Convex Brake Lining Support Plate for Uniform Disc Brake Wear
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Solution Overview
Problem
Existing disc brakes in commercial vehicles experience non-uniform wear on brake linings due to diagonal wear, leading to premature replacement of the action-proximal lining and reduced operational efficiency.
Innovation Solution
The design of a disc brake with a convexly molded lining support plate that distributes contact pressure evenly across the friction face, utilizing a brake plunger that rolls on the convex contact region to counteract diagonal wear, ensuring homogeneous wear on both lining halves.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a central brake plunger aligned axially parallel to the brake disc rotation axis is used, then the brake application device structure is simplified, but non-uniform loading and diagonal wear of the brake lining occurs
Solution Approach 1:
The brake plunger is offset from the central axis of the brake disc by a predetermined distance. This asymmetric positioning creates a moment arm that generates a counter-moment to compensate for the diagonal wear tendency, transforming the symmetric central plunger design into an asymmetric offset plunger design that actively counteracts the harmful wear pattern.
Solution Approach 2:
The offset brake plunger position is predetermined during design to pre-establish a counter-moment that opposes the diagonal wear momentum. By positioning the plunger offset before braking occurs, the system proactively creates a counteracting force that balances the wear forces during brake application, preventing the harmful non-uniform loading before it can occur.
2Ease of manufacture
If the brake plunger is positioned at the center axis, then the force introduction is simplified, but the momentum causing diagonal wear is not compensated
Solution Approach 1:
The brake plunger is deliberately positioned asymmetrically relative to the brake disc center axis. This offset positioning, while slightly complicating the force introduction path, creates a moment arm that generates a counter-moment to compensate for diagonal wear, thereby improving brake lining service life and wear uniformity.
Solution Approach 2:
The plunger position parameter is changed from the standard central axis location to an offset position at a predetermined distance. This parameter modification transforms the force introduction geometry to create a beneficial counter-moment that compensates for diagonal wear forces, extending brake lining life despite the added complexity.
3Ease of manufacture
If a flat contact region on the lining support plate is used, then the manufacturing is simpler, but the brake plunger cannot roll to adjust the pressure point position
Solution Approach 1:
The contact region on the lining support plate is given a convex curved surface instead of a flat surface. This curvature enables the brake plunger to roll on the contact region, dynamically adjusting the pressure point position to compensate for diagonal wear and achieve more uniform contact pressure distribution across the brake lining.
Solution Approach 2:
The convex contact region transforms the static pressure application into a dynamic system where the brake plunger can roll during brake application. This rolling motion allows the pressure point to shift and adapt, creating a dynamic compensation mechanism for diagonal wear that improves contact pressure uniformity.
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 achieves homogeneous wear on brake linings, extending their service life and reducing operational costs by optimizing the distribution of pressure and compensating for diagonal wear during both forward and reverse vehicle movements.
Implementation Method 1
the brake plunger rolls on the molded contact region of the lining support plate as soon as diagonal wear is generated and the assigned brake lining rotates
Implementation Method 2
The force generated by a brake cylinder is positively geared by a mechanical gear unit in the interior of the brake caliper, and the brake linings (also called brake pads) are pressed in the direction of the brake disc
Data Source
AI summary
A disc brake for a utility vehicle, includes a brake caliper which engages over a brake disc and is held axially displaceable, in relation to the brake disc, on guide rods which are connected to a vehicle-side brake carrier, wherein, in the case of a braking operation, an action-side brake pad, which is mounted in the brake carrier and has a pad support plate and a friction lining fastened thereon, can be pressed against the brake disc by way of an application device which has a pivotable brake lever and at least one central brake plunger. The brake plunger has an actuating spindle and a pressure piece contacting the pad support plate. The disc brake is designed in such a manner that the pad support plate has an at least partially convex design in the contact region with the brake plunger.