Disc Brake Adjuster Shaft Support for Single-Side Installation
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Solution Overview
Problem
The installation of actuation mechanisms in disc brakes, particularly air actuated disc brakes, is challenging due to the arrangement of wear adjustment mechanisms, which can interfere with maintenance of other brake components and require installation from both sides, complicating the process and restricting the orientation of the air actuator.
Innovation Solution
A disc brake design featuring a manual rewind apparatus with a manual adjuster shaft supported within the housing cavity, allowing for a seal to be formed internally, enabling installation from a single side and providing greater freedom in orienting the air actuator, with a roller defining the inboard support interface and secured to the caliper to prevent rotation and contamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the manual adjuster shaft is supported externally to the housing cavity, then the seal can be positioned at the exterior of the housing, but the adjuster shaft extends beyond the housing which interferes with maintenance of the pneumatic actuator and restricts orientation options
Solution Approach 1:
The support interface is moved from the external dimension to the internal dimension of the housing cavity. The inboard support interface is positioned within the housing cavity at the inboard end of the manual adjuster shaft, eliminating the need for the shaft to extend externally for support, thereby resolving the conflict between sealing effectiveness and maintenance access.
2Ease of manufacture
If the manual adjuster shaft extends beyond the housing to provide space for a seal, then the seal can be fitted externally, but installation must take place from both inboard and outboard sides of the brake
Solution Approach 1:
The seal installation requirement is extracted from the external housing surface and relocated to the internal housing cavity. By positioning the inboard support interface within the cavity, the seal can be installed from the inboard side along with other actuation mechanism components, eliminating the need for separate external seal installation and simplifying the overall procedure.
3Volume of moving object
If the wear adjustment mechanism is arranged in a compact configuration, then space is saved in the brake assembly, but the manual adjuster shaft may still require external support which complicates the arrangement
Solution Approach 1:
The support function is merged with the housing cavity structure itself. The inboard support interface is formed as part of the housing cavity at the inboard end, combining the housing's structural role with the support function for the manual adjuster shaft, thereby maintaining compactness without adding external support structures.
Data Source
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AI summary
A disc brake comprising an actuation mechanism (104) comprising a piston for applying an actuating force to a brake pad, and a wear adjustment mechanism (108) for adjusting extension of the piston to account for wear of said brake pad, the wear adjustment mechanism comprising a manual rewind apparatus having a manual adjuster shaft (110); a brake caliper having a housing cavity for at least partly accommodating the actuation mechanism, the housing cavity being partially defined by an inboard wall of the brake caliper; and an inboard support interface (112) and an outboard support interface where the manual adjuster shaft is supported. The inboard support interface (112) is located within the housing cavity, outboard of the inboard wall.