Electromechanical Disc Brake Guide Plate Force Redirection
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Solution Overview
Problem
Disc brakes in commercial vehicles face excessive wear on sensitive components due to high circumferential forces, particularly in sliding caliper designs where these forces are directly transmitted through the sliding guide to the axle-mounted brake carrier, leading to unnecessary stress on adjustment devices and guides.
Innovation Solution
The self-reinforcing disc brake design positions the stationary component of the self-boosting device parallel to the brake disc's axis of rotation, diverting circumferential forces directly to the axle-fixed brake carrier, thereby relieving sensitive components like the sliding caliper and wear adjustment system from these forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If circumferential forces are transmitted through the sliding guide to the brake carrier, then the brake can be actuated, but sensitive components experience excessive wear and must be oversized
Solution Approach 1:
The brake system is divided into functionally separate components: the guide plate handles circumferential force transmission independently, while the adjustment device focuses solely on wear compensation. This segmentation allows each component to be optimized for its specific function, reducing unnecessary loads on sensitive parts.
Solution Approach 2:
The guide plate acts as an intermediary component between the brake lining and the adjustment device. It receives circumferential forces from the brake lining and transmits them directly to the brake carrier, preventing these forces from being transmitted through the adjustment device and sliding guide.
2Device complexity
If the brake lining is supported directly on the brake carrier, then the structure is simple, but circumferential forces cause excessive wear on the brake carrier and sliding guide
Solution Approach 1:
The guide plate serves as a mediator that intercepts circumferential forces before they can reach the brake carrier and sliding guide. This intermediary component protects the original structural elements from excessive wear while maintaining the overall simplicity of the brake design.
Solution Approach 2:
The circumferential force transmission function is extracted from the brake carrier and sliding guide system and assigned to a dedicated guide plate component. This extraction allows the original components to focus on their primary functions without being overloaded by circumferential forces.
3Strength
If adjustment devices are oversized to handle circumferential forces, then component strength is sufficient, but the device becomes more complex and less efficient
Solution Approach 1:
The load-bearing functions are segmented: the guide plate handles circumferential forces while the adjustment device handles only axial wear compensation forces. This segmentation allows the adjustment device to be sized appropriately for its actual load requirements rather than being oversized to handle all forces.
Solution Approach 2:
The guide plate acts as a protective intermediary that shields the adjustment device from circumferential forces. This allows the adjustment device to be designed with optimal dimensions for wear compensation without requiring excessive strength margins.
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 the load on sensitive components and enhances the durability of the brake system by redirecting circumferential forces away from the sliding caliper and adjustment devices, particularly beneficial in sliding caliper brakes, where the brake lining is supported by pressure stamps rather than the brake carrier.
Implementation Method 1
The frictional force acting on the brake pad is transferred from a part of the self-boosting device connected to the brake pad and movable with it in the circumferential direction to a part of the self-boosting device that is stationary in the circumferential direction via rolling bodies or by means of sliding contact.
Implementation Method 2
the circumferential forces acting on the brake lining are supported by a wedge or ramp system, which causes self-reinforcement
Implementation Method 3
The frictional force acting on the brake pad
Data Source
Figure 1
Figure 2
AI summary
A self-boosting electromechanically actuable disc brake is characterized in that a component (pressure piston 9, 10), which is stationary during braking and which is connected to an adjusting device or is part of said adjusting device, of the self-boosting device is held, with slight play parallel to the brake disc rotational axis, between guide faces (29, 30) of that component (31) of the brake which is fixed with respect to the axle, in such a way that, during braking operations, the tangential forces which occur are supported directly by the stationary component of the self-boosting device on that component (31) of the brake which is fixed with respect to the axle.