Disc Brake Central Adjustment Element
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Solution Overview
Problem
Existing disc brake designs require numerous complex components, leading to high manufacturing and assembly costs, increased susceptibility to failure, and significant installation space, which hinders weight reduction and reliability.
Innovation Solution
A simplified disc brake design eliminates the need for synchronizing devices by using a centrally arranged adjustment element with guide rails, replacing adjusting spindles, and integrating the adjustment mechanism within a modular structure, allowing for easier production and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adjusting spindles are arranged on both sides of the brake lever with synchronous adjustment devices, then clearance compensation is achieved, but the number of components and structural complexity increase
Solution Approach 1:
The patent merges the two adjusting spindles into a single central adjusting element. This central element performs the clearance compensation function that previously required two separate spindles working in synchronization, thereby reducing the number of components while maintaining the reliability of clearance compensation.
Solution Approach 2:
The single central adjusting element serves multiple functions: it compensates for clearance, provides lateral guidance through integrated guide rails, and eliminates the need for separate synchronous adjustment devices. This multi-functional design reduces overall device complexity while maintaining adjustment effectiveness.
2Reliability
If synchronizing devices are used for adjusting spindles, then clearance is kept constant, but installation space increases
Solution Approach 1:
The synchronizing devices are merged into the single central adjusting element. The guide rails are integrated with the adjusting element structure, eliminating the need for separate synchronizing mechanisms and thereby reducing the installation space while maintaining constant clearance compensation.
Solution Approach 2:
The guide rails are nested within or integrated with the central adjusting element structure. This nesting approach allows the guidance function to be incorporated into the existing adjusting mechanism without requiring additional external space for separate guide structures.
3Ease of operation
If multiple adjusting spindles and synchronizing devices are used, then adjustment is achieved, but manufacturing and assembly costs increase
Solution Approach 1:
Multiple adjusting spindles and synchronizing devices are merged into a single central adjusting element with integrated guide rails. This consolidation reduces the number of parts that need to be manufactured and assembled, thereby lowering production costs while maintaining the adjustment function.
Solution Approach 2:
The adjusting element is designed as a modular component that can be manufactured separately and then installed as a single unit. This segmentation of the overall brake system into manageable modules simplifies manufacturing processes and reduces assembly complexity, leading to cost savings.
4Ease of operation
If a large number of components are used, then adjustment functionality is achieved, but susceptibility to failure increases
Solution Approach 1:
Multiple separate components are merged into a single integrated central adjusting element. This reduction in the number of components directly decreases the number of potential failure points, thereby improving system reliability while maintaining the clearance adjustment functionality.
Solution Approach 2:
The patent extracts and eliminates unnecessary components from the traditional adjusting mechanism. By removing redundant adjusting spindles and synchronizing devices, the design reduces the overall component count and minimizes the susceptibility to failure while preserving the essential adjustment 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
This design reduces production complexity, minimizes installation space, and enhances service life by eliminating the need for multiple components, enabling cost-effective manufacturing and modular maintenance.
Implementation Method 1
a compression spring (11), which serves to reset the system when braking is released
Implementation Method 2
an adjustment element (10), which is screwed into a threaded bore (14) of the bridge plate (5)
Implementation Method 3
two parallel and spaced-apart guide rails (9) which are displaceably mounted in the bridge plate (5)
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A disc brake with a clamping device arranged on a brake caliper, comprising a brake lever (1) supported on a bridge (4) for pressing a brake pad against a brake disc, and an adjusting device actuated by the brake lever (1) with which a wear-related change in the clearance between the brake pad and the brake disc can be substantially compensated, is designed such that the bridge (4) has a bridge plate (5) against which the brake lever (1) rests, and a pressure plate (6) corresponding with the brake pad, wherein an adjusting element (10) of the adjusting device, which is connected to the bridge plate (5) and the pressure plate (6), allows the pressure plate (6) to be moved in the clamping direction relative to the bridge plate (5) in accordance with the clearance compensation.