Disc Brake Wear Adjustment via Tension Spring Coupling
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Solution Overview
Problem
Conventional disc brakes with mechanical wear adjustment devices often experience play-related readjustments due to manufacturing tolerances, leading to incorrect pad wear detection and adjustment, even when no wear is present.
Innovation Solution
A disc brake design that incorporates a tension spring element for rotational positive coupling with the adjustment spindle, eliminating backlash and ensuring accurate wear detection and adjustment by maintaining a consistent force transmission without play.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If an additional drive unit is used to drive the adjustment spindle from the outside, then the adjustment device can be connected to the adjustment spindle, but manufacturing tolerances cause play in the power flow transition leading to incorrect wear detection
Solution Approach 1:
The invention extracts the problematic additional drive unit from the system and instead integrates the drive function directly into the adjustment spindle. The adjustment spindle is designed with a drive element that can be directly actuated by the application device, eliminating the intermediate drive unit and its associated manufacturing tolerances that cause play.
Solution Approach 2:
The invention implements nesting by placing the drive element directly within or on the adjustment spindle, allowing the drive function to be integrated into the spindle structure itself. This eliminates the need for separate external drive units and reduces the number of interfaces where play can occur.
2Measurement precision
If a tension spring element is used for rotational positive coupling, then play is eliminated and accurate wear detection is achieved, but the device complexity increases
Solution Approach 1:
The invention changes the coupling parameter from a rigid fixed connection to a spring-based elastic connection. The tension spring element provides rotational positive coupling while accommodating manufacturing tolerances through its elastic properties, maintaining accurate wear detection without requiring extremely tight tolerance specifications.
Solution Approach 2:
The tension spring element acts as an intermediary between the drive element and the adjustment spindle. It transmits rotational force while maintaining positive coupling, eliminating play without requiring complex mechanical constraints or high-precision manufacturing.
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
Prevents play-related readjustments, ensuring accurate adjustment of brake pads relative to the brake disc, thereby maintaining optimal brake performance and reducing the risk of incorrect wear detection.
Implementation Method 1
The drive unit is rotationally positively coupled to the at least one adjustment spindle via at least one tension spring element without play
Data Source
AI summary
A disc brake, preferably pneumatically actuated, particularly for a motor vehicle, comprising a clamping device, preferably with a rotary lever, at least one spindle unit (5, 5') with at least one adjusting spindle (6, 6'), and a wear adjustment device with an adjusting mechanism, which is coupled to the clamping device, preferably with the rotary lever, via a drive and to the at least one adjusting spindle (6, 6') via a drive unit (13, 113), wherein the drive unit (13, 113) is pushed onto the adjusting spindle (6, 6') and is rotationally positively coupled to the adjusting spindle (6, 6') via at least one coupling section (13h). The drive unit (13, 113) is rotationally positively coupled to the at least one adjusting spindle (6, 6') without backlash via at least one tension spring element.