Disc Brake Rotary Lever Support With Ball-Based Wear Compensation
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Solution Overview
Problem
Existing disc brake designs for commercial vehicles require complex manufacturing processes and numerous components, leading to high production costs and assembly challenges, particularly due to the need for precise fitting and functional components to absorb lateral forces.
Innovation Solution
A disc brake design that reduces the number of components by using a rotary lever with a convex section supported on a brake caliper via balls or plain bearings, eliminating the need for expensive rolling bearings and incorporating a threaded spindle arrangement with a rotatable screw and sleeve, along with a concave end face for wear compensation, and a driver device for gear reduction to minimize mechanical stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If rolling bearings (needle bearings) are used to support the rotary lever on the brake caliper, then the rotary lever can be reliably supported, but the manufacturing complexity and cost increase due to requiring bearing shells and precise fitting
Solution Approach 1:
The patent replaces expensive, complex rolling bearings with simple, inexpensive ball elements that can be easily replaced. The balls are held in recesses without requiring precision-machined bearing shells, dramatically simplifying the structure while maintaining functional reliability.
Solution Approach 2:
The ball support elements are designed to be self-contained within recesses in the brake caliper, eliminating the need for separate bearing shells or housings. The structure serves its own support function without requiring additional complex components.
2Manufacturing precision
If bearing blocks with troughs are molded onto the brake caliper to position the balls, then the balls can be properly positioned, but the manufacturing effort and cost increase due to requiring long, unstable tools through assembly openings
Solution Approach 1:
The patent integrates the ball-retaining recesses directly into the brake caliper body rather than using separate bearing blocks. This merging of functions eliminates the need for additional machining operations and tooling complexity while maintaining precise ball positioning.
3Ease of operation
If a convex eccentric section of the rotary lever rests on a bridge, then the rotary lever can be supported, but lateral forces act on the bridge requiring special design measures to absorb them
Solution Approach 1:
The patent uses a convexly curved support surface on the rotary lever that contacts a correspondingly curved recess in the brake caliper. This spherical contact geometry allows the rotary lever to be supported while accommodating lateral forces through the curved contact interface, eliminating the need for a separate bridge structure.
4Reliability
If multiple components (rolling rollers, bearing shells, intermediate pieces) are used in the clamping device, then the function can be achieved, but the number of components and assembly complexity increase
Solution Approach 1:
The patent combines multiple separate components (rotary lever, rolling rollers, bearing shells, intermediate pieces) into an integrated structure where the rotary lever is directly supported by balls in recesses within the brake caliper. This merging dramatically reduces the component count while maintaining all necessary functions.
Solution Approach 2:
The patent extracts and eliminates unnecessary intermediate components from the system. By using direct ball support in recesses, the design removes rolling rollers, bearing shells, and separate intermediate pieces, keeping only the essential elements needed for clamping function.
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 production and assembly, reduces costs, and enhances operational safety by minimizing lateral forces and mechanical stress, while allowing for easier adjustment and wear compensation.
Implementation Method 1
the rotary lever being arranged in the brake caliper in a pivotable manner relative to the latter and directly or via one or more intermediate elements is supported on the brake caliper in at least one support area
Implementation Method 2
a threaded spindle arrangement with a rotation axis (consisting of a rotationally movable screw and a threaded sleeve which is held against rotation in relation to this, the internal thread of which engages in an external thread of the screw)
Implementation Method 3
a driver device for gear reduction to minimize mechanical stress
Implementation Method 4
having on its side opposite the support point on the brake caliper at least one convex-shaped section which is in axial extension on a concave end face adapted thereto
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
The invention relates to a disc brake for a vehicle, particularly for a utility vehicle, comprising: - a brake caliper (1) which is designed to span across a brake disc (2) and in which an application device (8) is arranged; - a single-piece rotary lever (9) which comprises an eccentric element (16); and - at least one brake plunger (6) which is designed as a power screw arrangement (4) having a rotational axis (D) and with which, when said rotary lever (9) is actuated, at least one brake pad (3) can be pressed against the brake disc (2), - said rotary lever (9) being arranged in the brake caliper (1) such that it can pivot relative thereto, and being supported directly or by means of one or more elements connected therebetween, on said brake caliper (1), in at least one support region. The invention is designed such that - the rotary lever (9), which can pivot relative to the brake plunger (6), comprises at least one convexly-formed section (21) on the side thereof that lies opposite the support point on the brake caliper (1), and this section lies against a matching concave end face (23) in the axial extension of the rotational axis (D) of said power screw arrangement (4).