Caliper Parking Brake Piston Return Mechanism
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Solution Overview
Problem
Caliper parking brakes face issues with drag due to non-return of the piston and frictional pad, especially when strong brake forces are applied, leading to incomplete brake release and brake defects from abrasion, where the piston fails to return to its original position and the frictional pad maintains contact with the brake disc, causing inefficiency and incomplete braking.
Innovation Solution
A caliper parking brake design incorporating a return spring system with low-pressure and high-pressure springs, an abrasion compensation rod part, and a return pipe with a one-direction screw coupling, which allows the piston to return to its original position effectively even under strong brake forces and compensates for frictional pad abrasion by adjusting the piston's pressing distance, ensuring real-time contact with the brake disc.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single sealing ring is used to return the piston by elastic restoring force, then the structure is simple, but when strong brake force is applied the sealing ring is excessively deformed and loses restoring force, causing the piston to fail to return to original position
Solution Approach 1:
The single sealing ring is divided into multiple sealing rings (first sealing ring and second sealing ring) with different elastic restoring forces. The first sealing ring has a larger restoring force for strong brake forces, while the second sealing ring has a smaller restoring force for normal brake forces. This segmentation allows each sealing ring to handle specific brake force ranges effectively, preventing excessive deformation and ensuring reliable piston return.
Solution Approach 2:
The elastic restoring force parameter of the sealing rings is changed by using multiple sealing rings with different material properties or cross-sectional areas. This parameter change enables the system to adapt to different brake force magnitudes, ensuring that the total restoring force matches the applied brake force in various operating conditions.
2Manufacturing precision
If the piston is pressurized forward to maximum for abrasion compensation, then the frictional pad contacts the brake disc, but brake pressure does not substantially reach maximum pressure causing brake defect
Solution Approach 1:
The system dynamically adjusts the piston position and brake pressure based on operating conditions. The abrasion compensation mechanism allows the piston to move forward incrementally as the frictional pad wears, maintaining optimal contact pressure. This dynamic adjustment ensures that the frictional pad remains in contact with the brake disc throughout its service life while preventing brake defects from improper contact.
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 ensures quick and complete return of the piston and frictional pad to their original positions, preventing drag and brake defects by using the elastic repulsive forces of the springs and adjusting the piston's position to maintain contact with the brake disc, thus enhancing braking efficiency and reliability.
Implementation Method 1
a return spring part that is disposed within the cylinder on a common axis to the abrasion compensation rod part, is elastically compressed during brake and is elastically restored while brake is released
Implementation Method 2
the return spring part includes low-pressure and high-pressure springs
Data Source
Figure 1
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AI summary
A caliper parking brake including a caliper housing (3) having one end on which a cylinder (13) is formed and the other end on which a fork (15) is formed to face the cylinder, a brake force input terminal (5)that is rotatably mounted on an end of the cylinder of the caliper housing by a parking cable, a brake force switching terminal (7) that is installed within the cylinder on a common axis so as to rotate together with the brake force input terminal and switches a rotatative motion caused by a brake force introduced into the brake force input terminal to a straight motion, a brake force output terminal (9) that is directly connected to the brake force switching terminal (7) on a common axis and outputs the brake force switched to the straight motion by the brake force switching terminal (7), and a brake terminal (11) that is disposed between the fork (15) and the brake force output terminal (9) and stops rotation of a brake disc using the brake force output by the brake force output terminal, wherein the brake force output terminal (9) compensates for abrasion that occurs in the fork and a frictional pad of the piston by moving an initial position of the piston forward.