Disc Brake Clamping Lever Bolt Support Segmentation
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Solution Overview
Problem
The installation of disc brake application devices is complicated due to the arrangement of the clamping lever and the requirement for strong, dimensioned bolts that undergo significant deflection, leading to design and assembly challenges.
Innovation Solution
The application device is improved by using a bolt that can be inserted into the housing with local support on projections, limiting bolt deflection and allowing a slim design, with additional support from bores in the side walls and a threaded blind hole for axial fixation, and sealing to prevent dirt ingress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a strong, powerfully dimensioned bolt is used to support the clamping lever between two side flanges, then the bolt can withstand considerable clamping forces, but the installation becomes complicated and the bolt requires increased effort to install
Solution Approach 1:
The bolt support structure is segmented into multiple localized support points (at least three support points) distributed along the bolt length, rather than requiring a single strong bolt spanning the entire distance between side flanges. This segmentation allows the bolt to be thinner and easier to install while still distributing clamping forces effectively across multiple localized regions.
Solution Approach 2:
Instead of requiring uniform strength throughout the entire bolt length, the invention provides localized support at specific points along the bolt. The support structure offers concentrated strength only where needed (at support points), allowing the bolt to be Slimmer and more easily installed in non-critical regions while maintaining adequate strength at critical load-bearing locations.
2Ease of operation
If a long bolt section is used between the two side flanges of the brake caliper, then the clamping lever can be mounted, but the bolt undergoes considerable deflection and requires strong dimensioning
Solution Approach 1:
The long bolt span is divided into multiple shorter effective spans by introducing at least three support points along its length. This segmentation reduces the maximum deflection distance between supports, allowing the use of a Slimmer, less heavily dimensioned bolt that would otherwise be insufficient for spanning the entire distance between side flanges.
Solution Approach 2:
The support structure is integrated into the brake caliper housing rather than being a separate component. By forming support projections directly on the housing interior surface, the invention adds a dimensional layer of support within the existing structure, reducing bolt deflection without requiring a longer or stronger bolt.
3Strength
If the bolt is strongly dimensioned to prevent deflection, then it can support clamping forces, but it cannot be made slim and the installation remains difficult
Solution Approach 1:
The bolt support function is segmented into multiple localized support regions, allowing the bolt to be Slimmer while maintaining load-bearing capacity. The at least three support points create shorter effective spans that reduce bending moments, enabling a Slimmer bolt design that would otherwise be too flexible to support the required clamping forces.
4Ease of operation
If the clamping lever is pivotably mounted on a support element near the rear wall, then the application device can be installed, but the installation causes problems in practice
Solution Approach 1:
The support projections are pre-formed as integral parts of the brake caliper housing during manufacturing. This preliminary formation of support structures eliminates the need for separate installation steps to attach support elements, allowing the clamping lever to be directly mounted on the pre-existing projections and significantly simplifying the overall installation process.
Data Source
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AI summary
A disc brake is proposed with a clamping device arranged in a housing (2) of the disc brake, which acts on one or more brake pads via at least one pressure piston. The clamping device has a pivotable clamping lever (10) supported against a rear wall (13) of the housing (2) and a lever arm (11) at the free end of which a force element acts. Facing the pressure piston, the clamping lever (10) has a curved pressure transmission surface (16) whose reference line (17) is parallel and offset from the pivot axis (A) of the clamping lever (10). The aim is to improve the mountability of the clamping device within the housing (2) of the disc brake. For this purpose, the clamping lever (10) sits on a bolt (15) that can be inserted into the housing (2).The bolt is supported, facing away from the pressure transmission surface (16), on at least one projection (20) formed on the rear wall (13) of the housing (2), preferably in the form of a support shell (21).