Disc Brake Synchronization Gear Relocation for Rigidity
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing disc brake designs face challenges in achieving greater rigidity and reduced adjustment device capacity while maintaining effective wear compensation and installation space efficiency.
Innovation Solution
The synchronization gear is rearranged to be directly between the traverse and the rotary brake lever, eliminating the need for a separate cover and allowing for a larger reaction-side brake pad, which reduces the thickness of the friction material and enhances rigidity, and the use of a chain synchronizing mechanism with coupling wheels on the traverse provides increased space efficiency and adjustability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the synchronization gear is arranged between the rotary brake lever and the traverse, then the wear compensation function is maintained, but the brake pad size is limited and rigidity is reduced
Solution Approach 1:
The synchronization gear is relocated from a lateral arrangement (between brake lever and traverse) to an axial arrangement (on the traverse, forming an assembly with it). This dimensional change allows the reaction-side brake pad to be enlarged in the radial direction, increasing friction material thickness and brake rigidity without interfering with the synchronization function.
2Ease of manufacture
If a separate cover is used for the synchronization gear, then the gear is protected, but assembly complexity increases and space is consumed
Solution Approach 1:
The synchronization gear is integrated directly onto the traverse, forming a synchronized assembly. This merging eliminates the need for a separate protective cover, simplifying the overall structure and reducing the number of components. The traverse itself serves as the mounting structure, eliminating redundant parts.
3Duration of action of stationary object
If the friction material thickness is increased, then the brake pad durability is improved, but the brake rigidity is reduced and adjustment device capacity increases
Solution Approach 1:
By relocating the synchronization gear to an axial arrangement on the traverse, the radial space within the brake caliper is freed up. This allows the reaction-side brake pad to be enlarged with increased friction material thickness, improving durability while maintaining rigidity through the optimized spatial configuration.
4Weight of moving object
If the adjustment device capacity is reduced, then space and weight are saved, but wear compensation capability is limited
Solution Approach 1:
The synchronization gear is repositioned on the traverse to optimize the spatial distribution of components. This parameter change in positioning allows for a more compact adjustment device with reduced capacity, decreasing weight and space requirements while maintaining adequate wear compensation through the optimized geometric arrangement of the threaded spindles and gear mechanism.
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 results in a more rigid disc brake with reduced adjustment device capacity, leading to space and weight savings, and simplifies assembly and maintenance by eliminating the need for a separate cover and allowing for preassembled modular components.
Implementation Method 1
the use of a chain synchronizing mechanism with coupling wheels on the traverse
Implementation Method 2
the clamping force of a clamping device via threaded spindles to the brake pads and brake disc, with the wear on the brake disc and brake pads being compensated for via the threaded spindles
Implementation Method 3
The cylinder forces are applied to the internal mechanics, usually two brake pads and the brake disc. The cylinder forces are applied to the internal mechanics via a pneumatically actuated cylinder, amplified by an eccentric mechanism
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A disc brake (1), preferably pneumatically actuated, in particular for a motor vehicle, with a clamping device, with a brake rotary lever (9), at least two spindle units (5, 5') each with a threaded die (6, 6'), wherein the threaded dies (6, 6') are screwed into a cross member (8), wherein the cross member (8) interacts with the brake rotary lever (9), an adjusting device (11a) for compensating for pad and disc wear and a synchronizing device for transmitting the rotary movements of the adjusting device (11a) to the threaded dies (6, 6') and/or for synchronizing the rotary movements of the threaded dies (6, 6') is provided.