Commercial Disc Brake Centering for Easier Cylinder Removal
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing disc brake systems for commercial vehicles require significant space for disassembly and are cumbersome due to the need to pull the brake cylinder away from the caliper, making mounting and dismounting difficult, especially with heavy brake cylinders.
Innovation Solution
A disc brake system with a centering device that aligns the brake cylinder and caliper independently of the screw connection, allowing for easier assembly and disassembly by using a fastening device with screws and internal/external threads, and a centering mechanism to prevent relative movement between the brake cylinder and caliper.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If the brake cylinder is detached from the brake caliper by pulling it away in the direction of the bolts, then the bolts can be removed from the screw eyes, but a large amount of space within the wheel housing is required and disassembly takes a relatively long time
Solution Approach 1:
The patent inverts the traditional fastening approach: instead of protruding bolts that require pulling the brake cylinder away, the solution uses recessed screw eyes in the brake caliper that receive screws from the brake cylinder. This inversion allows the brake cylinder to be detached by simply moving it perpendicular to the screw axes, eliminating the need for large pulling space and reducing disassembly time.
2Weight of moving object
If the brake cylinder is heavy (8-9 kg), then it provides sufficient braking force, but aligning the brake cylinder with the brake caliper during mounting becomes difficult
Solution Approach 1:
The patent introduces a centering device as an intermediary element between the brake cylinder and brake caliper. This centering device, which may include centering pins or guide elements, facilitates the alignment of the heavy brake cylinder with the caliper during mounting by providing precise positioning references, thereby easing the mounting operation despite the brake cylinder's weight.
3Ease of repair
If the brake caliper is detachably fastened to the brake cylinder with screws, then the brake cylinder can be removed without pulling it away fully, but the screw connection requires precise alignment of screw eyes with holes
Solution Approach 1:
The patent applies preliminary action through the centering device that is installed before the screw connection. The centering device pre-aligns the brake cylinder with the brake caliper, ensuring that the screw eyes and corresponding holes are properly positioned relative to each other before the actual screwing operation begins, thereby reducing the alignment precision requirements during assembly.
Data Source
AI summary
A disc brake for a commercial vehicle has a pneumatic brake cylinder, a brake disc, a brake caliper, a brake application device and brake pads. The brake caliper engages over the brake disc. The brake application device, which can be actuated by the brake cylinder, is arranged in the brake caliper, by which the brake pads can be pressed against the brake disc on both sides during braking. An extendable and retractable piston rod of the brake cylinder is in engagement with the brake application device, and the brake caliper is detachably fastened to the brake cylinder by means of a fastening device. The fastening device includes at least one screw with a screw head, a screw shank and an external thread formed on the screw shank and at least one bore with an internal thread formed in or on the brake cylinder, with an internal thread, into which the screw shank is screwed with the external thread, wherein the screw head is locked on a counter surface of the brake caliper. A centering device is designed and provided to center the pneumatic brake cylinder and the brake caliper against each other independently of the screw connection of the at least one screw with the at least one bore.