Caliper Brake Piston Friction Reduction via Ball Cage Mechanism
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Solution Overview
Problem
Conventional caliper brake systems experience reduced component lifetime and piston speed due to high friction between the caliper housing and piston, leading to increased maintenance costs and safety risks.
Innovation Solution
A caliper brake device with a friction reducing part that includes a ball interposed between the caliper housing and piston, supported by a cage and a support member, which reduces direct friction and provides an elastic restoring force to assist piston movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a piston is forcibly press-fitted into a cylinder in a caliper housing through a hydraulic pressure generation device, then the piston can be securely fastened to the caliper housing, but direct friction between the caliper housing and the piston occurs upon braking, greatly shortening the lifetime of components and reducing piston speed
Solution Approach 1:
The patent introduces a ball and cage mechanism as an intermediary between the piston and caliper housing. The ball is interposed between the inner circumferential surface of the caliper housing and the outer circumferential surface of the piston, converting direct sliding friction into rolling friction through the ball's rotation within the cage. This mediator eliminates direct metal-to-metal contact while maintaining the fastening function, thereby resolving the contradiction between secure fastening and component durability.
2Reliability
If a piston is forcibly press-fitted into a cylinder in a caliper housing through a hydraulic pressure generation device, then the piston can be securely fastened to the caliper housing, but overall friction between the cylinder and the piston in the caliper housing occurs, greatly shortening the lifetime of components
Solution Approach 1:
The ball and cage assembly serves as a friction-reducing intermediary that prevents overall friction between the cylinder and piston. The ball rotates within the cage, allowing the piston to move forward and backward with minimal resistance. This intermediary mechanism converts harmful sliding friction into beneficial rolling motion, significantly reducing energy loss while maintaining secure fastening.
3Reliability
If direct friction occurs between the caliper housing and the piston upon braking, then the piston can be fastened securely, but the speed of the piston is reduced
Solution Approach 1:
The ball and cage mechanism acts as a kinetic intermediary that enables high-speed piston movement. The ball's rotation within the cage allows the piston to accelerate and decelerate rapidly during braking operations without the drag of direct friction. This intermediary system maintains secure fastening while enabling the piston to achieve higher speeds and faster response times.
4Duration of action of moving object
If a ball is interposed between the inner circumferential surface of the caliper housing and the outer circumferential surface of the piston to reduce friction, then component lifetime is extended and piston speed is increased, but the friction reducing part may separate from the inside of the caliper housing
Solution Approach 1:
The friction-reducing mechanism is segmented into distinct functional components: the ball for friction reduction, the cage for ball containment, and the support member for structural anchoring. This segmentation allows each component to perform its specific function while working together as an integrated system. The support member anchors the cage to the caliper housing, preventing separation while allowing the ball to rotate freely for friction reduction.
Solution Approach 2:
The support member is pre-installed within the caliper housing to provide preliminary anchoring before the ball and cage assembly is installed. This preliminary action ensures that the friction-reducing part is properly positioned and secured, preventing separation during operation. The support member's elastic body is pre-compressed or pre-positioned to maintain structural integrity throughout the device's operational life.
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 effectively extends the lifetime of components, increases piston speed, and reduces maintenance costs by minimizing overall friction and enhancing piston movement efficiency during braking.
Implementation Method 1
a ball interposed between the inner circumferential surface of the caliper housing and the outer circumferential surface of the piston
Implementation Method 2
The support member may be formed as an elastic body to provide a restoring force to the piston
Data Source
AI summary
Disclosed herein is a caliper brake. The disclosed caliper brake includes a carrier in which a pair of pad plates are installed to move forward to and backward from a disc, a caliper housing slidably installed on the carrier and provided with a cylinder, a piston installed in the cylinder and provided to move forward to and backward from the pad plate by brake hydraulic pressure, and a friction reducing part provided between an inner circumferential surface of the caliper housing and an outer circumferential surface of the piston, wherein the friction reducing part includes a ball interposed between the inner circumferential surface of the housing and the outer circumferential surface of the piston and a cage configured to accommodate the ball.