Sliding Caliper Disc Brake Lever Layout for Compact EV Packaging
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Solution Overview
Problem
Disc brakes in electrically powered vehicles face design compromises due to limited space and lower engagement forces, necessitating a redesign for optimized and compact design.
Innovation Solution
A disc brake design with a specific transmission ratio of 1:15.60-1:16.45, a longer brake lever, and a pivot angle of less than 90°, allowing for reduced component size and increased installation space for batteries, while maintaining effective engagement force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If the brake lever length is increased to achieve a higher transmission ratio, then the actuating element size can be reduced, but the brake caliper mounting space requirement increases
Solution Approach 1:
The patent repositions the engagement axis closer to the axis of rotation of the brake disc, utilizing the radial dimension more effectively. This dimensional reconfiguration allows for a longer brake lever arm without proportionally increasing the axial mounting space requirement, thereby achieving a higher transmission ratio (1:15.60-1:16.45) while maintaining compact caliper dimensions suitable for electric vehicle applications.
2Reliability
If the pivot angle of the brake lever is reduced to less than 90°, then progressive lines of force are eliminated improving ABS performance, but the engagement force transmission efficiency decreases
Solution Approach 1:
The patent optimizes the pivot angle parameter to be less than 90° (specifically around 45-60° in embodiments), which eliminates progressive lines of force and improves ABS system performance. To compensate for the reduced angular range, the patent simultaneously increases the brake lever length and adjusts the engagement axis position, maintaining the required engagement force transmission through the optimized transmission ratio of 1:15.60-1:16.45.
3Volume of moving object
If the brake cylinder size is reduced to save installation space, then batteries can be enlarged, but the actuating force available for braking is reduced
Solution Approach 1:
The patent replaces the need for a large-volume brake cylinder with a mechanically optimized lever system. By positioning the engagement axis closer to the brake disc rotation axis and increasing the brake lever length, the system achieves a higher mechanical transmission ratio (1:15.60-1:16.45). This mechanical substitution allows a smaller brake cylinder to generate sufficient actuating force, freeing up installation space for enlarged batteries in electric vehicles.
4Stability of the object's composition
If the caliper struts are thickened to improve caliper stability, then mechanical rigidity increases, but the radial space requirement increases
Solution Approach 1:
The patent employs asymmetric design in the caliper strut configuration, optimizing the distribution of material and structural support. Rather than uniformly thickening all struts, the design strategically places reinforcement where needed based on the altered force distribution from the repositioned engagement axis. This asymmetric approach improves caliper stability and rigidity while minimizing the overall radial thickness requirement.
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 redesigned disc brake achieves a compact and stable design, reducing progressive force lines and enhancing ABS system performance, with improved mechanical rigidity and reduced spatial requirements.
Implementation Method 1
The length of the brake lever is selected such that the transmission ratio between the actuating force and the engagement force is between 1:15.60-1:16.45
Implementation Method 2
The engagement device has a rolling bearing for pivotably mounting the brake lever
Implementation Method 3
The brake lever can have a spherical cap for receiving an actuating piston of the actuating element
Implementation Method 4
a set of brake pads for clamping the brake disc
Data Source
AI summary
A disc brake for a motor vehicle and/or bus with an electric generator brake includes a brake disc with an axis of rotation and a set of brake pads for engaging the brake disc. The disc brake has a brake caliper designed as a sliding caliper. The disc brake has an engagement device for actuating the brake pads, which is arranged in a mounting space of a brake caliper. The disc brake also has an actuating element for introducing force into the engagement device with an actuating force. The engagement device has a brake lever on which the actuating element acts with the actuating force, wherein the engagement device acts on the brake pads with an engagement force along an engagement axis. The length of the brake lever is selected such that the transmission ratio between actuating force and engagement force is between 1:15.60-1:16.45, preferably with a bridge stroke of 2.5-4 mm.