Disc Brake Resetting Device for Residual Grinding Torque Reduction
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Solution Overview
Problem
Residual grinding torques in disc brakes, especially in sliding caliper disc brakes, lead to increased fuel consumption and maintenance costs due to incomplete separation of brake pads from the brake disc, and existing solutions are either expensive or prone to failure and corrosion.
Innovation Solution
A disc brake design with a resetting device for each brake pad that uses restoring elements with different magnitudes of force on either side of the brake disc, eliminating the need for clamping elements and ensuring complete separation of the brake pads from the disc, thus preventing residual grinding torques and unnecessary wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If clamping elements are used to give the brake caliper a quasi-fixed position, then clearance adjustment on both sides is possible, but the solution is expensive and prone to failure due to component tolerances and deformations
Solution Approach 1:
The invention extracts the resetting function from the caliper body and implements it through separate resetting elements that are attached to the brake pads. This separates the clearance adjustment mechanism from the caliper structure, avoiding the complexity and reliability issues of clamping elements while maintaining effective clearance control on both sides of the disc.
Solution Approach 2:
The resetting function is segmented into individual resetting elements attached to each brake pad, rather than using a unified clamping mechanism on the caliper. This segmentation allows independent adjustment and simplifies the overall structure while improving reliability through distributed functionality.
2Reliability
If clamping elements are used to support the brake pad, then clearance can be adjusted, but the clamping elements are susceptible to dirt, corrosion, and can block due to rust
Solution Approach 1:
The invention removes the clamping elements from the system entirely and replaces them with resetting elements attached to the brake pads. This extraction eliminates the vulnerability to dirt and corrosion associated with clamping elements while maintaining the necessary clearance adjustment functionality.
Solution Approach 2:
The resetting elements act as intermediaries between the brake pad and the guide surfaces, providing a corrosion-resistant solution that mediates the interaction without being susceptible to the harmful environmental factors that affect traditional clamping elements.
3Reliability
If the brake pad is directly supported by friction against the guide surfaces, then the influence of the sliding caliper is excluded, but the clamping elements can impair brake effectiveness by rusting and blocking
Solution Approach 1:
The invention extracts the harmful clamping elements from the system and replaces them with resetting elements that perform the necessary function without generating rust and blocking issues. This eliminates the source of harmful factors while maintaining reliable brake performance.
Solution Approach 2:
The invention converts the potential harm of clamping elements by replacing them with resetting elements that use elastic restoring forces instead of friction-based clamping. This transformation eliminates the rust and blocking problems while achieving the desired brake pad support and clearance adjustment.
4Reliability
If restoring elements with different magnitudes of force are used on different sides of the brake disc, then complete separation of brake pads from the disc is ensured, but the device complexity increases
Solution Approach 1:
The invention applies local quality by using resetting elements with different restoring forces on different sides of the brake disc, tailored to the specific requirements of each side. This localized customization ensures complete brake pad separation while maintaining a relatively simple overall device structure through modular implementation.
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 residual grinding torques and brake pad wear, making it suitable for heavy commercial vehicles by maintaining a consistent clearance and minimizing the risk of component failure, while being robust and air-operated.
Implementation Method 1
Each restoring device (10) comprises at least two restoring elements (10) which are attached to the back of the pad carrier (5) of the respective at least one brake pad (4), the restoring devices having restoring forces of different magnitudes on different sides of the brake disc (3)
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
A disc brake (1) for a motor vehicle comprises a clamping device, a brake caliper extending over a brake disc (3), preferably a pad wear adjustment device, a brake carrier (2) with guide surfaces (2a) opposite the brake disc (3) in the circumferential direction, between which at least one brake pad (4) with a pad carrier (5) is slidably guided parallel to an axis of rotation of the brake disc (3) on both sides of the brake disc (3) and can be actuated by a clamping force, and a return device which supports the at least one brake pad (4) with the pad carrier (5) with at least one return section (13) on each guide surface (2a). Each return device comprises at least two return elements (10) which are attached to the back of the pad carrier (5) of the at least one brake pad (4).