Disc Brake Clamping Lever Shell Bearing Joint
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Solution Overview
Problem
Existing disc brake designs experience premature wear and slippage issues due to inadequate frictional contact between the application lever and link element, particularly under strong vibrations, leading to uneven pressure distribution and material wear on rolling surfaces.
Innovation Solution
Incorporating a joint, such as a shell bearing, in the power flow between the application lever and the flat bearing, which operates in a form-fitting manner transverse to the pressure piston axis, along with a spring element that supports the link element via a flat bearing, ensuring consistent and parallel guidance of the pressure piece and traverse.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If frictional contact between the eccentric section and link element is used for power transmission, then the structure is simple, but slippage occurs under strong vibrations leading to premature blocking and extreme material wear
Solution Approach 1:
A shell bearing is introduced as an intermediary element between the application lever and the link element. This shell bearing includes a first shell with a circular segment surface and a second shell with a corresponding circular segment surface, creating a form-fitting joint that eliminates slippage while maintaining structural simplicity. The intermediary bearing converts the frictional contact into a form-fitting connection.
Solution Approach 2:
The shell bearing employs circular segment surfaces (curved surfaces) instead of flat frictional contact surfaces. The first shell has a circular segment surface and the second shell has a corresponding circular segment surface, creating a spherical-like form-fitting joint that prevents slippage under vibration while allowing smooth rotational movement.
2Ease of operation
If the link element is supported against the traverse via a flat roller bearing, then the displacement is guided, but uneven pressure distribution occurs causing material wear on the rolling surfaces
Solution Approach 1:
A spring element is introduced as an intermediary between the link element and the pressure piece. This spring element includes a resilient section that applies consistent elastic force and a bearing plate that provides a flat bearing surface. The intermediary spring element ensures uniform pressure distribution across the rolling surfaces, preventing localized wear.
3Device complexity
If the pressure piece is supported against the brake housing without a guide surface, then the structure is simple, but non-parallel guidance occurs leading to inconsistent pressure application
Solution Approach 1:
A guide surface is pre-formed on the inner side of the brake housing before the pressure piece operates. This guide surface extends parallel to the pressure piston axis and is positioned to receive the pressure piece, ensuring that the pressure piece is guided in a predetermined parallel path. The preliminary preparation of the guide surface ensures consistent pressure application without adding complex guidance mechanisms.
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 configuration reduces wear and slippage by maintaining consistent pressure distribution and parallel guidance, minimizing material wear and enhancing the overall low-wear performance of the disc brake.
Implementation Method 1
The frictional contact between the eccentric section and the gate element takes place through linear rolling according to the pivoted position of the clamping lever. As a result of the frictional rolling, the place where the pressure is exerted on the gate element changes constantly.
Implementation Method 2
the link element is supported against the traverse via a flat roller bearing
Implementation Method 3
A spring element, the resilient section of which is supported on the one hand on the pressure piece and on the other hand on a side surface of the gate element
Data Source
Figure 1
Figure 2
Figure 3~5
AI summary
The brake has a pressure plunger (2) operating against a brake lining (4) and adjusted along a pressure plunger center axis of a brake housing. An actuating device is provided for actuating the plunger and has a clamping lever (13) supported at a bearing arrangement (14) of the housing in a pivotable manner. The clamping lever is supported by a flat bearing (18) opposite to the plunger, where the bearing is arranged transverse to the axis. A hinge (22) is arranged in magnetic flux between the lever and the bearing, and operates in a direction transverse to the plunger in a positive-fit manner.