Disc Brake Connector Shield Using a Separate Protective Part
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Solution Overview
Problem
Existing disc brake designs face manufacturing difficulties due to the need to protect electrical connectors from shocks, which results in complex and costly casing designs, particularly when using bulky and heavy covers or complex molding processes.
Innovation Solution
A separate, easily manufacturable protective part is attached to the brake, extending from a threaded rod to cover the electrical connector, allowing for a simpler and lighter brake casing design, using components like sinuous metal strips or protection tubes that can be screwed or bolted onto the brake, providing effective coverage without complicating the molding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the electrical connector is protected by extending the connecting lug or adding protective structures, then the protection against impacts is improved, but the manufacturing complexity and difficulty of the caliper casing increases
Solution Approach 1:
The protective structure is separated from the caliper casing into an independent component (protective part) that can be manufactured separately and then assembled. This segmentation allows the casing to be produced by simple molding without complex extensions, while the protective part provides the necessary protection against impacts to the electrical connector.
Solution Approach 2:
The protective function is extracted from the caliper casing structure and implemented as a separate protective part. This extraction eliminates the need for complex molding operations on the casing itself, allowing it to be manufactured by standard molding processes, while the protective part is specifically designed to shield the electrical connector from impacts.
2Reliability
If bulky covers are used to protect the electrical connector, then the protection is improved, but the weight and device complexity increase
Solution Approach 1:
Instead of using bulky covers that protect the entire assembly, the protective part is designed to provide localized protection only where the electrical connector is vulnerable to impacts. This localized approach reduces the amount of material needed and minimizes weight increase while maintaining effective protection against stones, gravel, and other impacting objects.
3Reliability
If complex molding processes are used to integrate protection into the casing, then the protection is improved, but the manufacturing cost and complexity increase
Solution Approach 1:
The protective function is segmented from the caliper casing and implemented as a separate protective part. This allows the casing to be manufactured by standard, simple molding processes without requiring complex extensions or integrated protective features, thereby reducing manufacturing cost and device complexity while maintaining protection effectiveness.
Data Source
Figure 1~2
Figure 3
AI summary
A gear motor (2) equipping a disc brake comprises an electrical connector (11) protruding out of the housing (3) and vulnerable to impacts or flying objects such as stones, mud or blocks of ice thrown up by the wheel. A rigid protection structure (17) is constructed separately from the brake casing and extends in front of the connector (11) in relation to possible paths of the dangerous objects. This structure (17) is assembled to an extension (16) of a rod (15) of one of the brake guide pins (7), connecting a clevis (5) to a calliper (1). It is no longer necessary to construct the casing with ribs that would complicate its manufacture.