Disc Brake Cover Plate With Integrated Cable Guide Protection

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Solution Overview

Problem

Existing cover panels for disc brakes in utility vehicles do not effectively protect sensor cables from heat and environmental damage, leading to potential brake pad detection failures and increased risk of brake disc damage due to undetected wear.

Innovation Solution

A cover panel with an integrated cable guide, featuring a recessed cable channel and variable-width design, along with fixing elements that can be formed from the cover panel itself, provides enhanced protection for sensor cables against heat and environmental factors, allowing for simultaneous installation of the cover panel and sensor cable without increasing the number of parts.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If the cable is guided freely on the cover panel, then the installation is simple, but the cable is exposed to heat and environmental damage

Engineering Contradiction:

Improvecable installation simplicityVSAvoidcable protection from heat and environment

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The cable is nested within a cable guide channel that is recessed into the cover panel. This recessed channel structure protects the cable from direct exposure to heat and environmental factors while maintaining a compact integrated design, resolving the contradiction between simple installation and reliable protection.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Device complexity

If the cable is arranged freely on the cover panel, then the cable guide structure is simple, but the cable is vulnerable to breaking during installation and removal

Engineering Contradiction:

Improvecable guide structure simplicityVSAvoidcable resistance to breaking

Core Design Contradiction:

Device complexityVSStrength

Solution Approach 1:

The cable guide channel is recessed into the cover panel, creating a protected pathway for the cable. This nested structure reduces the cable's vulnerability to mechanical damage during installation and removal operations while maintaining structural simplicity.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The recessed cable guide channel provides beforehand protection by creating a cushioning effect that absorbs mechanical stresses during installation and removal, preventing cable breaking before damage can occur.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Reliability

If a separate cable guide component is added, then the cable protection is improved, but the number of parts increases

Engineering Contradiction:

Improvecable protectionVSAvoidnumber of parts

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The cable guide channel is merged with the cover panel by recessing it directly into the panel structure. This integration combines the protective function with the existing cover panel, improving cable protection without increasing the number of separate parts.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The cover panel is given multi-functionality by incorporating the cable guide channel directly into its structure. The cover panel simultaneously serves as both the protective cover and the cable routing structure, eliminating the need for separate cable guide components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Ease of manufacture

If the cable guide is not recessed, then the manufacturing is simpler, but the cable is exposed to environmental influences like stone material

Engineering Contradiction:

Improvecable guide manufacturing simplicityVSAvoidcable exposure to environmental factors

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The cable guide channel is recessed into the cover panel, nesting the cable within a protected space. This recessed structure shields the cable from environmental harmful factors such as stone material and debris while maintaining manufacturing simplicity through direct formation of the channel in the panel.

Inventive Principle:

Principle #7Nested doll (Nesting)

Data Source

PatentUS11346412B2Cover plate for a disc brake

Publication Date: 2022.05.31 ZF CV SYST EURO BV

AI summary

A cover panel (1) for a disc brake (2) for covering an installation opening (5) of the disc brake (2), wherein the disc brake (2) comprises a brake carrier (13) and a brake caliper (3) sliding on the brake carrier (13) axially in the direction of an application side (Z) or axially in the direction of a rim side (F).