Disc Brake Plunger Support Surface to Reduce Brake Pad Tilting
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Solution Overview
Problem
The existing brake application devices for disc brakes in commercial vehicles suffer from premature wear of brake pads due to tilting under braking forces and caliper deformations, leading to reduced service life and increased operating costs.
Innovation Solution
The brake application device is enhanced by creating a larger support surface for the thrust piece, either by dimensioning the adjusting spindle's end face or using a separate ring to enlarge the support surface, which reduces the tilting moment and counteracts diagonal wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the thrust piece is secured on the adjusting spindle with a conventional support surface (outer diameter corresponding to nominal thread diameter or smaller), then the device complexity is low and manufacturing is simple, but the thrust piece tilts under braking forces causing diagonal wear of the brake pad
Solution Approach 1:
The support surface is extended beyond the conventional circular area defined by the thread diameter by adding an annular extension surface. This dimensional expansion in the radial direction increases the total support area without changing the axial dimensions, thereby reducing the tilting moment while maintaining a compact overall structure.
Solution Approach 2:
The support surface is divided into two distinct segments: the original circular support surface and the additional annular extension surface. This segmentation allows the thrust piece to be supported over a larger area while maintaining the original thread connection geometry, effectively reducing tilting without complicating the fastening mechanism.
2Reliability
If the support surface of the adjusting spindle is enlarged to reduce tilting moment, then the brake pad wear is improved, but the manufacturing complexity increases
Solution Approach 1:
The annular extension surface is integrated directly into the adjusting spindle body as a unified structure. By merging the extension surface with the existing spindle geometry, the invention achieves an enlarged support surface without requiring separate components or complex assembly operations, thus maintaining ease of manufacture while improving brake pad service life.
Data Source
AI summary
A brake application device of a disc brake for a commercial vehicle has a brake lever that acts on a brake plunger, wherein the brake plunger has an adjusting spindle provided with an external thread and a pressure piece, which bears against a radially aligned support surface of the adjusting spindle facing a brake pad. The outer diameter of the support surface is at least 60% of the diameter of the pressure surface of the pressure piece.