Floating Caliper Brake Clearance Readjustment via Dynamic Braking Force
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing disc brake systems for vehicles face challenges in efficiently managing clearance adjustments due to wear, leading to uneven wear distribution between brake pads and discs, which increases energy consumption and reduces braking performance.
Innovation Solution
A method and arrangement that utilize a wear detection device, actuator, and control unit to detect wear and adjust the braking force dynamically, ensuring optimal clearance distribution by readjusting the brake caliper, thereby reducing energy consumption and extending component lifespan.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If very high braking forces are applied to readjust air gap distribution, then the clearance distribution is corrected, but energy consumption increases
Solution Approach 1:
The system dynamically adjusts the braking force applied during reset operations based on detected wear values. Instead of always applying very high braking forces, the control unit calculates and applies only the necessary braking force required to achieve the desired clearance distribution, thereby reducing energy consumption while maintaining precision.
Solution Approach 2:
The system uses wear detection devices to continuously monitor brake pad and disc wear, then feeds this information back to the control unit. Based on this feedback, the control unit determines the optimal braking force needed for readjustment, avoiding unnecessary high energy consumption while ensuring proper clearance distribution is achieved.
2Ease of operation
If resetting device is used to reset brake caliper, then brake caliper returns to initial position, but wear on brake pads and disc increases
Solution Approach 1:
Instead of always applying excessive braking force to ensure reset, the system calculates and applies only the partial braking force necessary to achieve the reset function. The control unit determines the minimum required braking force based on wear detection, preventing unnecessary additional wear while still achieving complete resetting of the brake caliper.
3Use of energy by moving object
If clearance is not readjusted, then energy consumption is reduced, but braking performance deteriorates
Solution Approach 1:
The wear detection device continuously monitors brake component wear and provides feedback to the control unit. When wear reaches levels that would compromise braking performance, the system automatically initiates readjustment operations at optimal moments, ensuring braking performance is maintained without requiring continuous high energy consumption.
Solution Approach 2:
The system performs readjustment operations proactively based on detected wear trends before braking performance actually deteriorates. By detecting wear early and initiating readjustment at appropriate times, the system prevents performance degradation while minimizing unnecessary energy consumption from frequent readjustments.
Data Source
Figure 1
Figure 2
Figure 3~5
AI summary
The method involves determining (S1) a requirement for readjustment by detecting a clearance distribution between an inner clearance and an outer clearance, and determining (S2) a required braking force for readjustment. The two-sided clearance is readjusted (S3) by introducing the determined braking force in the disk brake with stoppage of the vehicle. An independent claim is also included for an arrangement for readjusting two-sided clearance for a disk brake of a vehicle between brake pads and a brake disk.