Commercial Vehicle Disc Brake Reset With Central Spring Arms
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Solution Overview
Problem
Existing disc brakes for commercial vehicles experience residual grinding moments after braking, leading to increased fuel consumption and reduced service life of brake components due to inadequate resetting mechanisms, particularly in pneumatically operated systems where component tolerances and deformations cause reliability issues.
Innovation Solution
A disc brake design featuring a spreading device with spring arms that automatically centers the brake caliper after braking, ensuring the brake pads are reset and fixed relative to the brake disc, using a holding bow and spring arms that engage centrally or symmetrically on the pad carrier plates to prevent tilting and maintain alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a resilient reset element is used to move the brake caliper to an initial position, then the brake pads are reset during driving, but the service life of brake pads and brake disc is still reduced due to residual friction torque
Solution Approach 1:
The patent implements periodic release of the brake pads during driving operation. The spreading device with spring arms periodically moves the brake caliper away from the brake disc during driving phases, creating alternating periods of contact and separation. This periodic action prevents continuous residual friction while maintaining braking capability when needed.
Solution Approach 2:
The patent transitions from a static brake caliper position after braking to a dynamic system that automatically adjusts during driving. The resilient spring arms enable the brake caliper to dynamically move away from the brake disc during driving phases, adapting the brake pad position based on operational phase (braking vs. driving) to eliminate continuous friction contact.
2Speed
If the brake caliper remains in contact with the brake disc after braking, then the brake pads are positioned for quick re-application, but residual friction torque increases fuel consumption
Solution Approach 1:
The spreading device creates periodic separation between brake pads and disc during driving phases, eliminating continuous friction contact that causes energy loss. The spring arms are designed to allow automatic return to contact position when braking is applied, maintaining quick response capability while preventing energy-wasting friction during coasting.
Solution Approach 2:
The patent changes the positional parameter of the brake caliper dynamically. During driving, the spring arms push the caliper away from the disc (increasing gap parameter). During braking, the caliper moves back into contact (decreasing gap parameter). This parameter change eliminates residual friction during driving while preserving rapid re-application capability.
3Extent of automation
If a reset device is arranged on the side opposite the brake application device, then effective automatic reset is achieved, but the system rigidity may be compromised
Solution Approach 1:
The patent segments the brake caliper structure into fixed and movable portions. The spreading device with spring arms is integrated into the caliper assembly, with spring arms that are resilient rather than rigid. This segmentation allows automatic reset functionality while the overall caliper structure maintains sufficient rigidity for braking forces.
Solution Approach 2:
The patent uses resilient spring arms (flexible elements) instead of rigid reset mechanisms. The spring arms provide the necessary flexibility for automatic reset movement while maintaining structural integrity. The flexible nature of the spring arms allows automatic adaptation to component tolerances and deformations without compromising overall system rigidity.
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 solution effectively reduces wear on brake pads and discs, minimizing fuel consumption and operational costs by ensuring proper alignment and resetting of brake components, thus enhancing the service life and reliability of the brake system.
Implementation Method 1
a spreading device (8) with spring arms (20), by means of which, during driving, the brake caliper (1) is moved away from the brake disc (2) in order to reset the brake pads (3)
Data Source
Figure 1
Figure 1a
Figure 2
AI summary
A disc brake (100) for a commercial vehicle, with a brake caliper (1) which engages over a brake disc (2) and is designed as a sliding caliper, which is fastened to a stationary brake carrier (6) and has a central opening (41) above the brake disc (2). , two brake pads (3) arranged in the brake caliper (1) and movable in opposite directions, each having a pad carrier plate (4) and a friction lining (5) attached thereto, of which an action-side or application-side brake pad (3) has at least one brake plunger by means of an application device can be pressed against the brake disc (2), in which case the brake pads (3) can be inserted into the associated pad shafts through the central opening (41) and removed again, as well as at least one restoring device, with which the brake caliper (1) after a braking-related displacement and release of the brake can be traced back, the restoring device acting on the opposing brake pads (3), has a spreading device (8) acting counter to the respective application direction, with resilient spreading elements acting on the respective lining carrier plate (4), which are designed as spring arms (20), the spreading device (8) being arranged in the central opening (41), the spring arms (20) are connected to a tie (21) which is attached to the brake carrier (6).