Caliper Disc Brake Hold-Down Geometry for Symmetric Manufacturing
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Solution Overview
Problem
The existing caliper disc brake designs for commercial vehicles face challenges in achieving economical and cost-optimized production due to asymmetrical bearing and support areas, requiring different casting patterns for left and right brakes, which complicates mechanical processing and increases costs.
Innovation Solution
The design introduces a symmetrical hold-down device with tangential prestressing generated by asymmetric dimensions of the hold-down device, allowing for standardized mechanical processing and avoiding mechanically unfavorable moments by separating areas of force introduction from maximum bending stress zones, enabling the use of the same molds for both left and right brakes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If asymmetrical bearing and support areas are used to generate tangential prestressing, then effective preloading of brake linings is achieved, but different casting patterns are required for left and right brakes, increasing manufacturing complexity and costs
Solution Approach 1:
The patent applies asymmetry principle by designing the hold-down device with asymmetric dimensions in the tangential direction. The hold-down device has a first dimension on the disc outlet side and a second dimension on the disc inlet side, where these dimensions differ to generate the required tangential prestressing force. This allows the asymmetric force generation to be achieved through the hold-down device itself rather than through asymmetric caliper design, resolving the contradiction by localizing the asymmetry where it is needed while keeping the overall caliper structure symmetric for manufacturing purposes.
2Reliability
If asymmetrical holding areas are used in the brake caliper, then tangential prestressing is achieved, but mechanical processing becomes more difficult and costs increase
Solution Approach 1:
The patent extracts the tangential prestressing function from the brake caliper structure and transfers it to the hold-down device. By removing the requirement for asymmetric holding areas in the caliper, the mechanical processing of the caliper becomes simpler and more standardized. The hold-down device independently provides the tangential prestressing through its own asymmetric geometry, separating the prestressing function from the caliper structure and thereby improving ease of manufacture.
3Reliability
If different caliper designs are used for left and right brakes, then proper tangential prestressing direction is achieved, but production economy is reduced
Solution Approach 1:
The patent applies universality principle by designing the brake caliper with symmetric holding areas that can accommodate the same hold-down device design for both left and right brakes. The hold-down device itself provides the directional tangential prestressing through its asymmetric dimensions, making the caliper design universal and interchangeable. This allows standardized production of calipers that can be used on both sides, significantly improving production efficiency and economy while maintaining proper prestressing direction control through the hold-down device geometry.
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
This approach simplifies the manufacturing process, reduces production costs, and enhances mechanical reliability by allowing symmetrical designs for both left and right brakes, while maintaining effective radial and tangential preloading of brake linings.
Implementation Method 1
a hold-down spring for holding down the power transmission element, and a hold-down device held and supported by a holding device on the saddle, which radially preloads the hold-down spring against the power transmission device and preloads the hold-down spring tangentially in the direction of rotation
Data Source
Figure 1~2
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Figure 5~6
AI summary
A caliper disc brake of a vehicle with a brake disc having an axis of rotation, a brake caliper, a brake anchor plate, a force transmission element, such as, for example, a lining support and/or a pressure plate, which is guided and supported in a shaft of the brake caliper or of the brake anchor plate, a holding-down spring for holding down the force transmission element, and a holding-down device (36) which is held and supported on the caliper by a holding device, pretensions the holding-down spring radially against the force transmission device and pretensions the holding-down spring tangentially in the direction of rotation against the force transmission device during forwards travel, wherein the holding device has a centre line lying parallel to the axis of rotation. The tangential pre-tensioning is at least partially attributed to the fact that the dimensions (V1, V2) of the holding-down device, as measured in the tangential direction from the centre line (M), are larger at least in sections on the disc exit side than on the disc entry side.