Disc Brake Synchronization Unit Asymmetric Collar Fixing
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Solution Overview
Problem
Disc brakes face challenges in maintaining a constant air gap due to wear of brake pads, leading to reduced response times and increased risk of brake failure under adverse loads, with existing solutions failing to securely fix the readjustment device in both angular and axial positions.
Innovation Solution
A disc brake design featuring a synchronization unit preassembled with a readjustment device and driver device, where the synchronizer is integrated within the brake caliper's bearing wall, allowing for simple installation and secure fixing through a bearing arrangement with collars and support discs, enabling axial and angular positioning without external mounting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the readjustment device is fixed only in angular position using a ball pressed into a pocket, then the readjustment device can be positioned angularly, but the fixing can loosen under adverse loads such as intense vibrations
Solution Approach 1:
The invention uses an asymmetric collar with a non-circular cross-section (trapezoidal or rectangular) that engages with a corresponding asymmetric recess in the bearing wall. This asymmetric geometry provides both angular positioning and axial fixation, preventing the fixing from loosening under vibrations while maintaining ease of positioning.
Solution Approach 2:
The collar is nested within the bearing wall structure, with the asymmetric collar fitting into an asymmetric recess. This nested arrangement integrates the fixation mechanism within the existing brake caliper structure, providing secure fixing without adding external components that could loosen.
2Ease of operation
If the synchronizer is positioned outside the brake caliper, then the readjustment device can be fixed angularly, but the fixing mechanism cannot secure the axial position and requires additional mounting complexity
Solution Approach 1:
The invention merges the angular positioning function and axial fixation function into a single integrated collar-recess assembly. The asymmetric collar simultaneously provides angular positioning through its non-circular geometry and axial fixation through its engagement with the bearing wall recess, eliminating the need for separate mounting mechanisms.
Solution Approach 2:
The collar serves multiple functions: it provides angular positioning, axial fixation, and structural integration within the brake caliper. This multi-functional component replaces what would otherwise require separate positioning and fixing mechanisms, reducing overall device complexity.
3Ease of manufacture
If the readjustment device is installed from the outside of the brake caliper, then assembly is complex, but installing through the brake disc side simplifies the assembly process
Solution Approach 1:
The readjustment device, collar, and synchronizer are pre-assembled as a complete unit before installation. This preliminary assembly allows the entire mechanism to be installed as one component through the brake disc side opening, simplifying the installation process and reducing the complexity of assembling multiple separate parts within the confined brake caliper space.
Data Source
AI summary
A disc brake, preferably actuated by compressed air, for a motor vehicle, has a brake caliper which has a brake application section with a brake application device with a rotary brake lever, at least one wear adjusting device for adjusting wear of brake pads, and a brake disc with a synchronization unit which includes an adjusting device, a drive device and a synchronizer. The adjusting device and the drive unit are inserted in each case into a threaded plunger of a spindle unit and are attached by way of a mounting arrangement on a bearing wall of the brake application section of the brake caliper. The synchronization unit is installed with the adjusting device and the drive device as a preassembled group into the brake application section of the brake caliper, wherein the synchronizer is arranged in the region of the mounting arrangements on the bearing wall within the brake application section. A method for installing a synchronization unit is provided.