) located inside the brake calliper on the other with the interposition of a shell (5), the curvature of the shell (5) being complementary to the curvature of the channel (6). To develop the disk brake and the shell assembly using design measures so as to prevent the shell assembly from moving out of its original position, even after long-term use and frequent stress as a result of braking processes, there is an opening of a bore hole (7) in the channel (6). On the shell (5), facing the channel (6), a projection (8) is formed by the deformation of the shell material, which projection extends in the form of a flange into the bore hole (7) and creates an interlocking connection between the shell (5) and the channel (6). In the projection (8), a shaped element (9) is arranged the outer diameter of which is the same as or almost the same as the inner diameter of the projection (8).