Disc Brake Caliper Back Alignment for Uniform Pad Wear
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Solution Overview
Problem
Disc brakes experience uneven wear of brake pads due to unfavorable leverage and design issues, leading to increased clearance and reduced braking performance as the pads wear down over time.
Innovation Solution
The design features a brake caliper with projections and recesses on the caliper back and brake pad carrier, respectively, arranged coaxially with the threaded tube units, which reduces uneven wear by ensuring proper alignment and force distribution, and includes a compact adjustment device within the threaded tube to maintain optimal clearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the rear brake pad rests against a milled surface on the back of the brake caliper, then the brake pad can be easily manufactured and installed, but uneven wear of the brake pads occurs due to unfavorable leverage
Solution Approach 1:
The contact surface carrier is pre-positioned on the brake caliper back with precisely defined contact surfaces before brake pad installation. This preliminary positioning ensures that the brake pad receives forces along its central axis from the start, preventing uneven wear during operation.
Solution Approach 2:
A contact surface carrier is introduced as an intermediary element between the brake caliper back and the brake pad. This carrier has precisely machined contact surfaces that ensure proper force distribution and alignment, mediating the interaction to eliminate unfavorable leverage effects.
2Device complexity
If the brake pad carrier is simplified without contact surface carrier, then the device complexity is reduced, but uneven wear and increased clearance occur
Solution Approach 1:
The contact surface carrier performs multiple functions: it provides precise contact surfaces for force distribution, ensures proper alignment of the brake pad with the threaded tube units, and maintains stable brake clearance. By consolidating these functions in one component, the overall device complexity is not significantly increased while reliability is improved.
3Device complexity
If the contact surfaces are not aligned with the threaded tube units, then the brake caliper design is simpler, but uneven wear increases due to adverse leverage effect
Solution Approach 1:
The contact surfaces on the contact surface carrier are asymmetrically positioned relative to the brake caliper back, but symmetrically aligned with the threaded tube units. This asymmetric yet aligned configuration ensures that forces are transmitted centrally through the brake pad without creating adverse leverage effects, while maintaining design simplicity.
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 configuration significantly reduces uneven wear of the brake pads, maintains optimal clearance, and enhances braking performance by ensuring consistent force application and alignment, leading to improved disc brake functionality and longevity.
Implementation Method 1
friction brakes to convert kinetic energy
Implementation Method 2
Forces are amplified by an eccentric mechanism and transmitted as clamping force via threaded rods
Implementation Method 3
projections and recesses on the caliper back and brake pad carrier, respectively, arranged coaxially with the threaded tube units, which reduces uneven wear by ensuring proper alignment and force distribution
Data Source
Figure 1
Figure 1a
Figure 2
AI summary
A disk brake, preferably pneumatically actuated, in particular for a motor vehicle, having a brake disk with a brake disk axis, a brake caliper, in particular a sliding caliper, with a brake application section (9) and a caliper back which are connected via tie bars (11, 12), at least two brake pads with in each case one brake pad carrier, wherein, of the brake pads, an application-side brake pad is assigned to the brake application section (9) and a back-side brake pad is assigned to the caliper back, wherein the brake pad carrier of the back-side brake pad and the caliper back of the brake caliper are in contact via at least one pair of bearing surfaces. One bearing surface of the at least one pair of bearing surfaces is an end surface of a projection (30, 32), and the other bearing surface of the at least one pair of bearing surfaces is a bottom surface of a recess; and a brake pad set.