Electrically Actuated Disc Brake Caliper for Even Pad Clearance
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Solution Overview
Problem
Existing disc brake systems for heavy commercial vehicles suffer from unwanted contact between brake pads and the rotor, leading to unnecessary wear, drag, and reduced efficiency, due to inadequate retraction mechanisms and differential wear rates.
Innovation Solution
A disc brake assembly with an electrically operated actuating arrangement that moves the brake caliper outboard relative to the brake carrier upon release of the disc brake, ensuring even running clearance and minimizing drag by optimizing the distance between brake pads and the rotor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the brake caliper is held in a fixed position relative to the brake carrier, then the brake pads can be easily positioned, but the brake pads cannot achieve even running clearance due to differential wear rates
Solution Approach 1:
The brake caliper is made dynamically adjustable relative to the brake carrier through the actuating arrangement. The actuator can move the brake caliper inboard or outboard along the guide assembly, allowing the running clearance to be dynamically adjusted to compensate for differential wear rates between inboard and outboard brake pads, thereby achieving even wear distribution.
2Loss of substance
If the brake pads are retracted using existing positive pad retraction systems, then contact between brake pads and rotor is reduced, but the brake caliper can still move during vibration or cornering causing unwanted contact
Solution Approach 1:
The existing mechanical positive pad retraction system is supplemented or replaced with an electrically operated actuating arrangement. This actuator can precisely control the brake caliper position and maintain the brake pads at an optimized running clearance from the rotor, preventing unwanted contact even during vehicle vibration or cornering by actively compensating for caliper movement.
3Reliability
If the brake caliper is made movable to adjust running clearance, then even wear can be achieved, but the device complexity increases
Solution Approach 1:
The actuating arrangement is integrated into the existing brake assembly structure, serving multiple functions: it adjusts the running clearance to achieve even wear, maintains the brake pads at an optimized distance from the rotor during operation, and can compensate for differential wear rates. This multi-functionality reduces the need for separate adjustment mechanisms.
4Loss of substance
If existing positive pad retraction systems are used, then brake pad retraction is achieved, but alignment and location are difficult due to machining tolerances
Solution Approach 1:
The electrically operated actuating arrangement replaces or supplements mechanical alignment systems. The actuator can electrically adjust the brake caliper position to compensate for machining tolerances in the guide assembly and other components, making alignment and location much easier during manufacturing and assembly.
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 solution effectively reduces brake pad and rotor wear, minimizes drag, and enhances vehicle efficiency by ensuring even running clearance and preventing unwanted contact between brake pads and the rotor.
Implementation Method 1
the actuating arrangement is electrically operated
Data Source
AI summary
A disc brake assembly that includes first and second brake pads for contacting a rotor, a brake carrier for receiving at least the first brake pad, a brake caliper arranged to slide with respect to the brake carrier, and an actuating arrangement. The actuating arrangement is configured to selectively move the brake caliper and is electrically operated.