Commercial Vehicle Disc Brake Axial Fixation Mechanism
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Solution Overview
Problem
Disc brakes in commercial vehicles experience increased wear and operating costs due to residual grinding torques, overheating, and potential brake pad sticking, leading to reduced service life and fuel efficiency, with undefined clearance causing continuous rubbing against the brake disc.
Innovation Solution
The disc brake design incorporates axial fixation and forced release of the reaction-side brake pad, ensuring it remains in contact with the caliper wall during non-braking, preventing rubbing and featuring recesses and retaining elements to maintain pad alignment and secure the brake pads, thus eliminating residual torque and wear during non-braking phases.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the brake pads are allowed to move freely axially towards the brake disc, then the brake pads can be applied effectively during braking, but the brake pads may come into contact with the brake disc during non-braking, causing residual grinding torques and increased wear
Solution Approach 1:
The holding element is pre-installed on the brake caliper with retaining brackets positioned to engage with the brake pad carrier plate before braking occurs. This preliminary positioning ensures that when the brake is released, the brake pad is automatically held at a defined clearance distance from the brake disc, preventing residual grinding contact during non-braking operation while maintaining reliable brake application when needed.
2Speed
If the brake pads are held close to the brake disc, then braking response is improved, but the brake pads may stick to the brake disc due to corrosion, preventing proper detachment during non-braking
Solution Approach 1:
The holding element provides localized axial positioning at the rear of the brake pad carrier plate, while the front of the brake pad maintains close proximity to the brake disc for rapid response. This differential positioning allows the brake pad to be held at an optimal distance that ensures both quick brake application and reliable detachment, preventing corrosion-related sticking while maintaining braking performance.
3Loss of substance
If an axial fixation mechanism is added to prevent brake pad contact during non-braking, then wear is reduced, but the device complexity increases
Solution Approach 1:
The holding element is integrated into the existing brake caliper structure, combining the axial fixation function with the caliper's mounting components. The retaining brackets are formed as part of the caliper assembly, and the holding element utilizes the existing mounting opening and web structure, thereby adding minimal complexity while effectively preventing brake pad contact during non-braking operation and reducing brake lining wear.
Data Source
Figure 1
Figure 2
Figure 3~5
AI summary
The brake has an application-side brake lining and a reaction-side brake lining (4) comprising respective lining support plates provided with a friction lining (7). A rear side of the support plate of the reaction-side brake lining is turned away from the friction lining and connected with a twin-leaf holding element (11). Both sides of the holding element are hinged at a recess formed at an edge of the saddle spine, which limits a mounting opening of a brake caliper in insertion direction of the reaction-side brake lining. An independent claim is also included for a brake lining for a disk brake.