Commercial Vehicle Disc Brake Caliper Segmentation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The production of disc brake calipers for commercial vehicles is complex and costly due to the demanding casting requirements for the receiving chamber and lever dome, which complicates the manufacturing process and increases costs.
Innovation Solution
A disc brake design featuring a C-shaped frame with a separate housing and connecting flange, allowing for simpler production methods such as deep-drawing or casting with lighter materials, eliminating the need for complex cores and enabling easier assembly and repair, while maintaining load capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the brake caliper is designed as a one-piece cast part to ensure sufficient strength for absorbing braking forces, then the load capacity and strength are improved, but the manufacturing complexity and cost increase due to demanding casting requirements for the receiving chamber and lever dome
Solution Approach 1:
The brake caliper is divided into two separate parts: a C-shaped frame and a cover. The frame is produced by casting and contains the receiving chamber and lever dome, while the cover is produced separately using simpler manufacturing processes such as deep-drawing or casting with lighter materials. This segmentation allows each part to be manufactured independently with appropriate processes, reducing overall manufacturing complexity while maintaining the structural integrity and load capacity of the complete caliper assembly.
2Ease of manufacture
If the brake caliper is designed in two parts and screwed together to reduce manufacturing costs, then the ease of manufacture is improved, but the device complexity increases
Solution Approach 1:
The cover is firmly connected to the C-shaped frame to form an integrated brake caliper assembly. This connection merges the two separately manufactured parts into a unified structure that functions as a single component during operation. The firm connection eliminates the need for complex assembly mechanisms while maintaining the benefits of separate manufacturing, thus reducing device complexity despite the two-part construction.
3Ease of manufacture
If the brake caliper is designed in two parts with separate housing and connecting flange to enable simpler production methods, then the ease of manufacture is improved, but the reliability may be affected by additional connection points
Solution Approach 1:
The connecting flange is pre-integrated into the C-shaped frame structure, and the cover is designed with predetermined connection features. This preliminary design ensures that when the two parts are assembled, the connection points are optimally positioned to distribute loads effectively. The pre-planned connection geometry and material selection ensure reliable bonding or fastening, maintaining structural integrity while enabling simpler production methods for each component.
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A disc brake for a commercial vehicle, comprising a brake caliper spanning a brake disc, a caliper back (2) with a connecting flange (6) for a brake cylinder, wherein the caliper back (2) and a caliper head (3) are connected to each other by two parallel and spaced-apart tension struts (4), and comprising a clamping device positioned in the brake caliper and associated with the caliper head (3), containing a pivotable brake lever, at least one brake piston (8) that can be pressed against a brake pad during braking, a cross member in which the brake piston (8) is rotatably mounted, and an adjusting device for compensating for a changing clearance, is designed such that the brake caliper consists of a C-shaped frame (1), a separate housing (5) receiving the clamping device, and the connecting flange (6) attached thereto, forming the caliper head (3) and connected to the frame (1).