Caliper Brake Adjuster Layout for Mechanical Clearance Reset
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional spring applied hydraulic release caliper brakes require hydraulic power for adjustment, are prone to corrosion and dirt exposure, and face difficulties in torque adjustment due to large thread radii and external adjuster components, making them cumbersome and costly to maintain.
Innovation Solution
A spring applied hydraulic release caliper brake design that allows for mechanical adjustment without hydraulic fluid, featuring a housing with an integrated adjuster that rotates to reset clearance between the piston and stator, protected from environmental contaminants without additional sealing plates, and utilizing a bolt for reduced torque requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If hydraulic pressure is applied for adjustment, then the brake can be adjusted to reset spring height, but hydraulic power source and fluid are required making adjustment complex
Solution Approach 1:
The patent replaces the hydraulic adjustment system with a pure mechanical adjustment mechanism. A threaded adjuster screw with a hexagonal head is used to mechanically push the piston, eliminating the need for hydraulic fluid and power source during adjustment. The adjuster screw threads into the piston and can be turned with a standard hex key to advance or retract the piston position.
Solution Approach 2:
The patent extracts the hydraulic system from the adjustment process. By removing the hydraulic fluid and power source requirements, the adjustment can be performed manually with simple mechanical components. The hydraulic chamber is sealed during normal operation but can be mechanically accessed through the adjuster screw for adjustment purposes.
2Ease of operation
If externally located adjuster components are used, then adjustment is accessible, but corrosion and dirt exposure make adjustment difficult
Solution Approach 1:
The adjuster screw is nested inside the caliper housing, protected from external contaminants. The hexagonal head of the adjuster screw is accessible through a sealed opening in the housing, allowing tool access while keeping the threaded portion and adjustment mechanism protected from corrosion and dirt. This nested configuration combines protection with accessibility.
Solution Approach 2:
The caliper housing acts as a protective shell that seals the adjuster mechanism from the external environment. The housing prevents corrosive elements and dirt from reaching the adjuster screw and threaded components, while still allowing access through controlled openings for tool insertion.
3Force
If large thread radius adjuster is used, then spring force can be applied, but large torque is required making adjustment difficult
Solution Approach 1:
The adjuster screw is designed with pre-set thread parameters that balance force multiplication with rotational ease. The thread pitch and diameter are optimized so that the spring force can be effectively applied to the piston without requiring excessive torque during adjustment. This preliminary design optimization eliminates the need for very long wrenches.
Solution Approach 2:
The patent optimizes the thread parameters of the adjuster screw, specifically the pitch and diameter, to achieve the right balance between force application capability and rotational ease. By carefully selecting these parameters, the system can generate sufficient force to compress the spring pack while requiring only moderate torque that can be applied with standard tools.
4Measurement precision
If shim is used for adjustment measurement, then clearance can be measured, but shims and specialized tools increase maintenance complexity
Solution Approach 1:
The adjuster screw itself serves as both the adjustment mechanism and the measurement reference. By counting the number of turns and using the known thread pitch, the exact linear displacement of the piston can be calculated without requiring external shims or specialized measurement tools. The system is self-sufficient for both adjustment and verification.
Solution Approach 2:
The threaded structure of the adjuster screw acts as an intermediary that converts rotational motion into precise linear displacement. The relationship between thread pitch and number of turns provides a built-in measurement system, eliminating the need for separate measurement tools like shims while maintaining measurement precision.
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
Enables easy, tool-free adjustment with minimal user effort, reduces corrosion risks, and lowers maintenance complexity by eliminating the need for shims and specialized tools, while maintaining effective braking performance across varying conditions.
Implementation Method 1
a spring applied hydraulic release caliper brake including springs acting on a piston
Implementation Method 2
hydraulic pressure is applied between a plug and the piston. Since the plug is trapped at the bottom of the piston bore, hydraulic pressure moves the piston toward the spring pack
Implementation Method 3
inserting a threaded bolt into a threaded hole within the piston; rotating the adjuster a predetermined amount
Data Source
AI summary
A spring applied hydraulic release caliper brake includes a housing carrying springs acting on a piston in a default position. The housing further carries an adjuster, with an outer portion of the adjuster being in direct contact with an outermost spring of the springs. A released position of the brake includes the piston being in contact with the adjuster. The adjuster is adapted to rotate a predetermined amount to thereby cause the adjuster to act on the springs. This removes an amount of clearance between the piston and a stator, such that the removal of the amount of clearance becomes a new default position for the spring applied hydraulic release caliper brake.