Disc Brake Return Spring Edge Cover for Safer Maintenance
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The maintainability of disc brakes is compromised due to fingers getting caught on the edge portions of return springs during maintenance, especially with the reduction in size of disc brakes leading to increased exposure of these edges.
Innovation Solution
The return spring design includes a fixing part, first and second extension parts, a contact part, and cover parts that cover at least a portion of the edge surfaces, preventing finger contact and improving maintainability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the disc brake size is reduced, then the compactness and space utilization are improved, but the edge portions of the return spring become more exposed and increase the risk of fingers getting caught
Solution Approach 1:
A cover part is introduced as an intermediary element between the hazardous edge portions and the operator's fingers. The cover part extends from the return spring body to cover the edge portions, physically blocking finger access while allowing the return spring to maintain its compact, reduced-size configuration. This mediator resolves the contradiction by adding a protective interface without increasing the overall brake assembly size.
Solution Approach 2:
The cover part is constructed as a thin, flexible plate-shaped component that drapes over and covers the edge portions of the return spring. This thin-film approach provides effective finger protection without adding significant volume or weight, allowing the disc brake to maintain its reduced size while eliminating the harmful exposed edges.
2Ease of operation
If cover parts are added to cover the edge portions, then the maintainability and safety are improved, but the device complexity increases
Solution Approach 1:
The cover part is integrally formed with the return spring as a single unified component rather than a separate assembly. The return spring and cover part are manufactured together from a single plate material through integral forming, eliminating the need for separate manufacturing and assembly processes. This merging approach improves maintainability by simplifying the overall structure while avoiding the complexity of additional parts and assembly steps.
Solution Approach 2:
The integrated return spring with cover part serves multiple functions simultaneously: it provides the necessary elastic return force, defines the structural geometry, and covers the hazardous edge portions. This multi-functionality eliminates the need for a dedicated separate cover component, reducing device complexity while maintaining improved safety and maintainability.
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 enhances maintainability by reducing the risk of fingers getting caught on the return spring edges, while maintaining the spring's performance and manufacturing efficiency.
Implementation Method 1
a return spring which is integrally formed by punching out a steel plate having spring properties and then bending it
Data Source
AI summary
A return spring includes a fixing part (100) configured to be fixed to a friction pad (8), a first extension part (101) formed in a plate shape and extending from the fixing part (100) in a direction away from the friction pad (8), a second extension part (102) formed in a plate shape and extending from the first extension part (101) in a direction of pressing the friction pad (8), a contact part (103) formed in a plate shape and extending from the second extension part (102) to come into contact with a carrier (5) attached to a non-rotating portion of a vehicle, edge portions which are surfaces each extending in a plate thickness direction of the first extension part (101), the second extension part (102), and the contact part (103), and a cover part (104, 105) covering at least a part of the edge portions.