Disc Brake Pivot Bearing Clamping Cap for Secure Assembly
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Solution Overview
Problem
Existing vehicle disc brake assembly methods are prone to component misalignment and separation during assembly, installation, and transportation, leading to potential malfunction and increased safety risks due to the lack of secure attachment of the pivot bearing to the thrust piece.
Innovation Solution
A clamping cap with a pin engages a corresponding recess on the mounting element, providing a positive connection that secures the pivot bearing to the thrust piece, ensuring accurate alignment and preventing separation during assembly and transport, thereby simplifying the assembly process and reducing the risk of damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a non-positive connection (e.g., hook engaging bore) is used to attach the pivot bearing to the thrust piece, then the assembly process is simple, but the bearing may accidentally separate during assembly, installation, and transportation
Solution Approach 1:
The connection system is divided into two distinct parts: a mounting element with a hook that engages the bore, and a separate clamping cap that secures the mounting element. This segmentation allows the bearing to be easily attached initially while providing a separate mechanism to secure it against separation during handling and transportation.
Solution Approach 2:
The mounting element (hook) is inserted into the bore of the thrust piece, and then the clamping cap is placed over the mounting element, creating a nested structure. The clamping cap acts as an outer shell that contains and secures the inner mounting element, preventing it from disengaging while maintaining assembly simplicity.
2Reliability
If extensive safety measures and repeated inspections are implemented to prevent component separation, then connection security is improved, but assembly time and production costs increase
Solution Approach 1:
The clamping cap is designed to be installed as part of the initial assembly process, securing the mounting element before the brake assembly undergoes handling, installation, or transportation. This preliminary securing action eliminates the need for repeated inspections and safety measures during subsequent operations, reducing time loss while maintaining connection security.
3Reliability
If the pivot bearing is securely attached to prevent separation, then connection security is improved, but the device complexity increases
Solution Approach 1:
The clamping cap is designed as a simple, inexpensive component that provides effective security without adding significant complexity. It functions as a dedicated securing element that can be easily manufactured and installed, providing reliable connection security while maintaining overall device simplicity through its straightforward design and function.
Data Source
Figure 1
Figure 2
Figure 3~4b
AI summary
A vehicle brake, in particular an air disc brake of a commercial vehicle comprising a thrust piece (100), a brake cylinder, and a pivot lever operatively coupled to the brake cylinder, wherein the lever is pivotally supported against the thrust piece (100) by means of at least one pivot bearing (400), wherein the thrust piece (100) has at least one mounting interface (120), and the pivot bearing (400) has at least one mounting element (410) configured to be mounted to the mounting interface (120) of the thrust piece (100), wherein the mounting element (410) is coupled to a clamping cap (500), and the clamping cap (500) is configured to be engaged with the mounting interface (120), said clamping cap (500) is configured to secure the mounting element (410) to the thrust piece (100) in a positive connection.