Utility Vehicle Disc Brake Guide Bushing Service
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Solution Overview
Problem
The existing disc brake systems are costly and inefficient in replacing wear parts, particularly slide bearings, as they require detaching the brake caliper from the brake carrier for guide bush removal, leading to increased effort and expense.
Innovation Solution
A disc brake design featuring a pocket-shaped tool holder on the brake caliper allows for the removal of the guide bushing without releasing the brake caliper from the carrier, with a radially outward collar forming an axial displacement limit and a contact ring for securing the sliding bush, enabling easy extraction and recycling of the guide bushing as a pre-assembled unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the guide bushing is held in the brake caliper bore by friction to ensure secure mounting, then the mounting reliability is improved, but the ease of repair deteriorates because the entire guide bushing must be removed by detaching the brake caliper from the brake carrier
Solution Approach 1:
The guide bushing is divided into two separate components: a bearing sleeve pressed into the brake caliper bore and a sliding bushing held within the bearing sleeve. This segmentation allows the sliding bushing to be replaced independently without removing the bearing sleeve or detaching the brake caliper, thus improving ease of repair while maintaining mounting reliability through the pressed-fit bearing sleeve.
Solution Approach 2:
The sliding bushing is extracted as a separate replaceable component from the guide bushing assembly. By taking out the wear-prone sliding bushing as an independent element that can be accessed and removed through the pocket-shaped tool receptacle, the design enables simple replacement without affecting the permanently mounted bearing sleeve or the brake caliper assembly.
2Manufacturing precision
If a stop ring is used to limit insertion of the guide bushing into the brake caliper bore, then the manufacturing precision is improved, but the device complexity increases due to additional components
Solution Approach 1:
The stop ring function is extracted from the guide bushing assembly and integrated directly into the bearing sleeve structure. The collar formed as part of the bearing sleeve provides the axial displacement limitation, eliminating the need for a separate stop ring component and reducing overall device complexity while maintaining precise insertion depth control.
Solution Approach 2:
The stopping function is merged with the bearing sleeve structure by forming a collar as an integral part of the bearing sleeve. This combination eliminates the need for a separate stop ring component, reducing the number of parts and simplifying the guide bushing assembly while still providing accurate axial positioning during assembly.
3Ease of repair
If the brake caliper is detached from the brake carrier to enable guide bushing removal, then the ease of repair is improved, but the loss of time increases due to additional assembly/disassembly operations
Solution Approach 1:
The guide bushing is segmented into a permanently mounted bearing sleeve and a removable sliding bushing. This segmentation enables the sliding bushing to be accessed and replaced independently through the pocket-shaped tool receptacle without requiring detachment of the brake caliper from the brake carrier, thus eliminating time loss while maintaining repairability.
Solution Approach 2:
The brake caliper is designed with a self-service feature in the form of a pocket-shaped tool receptacle that provides direct access to the sliding bushing. This allows the sliding bushing to be removed and replaced using simple extraction tools without requiring detachment of the brake caliper assembly, enabling quick maintenance operations that do not involve time-consuming assembly and disassembly of the entire brake system.
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 simplifies the replacement of wear parts, reduces manufacturing complexity, and standardizes caliper mounts, lowering logistical efforts and enabling easier service and type changes, while minimizing costs and maintaining structural integrity.
Implementation Method 1
the bearing sleeve, which is pressed into a bore of the brake caliper and thus held in place by friction
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
A disk brake for a utility vehicle, having a brake caliper (1) which engages over a brake disk and which, by way of two fastening elements in the form of slide bearings, is fastened, so as to be displaceable axially in relation to the brake disk, to a positionally static brake carrier, wherein at least one slide bearing has a guide bushing (3) which is held in the brake caliper (1) and which is composed of a bearing sleeve (6), of a stop ring arranged on said bearing sleeve at one end, and of a slide bushing (10) which is held in the bearing sleeve (6) so as to be secured against displacement, in which slide bushing a guide bar (4) which is connected to the brake carrier is guided in longitudinally displaceable fashion, is designed such that the stop ring is formed by a collar (7) which bears against the outer side of the brake caliper (1) and which is arranged, preferably integrally formed, on the bearing sleeve (6) so as to be directed radially outward, which collar has at least one projection (8) which, in correspondence with the brake caliper (1), forms a pocket-like tool receptacle (9).