Brake Lining Holding Spring Gearing for Easier Piston Insertion
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Solution Overview
Problem
The existing friction lining holding springs for motor vehicle disk brake linings require increasingly higher forces for push-in mounting, making the process ergonomically challenging and inefficient, both during manufacturing and servicing.
Innovation Solution
Incorporating an uneven brake piston insertion trajectory with integrated gearing means and a special surface treatment on the knee piece to reduce the force requirement, allowing for a constant or linearly increasing push-in force, and using a friction-reducing surface treatment to lower contact friction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a conventional friction lining holding spring with straight U-spring legs is used, then the structure is simple, but the push-in mounting force requirement increases progressively and becomes ergonomically challenging
Solution Approach 1:
The holding spring incorporates a curved insertion contour with gearing means that dynamically changes the mechanical advantage during insertion. As the spring is pushed into the brake piston, the curved trajectory transforms the linear push-in motion into a rotational movement, creating a progressive lever mechanism that reduces the required force throughout the insertion process
Solution Approach 2:
The U-spring legs are designed with a curved insertion contour instead of straight lines. This curvature creates a gearing effect where the contact point between the spring and brake piston inner wall moves along a predefined trajectory, generating a mechanical advantage that reduces the push-in force requirement by up to 35%
2Strength
If the U-spring legs are made more rigid to maintain structural integrity, then strength is improved, but the push-in mounting force requirement increases
Solution Approach 1:
The spring design incorporates a progressive lever mechanism through its curved geometry. The mechanical advantage varies dynamically during insertion, allowing the spring to maintain sufficient rigidity for structural integrity while the gearing effect reduces the instantaneous force requirement during mounting
Solution Approach 2:
The insertion contour is designed with specific curvature radii and angles that optimize the trade-off between structural strength and mounting force. The curved trajectory transforms the force application, allowing a rigid spring structure to be installed with reduced force through the mechanical advantage of the gearing means
3Productivity
If manual push-in mounting is used, then labor flexibility is maintained, but mounting time and physical effort increase
Solution Approach 1:
The curved insertion contour with gearing means creates a progressive lever mechanism that reduces the force requirement throughout the insertion process. This mechanical advantage allows both manual and automated systems to mount the spring faster and with less effort, improving productivity by up to 35%
Solution Approach 2:
The holding spring's curved geometry automatically generates the mechanical advantage during insertion without requiring external assistance or complex mounting tools. The spring itself provides the force reduction through its inherent gearing means, making the mounting process self-facilitating
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 significantly reduces the mounting force requirement by up to 35% compared to conventional designs, making the process easier and more efficient, both manually and robot-assisted, by utilizing a progressive lever mechanism and reduced friction surfaces.
Implementation Method 1
each knee piece has an integrated gearing means, which is in particular designed as an uneven brake piston insertion trajectory such that, when a brake piston is inserted, there is a predefined gearing reduction effect for the purpose of automatically influencing or modelling the necessary force requirement
Implementation Method 2
automatically adapted force reduction with a gearing effect in accordance with the physical principle of splitting the working force or extending the working travel is made available by means of the insertion trajectory
Implementation Method 3
the surface treatment can comprise a special coating of the holding spring. A particular preference is, for example, to incorporate friction-reducing constituents as an additive into an anticorrosion coating which is applied to the metal surface of the brake piston holding spring
Data Source
AI summary
A friction lining holding spring and the equipped component/assembly, specifically a motor vehicle disc brake lining, including the friction lining holding spring. The friction lining holding spring includes an offset knee piece of a U-spring leg, which branches off at an angle from a largely flat U base section, and wherein the largely flat base section has a fastening tab with a cup-shaped rim hole including a through-opening for the purpose of fixing on a backplate of the friction lining, wherein each knee piece has integrated gearing, which is in particular designed as an uneven brake piston insertion trajectory such that, when a brake piston is inserted, there is a predefined gearing reduction effect for the purpose of automatically influencing or modelling the necessary force requirement.