Caliper Brake Retraction Spring Structure to Prevent Pad Drag
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Solution Overview
Problem
Caliper brakes face issues with drag phenomenon when braking is released due to continuous contact between the brake disk and pad, requiring an effective retraction mechanism to restore the brake pad to its original position efficiently and reliably, while also minimizing material waste and simplifying assembly and maintenance.
Innovation Solution
A retraction spring with a pad coupling part, body part, and carrier support part is designed to provide an elastic restoring force, featuring bent arms and inclined portions that securely couple with protruding portions of the brake pad, allowing for adjustable restoring forces and reduced material usage through optimized manufacturing processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a retraction spring is integrated into the brake pad structure, then structural complexity is reduced, but ease of manufacture and maintenance deteriorate
Solution Approach 1:
The retraction spring is designed as a separate component from the brake pad, allowing independent manufacturing and assembly. The spring can be manufactured separately using coiling processes and then installed into the brake pad assembly, facilitating easier manufacturing and maintenance without requiring complex integrated structures.
2Reliability
If material usage is increased to improve restoring force, then reliability is improved, but material waste increases
Solution Approach 1:
The restoring force is optimized by adjusting parameters such as wire diameter, coil diameter, and number of active coils rather than simply increasing material usage. This allows achieving the required restoring force with minimal material, reducing waste while maintaining reliability.
Solution Approach 2:
The retraction spring features varying wire diameters along its length, with thicker sections at critical stress points and thinner sections where less strength is needed. This localized quality optimization ensures sufficient restoring force while minimizing overall material usage and waste.
3Ease of manufacture
If the retraction spring structure is simplified, then ease of manufacture is improved, but operational performance deteriorates
Solution Approach 1:
The retraction spring is divided into distinct functional sections: anchor portions for secure attachment, body portions for elastic deformation, and connection portions for linking components. This segmentation enables simple manufacturing of each section while maintaining overall operational performance through proper assembly.
Solution Approach 2:
The retraction spring incorporates curved and bent geometries in its body portions, which provide the necessary elastic restoring force. These curved sections are strategically positioned to maximize mechanical advantage while maintaining manufacturability through standard spring forming processes.
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 retraction spring effectively returns brake pads to their original position, preventing drag, improving operational reliability, reducing material waste, and facilitating easy assembly and maintenance, while allowing for customized restoring forces to enhance braking performance.
Implementation Method 1
a body part extending from the pad coupling part and configured to provide an elastic restoring force
Data Source
AI summary
A retraction spring includes a pad coupling part including a first arm and a second arm contacting a front surface and a rear surface of the protruding portion, respectively, and a connecting portion connecting between the first arm and the second arm, a body part extending from the pad coupling part and configured to provide an elastic restoring force, and a carrier support part extending from the body part and supported by a coupling hook formed on a carrier. The first arm is bent at or from one side of the connecting portion toward the front surface, the second arm is bent at or from the other side of the connecting portion toward the rear surface, and the body part is bent from the other side of the connecting portion.