Disc Brake Clamping Lever Pockets for Secure Bearing Shell Fixation
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Solution Overview
Problem
Existing methods for attaching bearing shells to the application lever in disc brakes result in high scrap costs and rejection rates due to the breaking out of journal parts during the pressing process and subsequent falling off, leading to inefficient fixation and assembly.
Innovation Solution
The introduction of pockets on the sides of the clamping lever base, which are preferably axis-parallel and can be symmetrically or asymmetrically arranged, allows for a secure and precise connection of bearing shells using lugs that create a non-positive locking mechanism, reducing the need for additional holes and enhancing assembly efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If bearing shells are pressed into boreholes in the support area, then the bearing shells are fixed to the application lever, but journals of the bearing shells break out and many bearing shells fall off after pressing, resulting in high scrap costs
Solution Approach 1:
The support area is divided into multiple pockets, each capable of holding a bearing shell. This segmentation allows for better distribution and secure positioning of bearing shells, preventing them from falling off after pressing and reducing scrap rate.
Solution Approach 2:
Pockets are introduced as an intermediary structure between the support area and the bearing shells. These pockets provide a containing environment that secures the bearing shells in place during and after the pressing process, preventing journal breakage and shell detachment.
2Ease of manufacture
If bearing shells are firmly pressed into boreholes, then fixation is achieved, but a large amount of scrap occurs due to journals breaking out during pressing
Solution Approach 1:
The pockets are designed to cushion and distribute the pressing force evenly across the bearing shell and support area. This prevents concentration of stress that could cause journal breakage, while still achieving secure fixation of the bearing shells.
3Ease of operation
If pockets are arranged on the sides of the clamping lever base, then connection and locking of bearing shells is simplified, but additional structural elements are required
Solution Approach 1:
The pockets are integrated directly into the support area structure of the application lever, merging the containing function with the existing lever design. This eliminates the need for separate external fixtures or complex assembly mechanisms, simplifying both structure and assembly process.
Data Source
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Figure 2
Figure 2a
AI summary
The invention relates to a clamping device for a disc brake, in particular for a sliding caliper disc brake, for clamping a brake disc. The disc brake has at least one brake caliper for receiving the clamping device and brake pads for clamping the brake disc. Furthermore, the clamping device comprises a clamping lever with at least one clamping lever foot. The clamping lever foot has a recess for receiving a bearing shell, either on the side facing the brake pad or on the side facing away from the brake pad.