Commercial Vehicle Disc Brake Mounting for Lower Carrier Load
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Solution Overview
Problem
The existing tangential interface design for disc brakes in commercial vehicles leads to heavy loading of the brake carrier, unfavorable deformation, and increased loading on the longitudinal bearings, making it difficult to replace and maintain, while axial interfaces are hard to access.
Innovation Solution
A disc brake design with a tangential interface that incorporates additional perpendicular surfaces on both the axle flange and brake carrier for precise alignment and axial force absorption, reducing deformation and loading, and utilizing form-fitting connections such as screws or pins for enhanced strength and assembly ease.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a tangential interface is used for attaching the brake carrier to the axle flange, then the brake can be firmly connected, but the brake carrier is heavily loaded and experiences unfavorable deformation
Solution Approach 1:
The invention transitions from a purely radial tangential interface to a three-dimensional interface by adding axial surfaces perpendicular to the brake disc. This dimensional extension allows the interface to accommodate both radial and axial forces, distributing the load more favorably and reducing stress on the brake carrier while maintaining firm connection.
2Strength
If a tangential interface is used for attaching the brake carrier to the axle flange, then the brake can be firmly connected, but the longitudinal bearings are heavily loaded
Solution Approach 1:
By adding axial surfaces perpendicular to the brake disc to the tangential interface, the invention creates a three-dimensional load path that reduces the force components transmitted to the longitudinal bearings, thereby reducing their loading while maintaining connection strength.
3Manufacturing precision
If an axial interface is used for attaching the brake carrier to the axle flange, then the brake is precisely positioned axially, but the fastening screws are difficult to access
Solution Approach 1:
The invention merges the advantages of both axial and radial interfaces by combining axial surfaces for precise positioning with radial surfaces for easy access fastening. This hybrid interface allows screws to be accessed radially while maintaining precise axial positioning through the axial surfaces.
4Strength
If a robust brake carrier design is used to handle high stress, then the connection strength is improved, but the material usage and weight increase
Solution Approach 1:
The invention changes the geometric parameters of the interface by adding perpendicular axial surfaces, which fundamentally alters the stress distribution and load path. This allows the brake carrier to be designed with less material while maintaining connection strength, as the new interface geometry naturally reduces unfavorable stress concentrations.
Data Source
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AI summary
The invention relates to the arrangement of a disk brake (1) for a utility vehicle and an axle flange (5), the disk brake (1) having a brake calliper (3) which surrounds a brake disk (2) and which is fastened, axially displaceably in relation to the brake disk (2), to a fixed backing plate (4). The backing plate (4) is fastened, by fastening elements (7, 7'), to the axle flange (5) at tangential interfaces that have surfaces (5b, 5'b; 9, 9') lying perpendicular to the brake disk (2), and is designed such that the tangential interfaces have at least one interlocking connection between each backing plate flange (4a, 4'a) of the backing plate (4) and its respective connecting section (5a, 5'a) of the axle flange (5).