Commercial Vehicle Disc Brake Caliper With Integrated Pad Lugs
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Solution Overview
Problem
Disc brakes for commercial vehicles face challenges with high inherent weight and large installation space requirements due to the need for a brake carrier, which increases production costs and reduces efficiency.
Innovation Solution
The arrangement of lugs within the brake caliper to receive brake pads eliminates the need for a brake carrier, reducing weight and installation space, allowing for a more compact and lightweight disc brake design with reduced production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a brake carrier is used to receive and support brake pads, then the brake pads can be properly positioned and supported, but the overall weight of the disc brake increases to at least 9 kg
Solution Approach 1:
The patent merges the brake carrier function into the brake caliper by integrating lugs directly into the caliper structure. The lugs are formed as part of the caliper body, eliminating the need for a separate brake carrier component while maintaining the function of receiving and supporting brake pads.
Solution Approach 2:
The brake caliper is designed to perform multiple functions: it provides clamping force through the clamping device, serves as the mounting structure for brake pads through integrated lugs, and maintains structural support without requiring a separate brake carrier. This multi-functionality reduces overall component count and weight.
2Reliability
If a brake carrier is used to receive brake pads, then proper pad support is achieved, but the installation space and production costs increase
Solution Approach 1:
The brake carrier function is merged into the brake caliper structure through integrated lugs, eliminating the need for a separate brake carrier component and reducing overall installation space requirements.
Solution Approach 2:
The separate brake carrier component is extracted from the system and its function is transferred to the brake caliper through integrated lugs, reducing the number of parts and installation space required.
3Volume of moving object
If a clamping device with reduced pad thickness is used, then axial arrangement space is reduced, but the structural form becomes more narrow
Solution Approach 1:
The patent transitions from a parallel arrangement of clamping and adjusting devices to a sequential axial arrangement, utilizing the axial dimension more efficiently. The clamping device is positioned in the first inside space, while the adjusting device follows axially in the same space, reducing the radial footprint.
Data Source
AI summary
A disc brake for commercial vehicle includes a brake caliper and brake pads for clamping the brake disc. The brake caliper has a first inside space with an opening on a side facing the brake disc for receiving a clamping device, and the brake caliper has a second inside space for receiving the brake disc. The brake caliper and brake pads have advantages in terms of installation space and is lightweight and reduces production costs. The brake caliper includes clamping-side lugs and reaction-side lugs. The lugs on each side define a channel for receiving the brake pads for each side. The brake pads include supporting surfaces and bearing surfaces on their perimeter that correspond to the arrangement of the lugs. The lugs on the clamping side define an L-shape. The axial length of supporting surfaces of the clamping side brake pad is shorter than that of the clamping-side lugs.