Disc Brake Adjuster With Overload Protection for Manual Rewind
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Solution Overview
Problem
Conventional disc brake adjuster mechanisms are prone to damage from excessive manual torque, leading to operational failures and the need for frequent component replacement.
Innovation Solution
An adjuster system with a manual rewind apparatus and an overload device, where the overload device is an elastically deformable member that interrupts the driving engagement when excessive torque is applied, preventing damage and allowing for reuse without replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a manual rewind apparatus is provided in conventional adjuster mechanisms, then the brake pads can be removed and replaced, but excessive manual torque can cause damage to internal components
Solution Approach 1:
The patent incorporates a torque-limiting mechanism beforehand in the adjuster system that prevents excessive torque from reaching the internal components. This cushioning mechanism allows manual rewind operation while protecting against damage, resolving the contradiction between ease of operation and reliability.
Solution Approach 2:
The patent introduces a torque-limiting intermediary element between the manual rewind apparatus and the adjuster mechanism. This intermediary component transmits necessary torque for brake pad replacement but blocks excessive torque, thereby protecting the internal components while maintaining operational ease.
2Reliability
If a shearable element is provided to prevent excessive torque damage, then the adjuster mechanism is protected, but the element must be replaced after deformation
Solution Approach 1:
The patent changes the parameter of the torque-limiting element from a permanent deformation type to a resettable type. The element can be manually reset to its original position after limiting torque, eliminating the need for replacement and improving ease of repair while maintaining reliability.
Solution Approach 2:
The torque-limiting element is designed to automatically reset itself after limiting excessive torque, without requiring external intervention or replacement. This self-service capability resolves the contradiction by maintaining protection functionality while eliminating repair complexity.
3Reliability
If a separate tool is provided to fail at excessive torque, then the adjuster shaft is protected, but the tool needs to be replaced after failure
Solution Approach 1:
The patent merges the torque-limiting function with the existing adjuster mechanism components, eliminating the need for a separate tool. The torque-limiting capability is integrated into the adjuster system itself, reducing device complexity while maintaining shaft protection.
Solution Approach 2:
The patent makes the adjuster mechanism components multi-functional, serving both the adjustment function and the torque-limiting function. This universality eliminates the need for separate protective tools, resolving the contradiction between reliability and device complexity.
4Length of moving object
If the overload device is arranged radially intermediate the manual rewind apparatus and the rotatable portion, then the longitudinal length is reduced, but the manufacturing complexity increases
Solution Approach 1:
The patent transitions the torque-limiting mechanism from a longitudinal arrangement to a radial arrangement. By placing the overload device radially intermediate components, the longitudinal length is reduced while the radial space is utilized, resolving the contradiction between length and manufacturing complexity.
Solution Approach 2:
The patent employs a flexible, elastically deformable member as the overload device. This flexible component can be easily manufactured in a radial configuration and provides the necessary torque-limiting function without complex assembly, resolving the manufacturing complexity concern.
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 solution effectively prevents damage to the adjuster system during manual rewind operations, reduces the size and manufacturing complexity of the system, and eliminates the need for consumable torque-limiting components, ensuring reliable and cost-effective operation.
Implementation Method 1
the overload device is an elastically deformable member that interrupts the driving engagement when excessive torque is applied
Data Source
Figure 1
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AI summary
An adjuster system for a disc brake, the adjuster system comprising: a piston for applying an actuating force to a brake pad, the piston having a rotatable portion to adjust the running clearance between a brake disc and the brake pad; a manual rewind apparatus located within the piston and being in driving engagement with the piston such that when a torque is applied to the manual rewind apparatus, torque is transmitted to the piston; and a overload device arranged between the manual rewind apparatus and the piston, wherein the overload device is configured to interrupt the driving engagement between the manual rewind apparatus and the piston when the torque applied is above a predetermined value.