Disc Brake Adjustment Mechanism Thread Integration
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Solution Overview
Problem
Existing disk brakes face challenges in maintaining precise adjustment and accuracy due to relative movements between the application device and adjustment device, leading to increased assembly effort and potential inaccuracies, especially in commercial vehicle applications where space and flexibility are limited.
Innovation Solution
A disk brake design where the adjustment mechanism is directly mounted on the actuating spindle with a thread device that meshes with the external thread, allowing for rotational coupling and axial movement synchronization, eliminating the need for separate fastening components and reducing installation space requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the adjustment device is held in a fixed manner in the movable element, then the adjustment mechanism maintains stability during brake actuation, but the assembly effort increases and installation space requirements grow
Solution Approach 1:
The adjustment mechanism is integrated directly onto the actuating spindle, merging two previously separate components (adjustment device and actuating spindle) into a unified assembly. This eliminates the need for separate fastening components and reduces the number of assembly steps while maintaining adjustment accuracy through the threaded connection that ensures precise positional relationship.
Solution Approach 2:
The actuating spindle serves dual functions: it acts as both the actuating component for brake application and as the mounting base for the adjustment mechanism. This multi-functionality eliminates the need for separate mounting structures and fastening components, thereby reducing assembly complexity while maintaining the stability required for accurate adjustment.
2Reliability
If separate fastening components are used to secure the adjustment mechanism, then the adjustment device remains stable during operation, but the installation space requirements increase
Solution Approach 1:
The adjustment mechanism is directly integrated onto the actuating spindle through a threaded connection, eliminating the need for separate fastening components such as nuts, bolts, or clips. This merging of components significantly reduces the installation space required while maintaining operational stability through the inherent mechanical connection of the threaded interface.
Solution Approach 2:
The separate fastening components that would normally be required to secure the adjustment mechanism are completely removed from the design. The adjustment mechanism utilizes the actuating spindle's own threaded structure for mounting, extracting the need for additional fastening elements and thereby reducing the overall volume and installation space requirements.
3Device complexity
If the adjustment mechanism is integrated directly on the actuating spindle, then the assembly effort is reduced and installation space is minimized, but the manufacturing precision requirements increase
Solution Approach 1:
The threaded connection parameters (thread pitch, diameter, engagement length) are optimized to balance manufacturing precision requirements with assembly simplicity. By carefully selecting these parameters, the design achieves adequate precision for adjustment functionality while maintaining ease of assembly and reducing the stringency of manufacturing tolerances compared to tighter-fitting alternatives.
Solution Approach 2:
The threaded connection is designed with segmented engagement zones that distribute the precision requirements across multiple thread engagements rather than requiring extreme precision in a single critical interface. This segmentation of the connection interface reduces the overall manufacturing precision burden while maintaining reliable attachment.
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
This design enhances the accuracy and flexibility of the adjustment mechanism, simplifies the brake structure, and allows for more generous part dimensions, while ensuring precise adjustment and reduced assembly effort, even under conditions of wear and vibration.
Implementation Method 1
the adjustment mechanism has a thread device, which, at least in the case of rotation in a second direction of rotation opposite the first direction of rotation, meshes with the external thread of the actuating spindle and screws the adjustment mechanism in relation to the actuating spindle
Data Source
AI summary
A disk brake includes a brake disk, a brake caliper, at least one application device lying within the brake caliper on one side of the brake disk, an axially movable device configured to move a brake pad axially toward the brake disk, and an adjustment mechanism configured to be rotated about an rotation axis lying parallel to a rotation axis of the brake disk and which, in the case of rotation in a first direction of rotation bringing about adjustment, is configured to rotate the actuating spindle. The adjustment mechanism includes a thread device which, at least in a rotation in a second direction of rotation opposite the first direction of rotation, is configured to mesh with the external thread of the actuating spindle and to screw the adjustment mechanism in relation to the actuating spindle.