Commercial Vehicle Disc Brake Centering for Tight-Space Disassembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing disc brakes for commercial vehicles require significant space for disassembly due to the need to pull the brake cylinder away from the caliper, and alignment during assembly is difficult due to the weight of the caliper.
Innovation Solution
A disc brake design with a fastening device using screws and bores, combined with a centering device, allows for detachable attachment of the brake caliper to the brake cylinder without requiring additional space for disassembly and simplifies alignment by centering the components before screwing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If the brake cylinder is detached by pulling it away from the brake caliper in the direction of the bolts, then the bolts can be pulled out of the screw eyes, but a large amount of space within the wheel housing is required which is often not available
Solution Approach 1:
The patent inverts the traditional fastening approach: instead of protruding bolts on the brake caliper that require pulling the brake cylinder away, the brake caliper is provided with bores into which screws are screwed. The screw heads are countered on the brake caliper surface, allowing the brake cylinder to be detached by simply unscreving the screws without requiring additional pulling space.
Solution Approach 2:
The patent extracts the fastening function from the brake caliper's external protruding bolts and relocates it to internal bores with screwed-in fastening elements. This extraction allows the brake cylinder to be detached without requiring the space previously needed for bolt removal.
2Strength
If the brake caliper is provided with protruding bolts for fastening the brake cylinder, then the brake cylinder can be securely attached, but the brake cylinder must be pulled away significantly during disassembly
Solution Approach 1:
The patent inverts the fastening mechanism from external protruding bolts to internal screwed bores with countered screw heads. This inversion maintains secure attachment during operation while enabling easy disassembly by simply unscreving the fastening elements without requiring significant pulling motion.
Solution Approach 2:
The patent segments the fastening function into separate screwed-in fastening elements that can be independently removed. This segmentation allows the brake cylinder to be detached in a controlled manner by removing individual screws rather than requiring forceful pulling against the entire bolt structure.
3Strength
If the brake caliper is heavy (8-9 kg), then it provides sufficient structural strength, but aligning the brake cylinder with the brake caliper during mounting becomes difficult
Solution Approach 1:
The patent introduces a centering device that performs preliminary alignment of the brake cylinder with the brake caliper before the actual fastening process. This preliminary centering action simplifies the subsequent screwing operation by ensuring proper alignment is already established, making assembly easier despite the heavy weight of the brake caliper.
Solution Approach 2:
The centering device acts as an intermediary tool between the brake cylinder and brake caliper during assembly. It facilitates the alignment process by providing a guiding mechanism that enables precise positioning of the heavy brake caliper relative to the brake cylinder before the fastening screws are installed.
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The invention relates to a disc brake (1) for a commercial vehicle with a pneumatic brake cylinder (4), a brake disc, a brake caliper (3), a brake application device (7) and with brake pads (8), wherein the brake caliper (3) engages over the brake disc and the brake application device (7), which can be actuated by the brake cylinder (4), is arranged in the brake caliper (3), by means of which the brake linings (8) can be pressed against the brake disc on both sides during braking, wherein an extendable and retractable piston rod (6) of the brake cylinder (4) is in engagement with the brake application device (7) and the brake caliper (3) is detachably fastened to the brake cylinder (4) by means of a fastening device (2), wherein the fastening device (2) comprises at least one screw (11a, 11b) with a screw head (12a, 12b), a screw shank (13a, 13b) and an external thread formed on the screw shank (13a, 13b) and at least one bore (14a, 14b) with an internal thread formed in or on the brake cylinder (4) with an internal thread, into which the screw shank (13a, 13b) is screwed with the external thread, wherein the screw head (12a, 12b) is locked on a counter surface (15a, 15b) of the brake caliper (3). According to the invention, a centering device is designed and provided to center the pneumatic brake cylinder (4) and the brake caliper (3) against each other independently of the screw connection of the at least one screw (13a, 13b) with the at least one bore (14a, 14b).