Compact Disc Brake Caliper With Integrated Rotary Lever
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Solution Overview
Problem
Conventional disc brakes have a high number of parts and sealing surfaces, which increases weight and cost, while compromising performance and space efficiency, particularly in commercial vehicles where weight reduction and cost optimization are critical.
Innovation Solution
A compact disc brake design with a reduced number of parts and sealing surfaces is achieved by integrating the brake caliper and rotary brake lever into a single, space-saving structure, utilizing two spindle units with threaded rods and a sloping support wall to enhance force introduction and stability, and incorporating a curved, slender rotary brake lever for efficient force transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional disc brake design with multiple housings is used, then reliable braking function is achieved, but the number of parts and sealing surfaces increases, leading to increased weight and cost
Solution Approach 1:
The brake caliper is designed as a single-integral component that combines the functions of multiple housings into one piece. This merging eliminates the need for separate housing components and their associated sealing surfaces, thereby reducing the total number of parts while maintaining the reliable braking function through the integrated structure
2Reliability
If conventional disc brake design with multiple housings is used, then reliable braking function is achieved, but the number of sealing surfaces increases, leading to increased weight and cost
Solution Approach 1:
By merging multiple housing functions into a single-integral brake caliper, the number of sealing surfaces is dramatically reduced. The integrated design eliminates the need for seals between multiple housing components, thereby reducing sealing surface requirements while preserving braking reliability
3Reliability
If conventional disc brake design is used, then adequate braking performance is achieved, but the space required around the axle increases
Solution Approach 1:
The brake pads are arranged in a staggered configuration where they are offset from each other in the axial direction. This dimensional arrangement allows the brake caliper to apply braking force effectively while requiring less radial clearance around the axle, as the staggered positioning optimizes the space utilization within the available area
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 number of parts and sealing surfaces, allowing for a larger clearance around the axle, improved force introduction, and enhanced stability, while maintaining or improving performance and facilitating easier assembly and adjustment.
Implementation Method 1
amplified by an eccentric mechanism and applied as an application force via threaded tubes, which are also threaded stamps, threaded spindles, threaded rods
Implementation Method 2
amplified by an eccentric mechanism and applied as an application force
Implementation Method 3
The brake lining on the application side of the brake disc is called the application-side brake lining... As soon as this is in contact with the brake disc, the resulting counterforce moves the brake caliper
Data Source
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AI summary
The invention relates to a disc brake (1), preferably a compressed air-actuated disc brake, in particular for a motor vehicle, having a brake application mechanism with a brake rotary lever (11), at least one spindle unit, each of which comprises a threaded rod screwed into a bridge, and a brake caliper (6), in particular a sliding caliper, which preferably covers an edge region of a brake disc (2) in the manner of a frame, said brake caliper (6) comprising a brake application portion (6a) and a caliper back (6b) which are connected together via tie bars. The brake application mechanism with the brake rotary lever (11) is received on an application face (ZS) of the brake disc (2) in the brake application portion (6a) of the brake caliper (6), and the brake application portion (6a) of the brake caliper (6) receives a first region, in which the application mechanism and a force transmission portion of the brake rotary lever (11) are arranged, a second region, which is formed as a lever housing (6e), and a lever portion of the brake rotary lever (11). A support wall (62) with a bearing portion (66), which forms a pivot bearing with a brake rotary lever axis that runs parallel to the brake disc (2), for the brake rotary lever (11) is arranged between the first region and the second region.