Floating Disc Brake Pad Spring Engagement Mechanism
Solution Overview
Problem
The existing floating disc brake design faces challenges in workability during assembly of the outer pad to the yoke, requiring a large force and limiting design freedom due to the direct support of the outer pad to the yoke without proper engagement mechanisms, leading to potential misassembly and restricted design options.
Innovation Solution
The design incorporates a pad spring with concavo-convex engagement portions that securely attach the outer pad to the yoke, reducing assembly force requirements and providing clear assembly confirmation through tactile and auditory feedback, while allowing for improved design flexibility by housing the pad spring within the support structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the outer pad is supported directly to the yoke without engagement portions, then the support structure is simplified and weight is reduced, but the assembly workability deteriorates due to large pressing force requirements
Solution Approach 1:
The support structure is segmented into engagement portions (concave portions in the yoke, convex portions on the pad spring) that separately handle different functions: positioning, elastic engagement, and force reduction during assembly. This segmentation allows the outer pad to be supported by the yoke while incorporating assembly aids without significantly increasing overall structural complexity.
Solution Approach 2:
The pad spring acts as an intermediary element between the outer pad and the yoke. It provides elastic engagement through its convex portions that fit into the concave portions of the yoke, mediating the connection and reducing assembly force requirements while maintaining the direct support relationship.
2Reliability
If the pad spring covers part of the axially outer surface of the claw portion, then the outer pad is securely held to the yoke, but the design freedom deteriorates
Solution Approach 1:
The pad spring provides localized engagement only where needed - through convex portions fitting into specific concave portions on the yoke. This local engagement ensures reliable holding while leaving the rest of the axially outer surface of the claw portion exposed and available for design purposes, thus maintaining design freedom.
3Ease of manufacture
If the outer pad is held to the claw portion before protrusions are fitted into reception holes, then the assembly process is simplified, but misassembly risk increases
Solution Approach 1:
The convex portions of the pad spring are designed to preliminarily engage with the concave portions of the yoke before the final assembly step of fitting protrusions into reception holes. This preliminary engagement provides tactile and auditory feedback that confirms correct positioning, preventing misassembly while simplifying the overall process by establishing the connection early.
Solution Approach 2:
The elastic engagement between the convex portions of the pad spring and concave portions of the yoke provides immediate tactile and auditory feedback during assembly. This feedback mechanism allows the operator to confirm proper alignment and engagement before completing the assembly with protrusion-reception hole fitting, thereby preventing misassembly.
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 enhances the workability of assembling the outer pad to the yoke by reducing the necessary assembly force and preventing misassembly, while offering increased design freedom and a centering function for the outer pad.
Implementation Method 1
two circumferential side portions of a pad spring (23) fixed to an axially outer surface (back surface) of the outer pad 5a are elastically engaged with the claw portion 7 from the axially outer side
Data Source
Figure 1
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AI summary
A support hole (45) that opens only on an axially inner surface and a radially inner surface is provided in a circumferentially central part of a pad support (39) disposed on the axially outer side (O) of an outer pad (5a) within a yoke (3a). A pair of yoke-side engagement parts (47), each of which is recessed toward the circumferentially outer sides (L), (R), are provided on inner-side surfaces (46) within the support hole (45) that face each other with respect to the circumferential direction. A pair of pad-side engagement parts (26), each of which projects toward the circumferentially outer side, are caused to engage with the pair of yoke-side engagement parts (47) in an inter-fitting manner along the circumferential direction, the pair of pad-side engagement parts (26) being provided on both circumferential-direction sides of a pad spring (23), which is secured to the axially outer-side surface of the outer pad (5a).