Utility Vehicle Disc Brake Caliper Segmentation
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Solution Overview
Problem
Existing disc brake calipers for commercial vehicles face challenges in production, processing, and component assembly, with issues related to material usage, flexibility, and strength, particularly due to the introduction of braking forces into the screw-on cover area, which leads to strength and sealing problems, and requires complex machining and angular adjustments.
Innovation Solution
A disc brake design where the first opening is closed by a removable cover outside the support area, allowing for the use of lighter materials and reducing the need for complex machining, with a non-rotatable but axially displaceable pressure spindle and a hood-shaped cover providing space for the rotary lever, enabling simpler assembly and disassembly without exposing the brake disc.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If the brake caliper is closed at the back with a screwed-on cover to protect internal components, then protection from environmental influences is improved, but strength and sealing problems arise due to braking forces being introduced into the cover area
Solution Approach 1:
The brake caliper is divided into two separate parts: a fixed support area that absorbs braking forces and a movable cover area that provides protection. This segmentation allows the support area to handle mechanical loads while the cover focuses on environmental protection, resolving the contradiction between protection and strength.
Solution Approach 2:
The support area is extracted as a distinct functional zone within the caliper structure. By separating the force-absorbing function from the protective cover, the design eliminates the weakness caused by introducing braking forces into the cover area, while maintaining both protection and strength.
2Ease of manufacture
If the brake caliper is designed as a monoblock without a cover to simplify structure, then manufacturing is improved, but accessibility for assembly and disassembly deteriorates
Solution Approach 1:
The caliper is segmented into a fixed support area and a removable cover, allowing simple monoblock manufacturing of the support area while enabling easy assembly and disassembly through the removable cover, thus resolving the contradiction between manufacturing simplicity and operational accessibility.
Solution Approach 2:
Different parts of the caliper have different qualities: the support area is designed as a simple monoblock for easy manufacturing, while the cover area is made removable for accessibility. This local differentiation resolves the contradiction by optimizing each zone for its specific function.
3Ease of operation
If the first opening is made large enough to allow passage of assembly components, then ease of assembly is improved, but structural integrity and protection deteriorate
Solution Approach 1:
The opening is segmented into two functional zones: a large first opening in the support area for assembly access, and a smaller second opening in the cover for protection. This segmentation allows easy assembly through the large opening while maintaining protection through the smaller covered opening, resolving the contradiction between ease of assembly and structural integrity.
Solution Approach 2:
The removable cover acts as an intermediary element that provides protection while allowing controlled access. It mediates between the need for a large opening for assembly and the need for protection, enabling both functions to coexist by being removable during assembly and fixed during operation.
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
This design simplifies assembly and disassembly, reduces material and weight usage, and allows for flexible angular adjustments of the brake cylinder, while maintaining structural integrity and accessibility for maintenance, without the need for new casting models or removing the caliper from the disc.
Implementation Method 1
an application device which has an eccentric located within the brake caliper and supported on a support area of the brake caliper
Data Source
Figure 1
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AI summary
The invention relates to a disc brake for utility vehicles, comprising a brake calliper (10), a brake application device having an eccentric that lies inside the brake calliper and is supported on a supporting region of the brake calliper and having a rotary lever for rotating the eccentric, said lever lying inside the brake calliper. The disc brake also comprises a first actuation device that lies outside the calliper and is coupled to the rotary lever by means of a functional opening, (27), the brake calliper (10) having a first opening (20) that lies outside the supporting region, through which opening the eccentric and the rotary lever pass during assembly/disassembly. The first opening (20) is closed by a detachable cover (26), on which the first actuation device is mounted.