Fixed-Caliper Disc Brake Bracket Layout for Easier Manufacturing
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Solution Overview
Problem
The manufacturing process of disc brakes with fixed calipers is complex and costly due to the integrated structure of the cylinder body, which restricts design changes and poses challenges in cooling and hub shaft length.
Innovation Solution
A disc brake design where a separate bracket is fixed to the knuckle instead of the cylinder body, allowing for a simplified manufacturing process and reduced component count, thereby lowering production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the cylinder body is used as an integrated structure to support pads and mount to knuckle, then the structure is stable and braking force is dispersed, but the manufacturing process becomes complex and costly
Solution Approach 1:
The patent divides the integrated cylinder body into separate components: the cylinder body and the bracket are separated into independent parts that are assembled together. The bracket is fixed to the knuckle while the cylinder body is mounted to the bracket, allowing each component to be manufactured independently with simpler processes while maintaining the stable structure and braking force dispersion of the original integrated design.
2Ease of operation
If the integrated cylinder body structure is used, then pad support and guidance are achieved, but design changes require changing all integrated shapes
Solution Approach 1:
By separating the bracket from the cylinder body, the patent enables independent design and modification of each component. The bracket can be redesigned for different mounting dimensions and vehicle applications without affecting the cylinder body design, significantly improving design adaptability while maintaining pad support functionality.
Solution Approach 2:
The bracket is extracted from the integrated cylinder body structure and becomes a separate component. This extraction allows the bracket to be independently optimized for different mounting requirements while the cylinder body maintains its core braking function, enhancing overall design versatility.
3Volume of moving object
If the cylinder body is fixed to the knuckle, then the structure is compact, but the manufacturing process is restricted and costs increase
Solution Approach 1:
The patent segments the mounting function from the cylinder body by introducing a separate bracket that attaches to the knuckle. The cylinder body only needs to interface with the bracket, simplifying its manufacturing requirements while the bracket handles the complex mounting adaptations, reducing overall manufacturing costs.
Solution Approach 2:
The bracket acts as an intermediary component between the cylinder body and the knuckle. This mediator absorbs the manufacturing complexity and design adaptability requirements, allowing the cylinder body to be manufactured with simpler processes while maintaining compact overall structure.
Data Source
AI summary
A disc brake according to an embodiment of the present disclosure includes a cylinder body and a bracket assembly. The bracket assembly is disposed in a space in the cylinder body. The cylinder body and the bracket assembly are fastened to each other by fastening members.