Utility Vehicle Disc Brake Retainer Spring Misalignment Detection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Commercial vehicle disc brakes often experience incorrect installation due to lack of clear installation guidance, leading to malfunctions and brake failures, as hold-down springs are not effectively coupled to the brake lining, causing issues with alignment and support.
Innovation Solution
A disc brake design featuring a single-piece hold-down spring with a projection that overlaps with the brake disc when incorrectly installed, ensuring immediate detection of misalignment, and optionally serving as a pressure plate holder to reduce parts and simplify assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If hold-down springs are not coupled to the brake lining, then assembly is simpler, but alignment and support are compromised leading to malfunctions
Solution Approach 1:
The patent combines the hold-down spring and brake lining into a single integrated component. The hold-down spring is formed as an integral part of the brake lining, eliminating the need for separate coupling mechanisms while ensuring proper alignment and support through the unified structure.
Solution Approach 2:
The integrated hold-down spring serves multiple functions simultaneously: it provides the holding-down force, ensures proper alignment of the brake lining, and provides structural support. This multi-functional design eliminates the need for separate components while maintaining reliability.
2Manufacturing precision
If hold-down springs are captively connected to the brake pad carrier, then alignment is ensured, but the number of parts increases and assembly becomes more complex
Solution Approach 1:
The patent merges the hold-down spring and brake lining into one component, reducing the total number of parts while maintaining alignment through the integral design. The unified structure inherently ensures proper alignment without requiring additional fastening elements or complex assembly procedures.
3Productivity
If brake pads are inserted without installation guidance, then assembly is faster, but incorrect installation occurs leading to brake failures
Solution Approach 1:
The integrated design of the hold-down spring and brake lining provides self-guiding features that automatically ensure correct installation. The component's geometry and the spring's configuration guide the installer into the proper position, making incorrect installation impossible while maintaining fast assembly speed.
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 design enhances operational reliability by preventing incorrect installations and simplifying assembly by automatically indicating errors, reducing the number of parts and ensuring proper alignment through the hold-down spring's configuration and projection mechanism.
Implementation Method 1
a first hold down spring (28) having an aperture (42) for receiving the first protrusion (46) for holding down the brake pad
Implementation Method 2
Because of the weight and size of commercial vehicle brake linings, leaf springs with the required spring force are preferably used as hold-down springs
Data Source
Figure 1
Figure 2~4
Figure 5~6
AI summary
The invention relates to a disc brake, in particular for utility vehicles, comprising a brake lining (20) that comprises a first protrusion located eccentrically in the thickness direction, a tensioning unit for pressing the brake lining against a brake disc, a pressure plate (34), via which the tensioning unit presses the brake lining (20) against the brake disc when braking, and a first retainer spring for retaining the brake lining, which retainer spring comprises an opening for accommodating the first protrusion (46), wherein a projection (52) on the retainer spring extends in the mounted state over the brake lining on one side in the axial direction of the brake disc.