External Disc Brake Synchronization Around Lever Housing
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Solution Overview
Problem
The existing design of radial disc brakes with a monoblock caliper is hindered by the protruding shape of the brake lever, which prevents the integration of a roller chain synchronization mechanism, leading to complex assembly and weight distribution issues.
Innovation Solution
The synchronization mechanism is arranged outside the brake caliper housing within a sealed cover, utilizing a synchronizer element like a chain or toothed belt, guided around the lever housing, allowing for a monoblock caliper design with reduced weight and simplified assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the roller chain synchronization mechanism is integrated into the monoblock caliper design, then the structural integrity and robustness of the caliper is improved, but the brake lever must have a protruding shape which increases device complexity and assembly difficulty
Solution Approach 1:
The synchronization mechanism is extracted from the internal structure of the caliper and positioned externally on the end face. This allows the brake lever to maintain a simple, non-protruding design while the synchronization mechanism operates independently on the external surface, resolving the conflict between structural integrity and lever simplicity.
Solution Approach 2:
The synchronization mechanism is relocated from a two-dimensional internal arrangement to a three-dimensional external position on the end face of the caliper. This dimensional change allows the mechanism to function effectively without interfering with the brake lever's geometry, eliminating the need for protruding lever shapes.
2Volume of moving object
If the synchronization mechanism is arranged inside the caliper housing, then the overall compactness is improved, but the assembly complexity and weight distribution issues arise due to the protruding brake lever shape
Solution Approach 1:
The synchronization mechanism is extracted from the internal housing space and positioned externally on the end face. This extraction eliminates the need for complex internal routing and protruding brake lever designs, thereby simplifying assembly while maintaining compact overall dimensions.
Solution Approach 2:
The caliper system is segmented into distinct functional zones: the internal housing contains the brake lever and application device, while the external end face accommodates the synchronization mechanism. This segmentation allows each component to be optimized independently, improving assembly ease without compromising compactness.
3Reliability
If the brake lever is designed with a protruding shape to accommodate the synchronization mechanism, then the synchronization function is achieved, but the weight distribution and structural balance of the caliper deteriorates
Solution Approach 1:
The synchronization mechanism is extracted from the brake lever structure and positioned independently on the end face of the caliper. This separation eliminates the need for a protruding brake lever design, thereby maintaining proper weight distribution and structural balance while preserving the synchronization function.
Solution Approach 2:
The end face of the caliper serves as an intermediary surface that hosts the synchronization mechanism without requiring modifications to the brake lever. This intermediary position allows the synchronization function to be achieved while maintaining the brake lever's original simple geometry and optimal weight distribution.
Data Source
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AI summary
The invention relates to a disc brake (1), in particular for a motor vehicle, comprising a brake caliper (3) that has a clamping section (3a), which is equipped with a clamping device with a brake rotary lever (11), at least two threaded pistons (7, 8), an adjustment device (9), and a driver device (10), and comprising a synchronization mechanism (12) for synchronizing the rotational movements of the threaded pistons (7, 8), wherein the synchronization mechanism (12) is arranged outside of the housing of the brake caliper (3) within a sealed cover (21) on the clamping section (3a) of the brake caliper (3), and the synchronization mechanism (12) has at least one synchronizing element (13) and two synchronizing wheels (14, 15), a first synchronizing wheel (14) of which is coupled to one threaded piston (7) and a second synchronizing wheel (15) of which is coupled to the other threaded piston (8). The synchronization mechanism (12) is arranged on the clamping section (3a) of the brake caliper (3) so as to be guided about a lever housing (3c) of the brake rotary lever (11), said lever housing protruding from the clamping section (3a) of the brake caliper (3).