Sliding Caliper Disc Brake Pad Reset to Cut Residual Drag
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Solution Overview
Problem
Commercial vehicle disc brakes experience increased fuel consumption and reduced service life due to residual grinding torques, which are not effectively mitigated by existing restoring devices, especially in compressed air-actuated systems where component tolerances and deformations lead to reliability issues.
Innovation Solution
A disc brake design featuring a sliding caliper with a central opening, utilizing two counter-moving pad carrier plates and a spreading device with resilient expanding elements that synchronously reset both brake pads and the caliper, minimizing oblique wear and eliminating the need for additional pad retaining springs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a resilient restoring element is used to reset the brake caliper, then the brake caliper can be returned to the starting position, but the service life of brake pads and brake disc is reduced due to residual grinding torques
Solution Approach 1:
The restoring device is segmented into multiple resilient restoring elements (first and second restoring elements) that act independently on different brake pads. This segmentation allows each element to be optimized for its specific function of preventing residual grinding torques on respective brake pads, thereby extending service life while maintaining resetting capability
Solution Approach 2:
The resilient restoring elements are pre-installed in the restoring device to automatically prevent residual grinding torques as soon as the brake is released. This preliminary action occurs before any wear damage can occur, continuously protecting the brake pads and disc throughout operation
2Ease of operation
If a restoring device is added to reset the brake caliper, then the starting position can be restored, but the device complexity increases
Solution Approach 1:
The first and second resilient restoring elements are merged into a single integrated restoring device structure that resets both brake pads simultaneously. This merging reduces the number of separate components and simplifies the overall device structure while maintaining the resetting function for both brake pads
Solution Approach 2:
The restoring device is designed with multi-functionality to simultaneously reset both the first and second brake pads, as well as the brake caliper position. This universal design eliminates the need for separate resetting mechanisms for each component, reducing overall device complexity
3Force
If the brake caliper is displaced counter to the application direction, then the reaction-side brake pad is pressed against the brake disc, but residual grinding torques occur after brake release
Solution Approach 1:
The resilient restoring elements act as counterbalancing elements that apply a counteracting force to the brake pads after brake release. This counterweight effect pushes the brake pads away from the brake disc, eliminating the residual grinding torques that would otherwise occur due to the displaced caliper position
Solution Approach 2:
Instead of relying on the brake caliper displacement to maintain contact, the invention inverts the approach by using resilient elements to actively push the brake pads away from the disc after braking. This inversion of the contact maintenance mechanism eliminates harmful residual grinding while preserving necessary braking force during operation
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 enhances the service life of brake pads and brake discs, reduces operating costs, and ensures reliable operation by minimizing residual grinding torques and maintaining consistent spring forces across the brake pads.
Implementation Method 1
resilient expanding elements, with the spreading device arranged in the central opening, wherein the expanding elements act directly or indirectly outside the friction linings on at least two contact areas of the brake linings
Data Source
Figure 1
Figure 1a
Figure 2
AI summary
The invention relates to a disk brake (10) comprising a brake caliper (1) that engages over a brake disk (2) and is designed as a sliding caliper. The disk brake comprises two brake pads (3, 3') which are located in the brake caliper (1), can be moved in opposite directions and each of which has a pad backing plate (4) with a friction lining (5) secured thereon. An actioning- or application-side brake pad (3) of the two brake pads can be pressed against the brake disk (2) by means of a brake application device with the aid of at least one brake plunger. The brake also comprises at least one restoring device, by means of which the brake caliper (1) can be returned after a displacement and release of the brakes caused by a braking action. The restoring device has a spreading device (8) which engages on the brake pads (3) lying opposite one another and which acts with an identical force in opposition to the respective application direction, the spreading device comprising spring-loaded spreading elements, each engaging on its respective pad backing plate (4). The spreading device (8) is located in the central opening (9) and the spreading elements engage directly or indirectly, outside the friction linings (5), on at least two contact regions of the brake pads (3), said regions facing each other at a distance from the centre. Each contact region has a contact surface and a support surface (4c), on which surfaces the spreading elements are movably located. Also disclosed is a corresponding brake pad set.