Disc Brake Caliper Position Control via Friction Clutch
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Solution Overview
Problem
Existing disc brake systems with floating calipers experience unwanted drag torque due to dynamic effects from road surfaces and turning maneuvers, leading to increased fuel consumption, power loss, and brake pad/wear issues, as existing solutions like expansion springs are sensitive to manufacturing tolerances and wear, and fail to effectively center the caliper.
Innovation Solution
A pneumatically actuated disc brake with a caliper position control unit and friction clutch that adjusts the clearance between the brake pads and disc, allowing the caliper to move relative to the brake carrier using a single actuator, ensuring equal contact pressures and eliminating drag torque without the need for additional sensors or complex adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If expansion springs are used to center the caliper, then the caliper position can be adjusted, but the spring is sensitive to manufacturing tolerances and deformation, reducing reliability
Solution Approach 1:
The invention extracts the caliper centering function from the brake actuator operation and creates a separate, independent control system. The caliper position control unit with friction clutch operates autonomously to maintain caliper centering, separating this function from the braking operation and eliminating the reliability issues associated with complex spring designs.
Solution Approach 2:
The friction clutch acts as an intermediary mechanism between the caliper position control unit and the caliper. It provides controlled friction engagement to adjust and maintain caliper position without the complexity and reliability issues of expansion springs, serving as a mediator that translates control unit movement into precise caliper positioning.
2Productivity
If the caliper is float-mounted to allow movement, then the brake pads can apply force effectively, but dynamic effects can move the caliper off-position, causing unwanted drag torque
Solution Approach 1:
The invention implements a dynamic position control system that actively maintains caliper centering during vehicle operation. The caliper position control unit continuously monitors and adjusts caliper position in response to dynamic effects like road surface variations and turning maneuvers, preventing drag torque while preserving the float-mounted brake application effectiveness.
Solution Approach 2:
The system uses feedback from the caliper's actual position and the forces acting upon it during braking and vehicle dynamics. The friction clutch engagement and disengagement is controlled based on detected caliper position deviations, creating a feedback loop that eliminates drag torque while maintaining effective brake application.
3Ease of operation
If the caliper position is not fixed in the release position, then the brake can release fully, but residual drag torque causes unwanted fuel consumption and wear
Solution Approach 1:
The invention performs preliminary centering action of the caliper using the friction clutch and caliper position control unit before normal braking operation begins. This preliminary positioning ensures the caliper starts in the correct centered position, preventing drag torque and associated fuel consumption while maintaining complete brake release capability.
Solution Approach 2:
The caliper position control unit with friction clutch provides self-service centering of the caliper during brake release and idle periods. The system automatically maintains proper caliper position without requiring external intervention or additional energy consumption, eliminating drag torque while preserving full brake release function.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Significantly reduces wear and costs by maintaining optimal clearance between brake pads and disc, preventing unwanted contact and drag torque, thus enhancing operational efficiency and extending the lifespan of brake components.
Implementation Method 1
a friction clutch for coupling the actuator to the caliper and/or the brake carrier
Data Source
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AI summary
A disc brake (1), in particular pneumatically actuated, for a vehicle, in particular for a commercial vehicle, comprising a floating caliper (4) straddling a brake disc (2) and shiftably mounted on at least one guide bearing (5) of a stationary brake carrier (3); two brake pads (6, 7) displaceable arranged in opposite direction in the caliper (4), wherein an inner brake pad (6) of the two brake pads (6, 7) can be pressed against the brake disc (2) by a brake actuator (10). The disc brake further comprises a caliper position control unit (20) with an actuator for moving the caliper (4) relative to the brake carrier (3) and a friction clutch (26) for coupling the actuator to the caliper (4) and/or the brake carrier (3). Further a method for operating a disc brake is disclosed.