Brake Caliper Housing Ribs for Sensor Reset Unit Impact Protection

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Solution Overview

Problem

Existing brake calipers for commercial vehicles lack cost-effective and reliable protection for the sensor reset unit against external shocks and impacts, which can lead to damage during assembly, transport, or storage, and require additional costly processing steps.

Innovation Solution

Incorporating ribs formed from the brake caliper housing between sliding bushes and the flange surface to provide protection for the sensor reset unit, which are casted during the manufacturing process, eliminating the need for additional machining and ensuring complete coverage without increasing material costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the sensor reset unit is mounted directly on the caliper housing with full-surface mounting, then the sensor reset unit is protected from impacts and shocks, but additional machining steps (milling) are required, increasing costs and machining time

Engineering Contradiction:

Improveprotection of sensor reset unitVSAvoidmachining time and cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The rib structure is integrated directly into the caliper housing during the casting process, merging the protective function with the existing housing structure. This eliminates the need for separate protective components and additional machining operations, as the rib is formed as part of the single-piece casting of the caliper housing

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The protective rib is formed during the initial casting process of the caliper housing, before any machining or assembly operations. This preliminary formation of the protective structure eliminates the need for subsequent machining steps that would be required if the sensor reset unit were mounted directly on the housing surface

Inventive Principle:

Principle #10Preliminary action

2Reliability

If the sensor reset unit is protected by covering it completely with the brake caliper housing, then protection against external influences is guaranteed, but more raw materials are required and pouring the groove is not economical

Engineering Contradiction:

Improveprotection against external influencesVSAvoidraw material consumption

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

Instead of providing complete coverage of the sensor reset unit with additional material, the rib structure provides localized protection only at the critical areas where the sensor reset unit is most vulnerable to external influences. This selective protection approach uses minimal additional material while maintaining adequate protection

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The rib structure provides partial coverage of the sensor reset unit, protecting it from the most critical external influences (shocks and impacts during assembly, transport, and storage) without requiring complete enclosure. This partial action is sufficient to achieve the protection goal while minimizing material consumption

Inventive Principle:

Principle #16Partial or excessive action

Data Source

PatentEP3623656B1Brake calliper of a disk brake for motor vehicles

Publication Date: 2021.01.27 ZF CV SYST EURO BV

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AI summary

Brake caliper (1) for a disc brake with a clamping side (2) and a rim side (3) comprising a brake cylinder flange surface (4) arranged on the clamping side (2) for receiving a brake cylinder, two sliding bushings (5, 6) for axial displacement of the brake caliper (1) on a brake carrier, and two axially parallel flange surfaces (8, 8a) arranged on the clamping side (2), between the sliding bushings (5, 6) for receiving a sensor reset unit (9)