Disc Brake Spring Sleeve Tolerance Compensation
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Solution Overview
Problem
Existing disc brake designs for commercial vehicles face issues with rattling noises due to larger bearing play, leading to increased wear on elastomer sliding bushings and higher production and assembly costs, particularly due to the need for separate metal components like stop rings and bearing sleeves.
Innovation Solution
A disc brake design featuring a spring sleeve with radially deformed spring clips that are non-detachably connected to the elastomer sliding bush, which compensates for tolerances and thermal expansion, and includes support rings to secure the sliding bush in the brake caliper bore, reducing wear and eliminating the need for separate metal components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a sliding bush made of elastomer is used to dampen rattling noises, then damping properties are improved, but wear increases and service life decreases
Solution Approach 1:
The guide bush is designed as a composite structure combining an elastomer sliding bush with a metal spring sleeve. The elastomer provides damping properties to prevent rattling noises, while the spring steel sleeve provides high abrasion resistance. This composite design allows both materials to contribute their advantageous properties without the drawbacks of using either material alone.
2Reliability
If separate metal components like stop rings and bearing sleeves are used, then functionality is improved, but production and assembly costs increase
Solution Approach 1:
The invention merges multiple separate metal components (stop ring, bearing sleeve, guide elements) into a single integrated spring sleeve made of spring steel. This one-piece component performs all the functions previously requiring multiple parts, including guiding the brake caliper, limiting insertion depth, and providing structural support. The spring steel material allows the single component to fulfill multiple functional requirements that previously demanded separate specialized parts.
Solution Approach 2:
The spring sleeve serves multiple functions simultaneously: it acts as a bearing sleeve for guiding the brake caliper axially, functions as a stop ring to limit insertion depth, and provides structural reinforcement. This multi-functional design eliminates the need for separate specialized components, simplifying both manufacturing and assembly processes while maintaining all necessary functionalities.
3Adaptability or versatility
If a floating bearing with larger bearing play is used, then tolerance compensation is improved, but rattling noises increase
Solution Approach 1:
The guide bush combines elastomer and spring steel to create a composite structure where the elastomer fills and dampens the gaps created by larger bearing play, while the spring steel provides structural integrity. This allows the floating bearing to compensate for tolerances and thermal expansion without creating rattling noises, as the elastomer material absorbs the play while the metal framework maintains proper alignment.
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 design significantly increases the service life of the sliding bush, reduces operating costs, and simplifies manufacturing and assembly by using stamped spring steel clips and elastomer overmoulding, while maintaining damping properties to prevent rattling noises.
Implementation Method 1
the spring clip is now radially deformed, just as with operational thermal expansion of the brake caliper
Implementation Method 2
the damping properties of the sliding sleeve, in particular to prevent rattling noises that occur when driving
Implementation Method 3
The contact of the spring clip of the spring sleeve formed from a spring steel sheet on the guide bar significantly increases the service life of the sliding bush due to the higher abrasion resistance of the spring clip
Data Source
Figure 1
Figure 2~3
AI summary
A disc brake for a commercial vehicle, with a brake caliper (2) which comprises a brake disc (3) and is fastened by means of two fastening elements, of which one is designed as a fixed bearing (4) and the other is designed as a movable bearing (5), to a positionally fixed brake anchor plate (1) in an axially displaceable manner with respect to the brake disc (3), wherein the movable bearing (5) has a guide bush (6), which is held fixedly in the brake caliper (2), with a slide bush (11) made from a plastic, in particular an elastomer, in which a guide strut connected to the brake anchor plate (1) is guided in a longitudinally displaceable manner. Said disc brake is designed in such a manner that a spring sleeve (7) is held in the slide bush (11), the spring sleeve having spring clips (8) which extend in the direction of the longitudinal axis, are arranged spaced apart from one another over the circumference and make contact with the guide strut.