Disc Brake Clearance Adjustment With Dual Cylinder Units
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current disc brake adjustment systems, particularly in pneumatically actuated disc brakes, struggle to accurately correct clearances that are too small, leading to impaired operating behavior such as increased residual grinding torque and brake overheating, as existing mechanical wear adjusters can only compensate for excessive clearance and require complex adjustments.
Innovation Solution
A disc brake with a dual-directional adjustment device featuring two cylinder units, allowing for independent operation with a pressure medium, where the first cylinder unit sets the nominal clearance and the second unit adjusts clearances in both directions, enabling rapid correction of both excessive and insufficient clearances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a mechanical wear adjuster with single direction of action is used, then excessive clearance can be compensated, but clearance that is too small cannot be corrected
Solution Approach 1:
The invention applies reverse action principle by providing adjustment devices that can move in both directions: one adjustment device pushes the brake lining toward the brake disc to reduce excessive clearance, while another adjustment device pulls the brake lining away from the brake disc to increase insufficient clearance. This bidirectional adjustment capability resolves the limitation of single-direction mechanical adjusters and enables correction of both excessive and insufficient clearance conditions.
2Productivity
If a decoupled adjuster with single-stage mode of operation is used, then clearance deviation can be compensated by a single adjustment step, but the system requires its own actuator and energy supply
Solution Approach 1:
The invention integrates the adjustment function into the existing brake actuation system. The same actuator that applies the brake also activates the adjustment devices through a coupling mechanism. When the brake is applied, the adjustment devices are activated to correct clearance deviations. This multi-functional design eliminates the need for separate actuators and energy supply systems, reducing device complexity while maintaining single-stage adjustment capability.
3Ease of operation
If an adjuster activated during brake actuation with asymptotic mode of operation is used, then adjustment path depends on clearance deviation size, but clearance correction in a single step is not possible
Solution Approach 1:
The invention employs a dynamic adjustment mechanism where the adjustment path is determined by the actual clearance deviation measured during brake actuation. The adjustment devices are designed to traverse the full range of required adjustment in a single brake actuation cycle, regardless of the deviation magnitude. This dynamic response enables both automatic operation and single-step correction by adapting the adjustment path to the specific clearance condition while completing the correction in one action.
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
The solution allows for immediate and precise correction of clearance deviations, ensuring safe operation by enabling correction of both excessive and insufficient clearances in a single step, reducing the influence of thread play tolerance and allowing for selective adjustment of brake calipers, thus enhancing brake performance and reliability.
Implementation Method 1
A disc brake with an adjustment device with at least one adjustment device (7, 7') for adjusting friction surface wear on the brake pads (3, 3') and brake disc (2), said adjustment device (7, 7') being operable with a pressure medium independently of the application device (ZV)
Implementation Method 2
The cylinder forces are applied to the internal mechanics via a pneumatically actuated cylinder, amplified by an eccentric mechanism and transmitted as a clamping force, e.g. via threaded spindles, to the brake pads and brake disc
Implementation Method 3
friction brakes to convert kinetic energy. The disc brake is preferred here
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to a disc brake (1), preferably a pneumatic disc brake, in particular for a motor vehicle, comprising a brake disc (2), a brake caliper (6) engaging over the brake disc (2), in which a tensioning device (ZV) is arranged, wherein a respective brake pad (3, 3') is provided on both sides of the brake disc (2), and an adjuster device having at least one adjuster unit (7, 7') for adjusting a friction surface wearing at the brake pads (3, 3') and brake disc (2), wherein the at least one adjuster unit (7, 7') can be operated with a pressure medium independently of the tensioning device (ZV). The at least one adjuster unit (7, 7') is designed with a first cylinder unit (ZE1) having a first pressure piston, and with a second cylinder unit (ZE2) having a second pressure piston, wherein the second pressure piston of the second cylinder unit (ZE2) has a piston (16) that is in contact with the brake pad (3, 3'), and an adjuster piston (18) that is arranged on the piston (16). The invention also relates to a method for adjusting a clearance of a disc brake (1).