Utility Vehicle Disc Brake Synchronizing Device Integration
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Solution Overview
Problem
Existing disc brake designs for commercial vehicles require complex and costly measures for the synchronizing device, which increases structural dimensions and necessitates an external cover for protection and sealing, counteracting the goal of minimization.
Innovation Solution
The synchronizing device is integrated within the brake caliper, utilizing two-part drive wheels with interlocking teeth for precise spindle adjustment, eliminating the need for an external cover and sealing measures, and allowing for pre-assembly synchronization of adjusting spindles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the synchronizing device is arranged outside the brake caliper, then the synchronizing device is protected from weather effects, but the structural dimensions increase and sealing complexity increases
Solution Approach 1:
The synchronizing device is merged with the brake caliper by integrating it into the internal cavity of the caliper body. The drive wheels are mounted on the bridge structure within the caliper, and the synchronizing mechanism shares the same protective enclosure as other brake components, eliminating the need for separate external housing and reducing overall structural dimensions.
Solution Approach 2:
The brake caliper is designed to serve multiple functions: it houses the brake pads, mounting bridge, and synchronizing device simultaneously. The internal cavity of the caliper provides a universal protective environment for all these components, eliminating the need for dedicated external protection for the synchronizing device and reducing sealing complexity.
2Reliability
If the synchronizing device is arranged outside the brake caliper, then the synchronizing device is protected from weather effects, but the sealing complexity and cost increase
Solution Approach 1:
The synchronizing device is merged with the brake caliper by integrating it into the internal cavity of the caliper body. The drive wheels are mounted on the bridge structure within the caliper, and the synchronizing mechanism shares the same protective enclosure as other brake components, eliminating the need for separate external housing and reducing sealing complexity.
Solution Approach 2:
The brake caliper is designed to serve multiple functions: it houses the brake pads, mounting bridge, and synchronizing device simultaneously. The internal cavity of the caliper provides a universal protective environment for all these components, eliminating the need for dedicated external protection for the synchronizing device and reducing sealing complexity.
3Ease of manufacture
If the drive wheel has coarse tooth pitch for form fit with traction device, then the form fit is simplified, but the presetting precision of adjusting spindles decreases
Solution Approach 1:
The drive wheel is segmented into two distinct parts: an outer wheel with coarse teeth for engaging the traction device and an inner wheel with fine teeth for precise spindle adjustment. This segmentation allows each part to be optimized for its specific function - the outer wheel provides robust mechanical engagement while the inner wheel delivers precise positioning, resolving the contradiction between manufacturing simplicity and positioning precision.
Solution Approach 2:
Different regions of the drive wheel assembly have different tooth pitches tailored to their specific functions. The outer wheel features coarse teeth optimized for easy engagement with the chain or belt, while the inner wheel features fine teeth optimized for precise spindle positioning. This local differentiation of quality allows both coarse form fit and fine presetting precision to coexist in the same mechanism.
4Volume of moving object
If the synchronizing device is arranged inside the brake caliper, then the structural dimensions are minimized, but the space for component accommodation is limited
Solution Approach 1:
The synchronizing device is nested within the existing internal cavity of the brake caliper, utilizing the space already allocated for brake component accommodation. The drive wheels are mounted on the bridge structure, and the synchronizing mechanism is positioned in the available internal volume, effectively nesting the synchronizing function within the existing caliper structure without requiring additional external space.
Data Source
Figure 1~3
Figure 2
AI summary
Disclosed is a disk brake for a utility vehicle, comprising a brake caliper that grips a brake disk, a clamping device, arranged in the brake caliper, for pressing brake linings against the brake disk, two parallel, spaced-apart adjusting spindles (3) which are mounted in a twistable manner, by means of a corresponding thread, in a bridging element (1) gripped by the clamping device, a readjustment device which is arranged in the brake caliper and allows a wear-related change in the clearance between the brake lining and the brake disk to be substantially compensated by axially moving the adjusting spindles (3), and a synchronizing device (2) having a tensile driving mechanism which allows the two adjusting spindles (3) to be synchronously moved. The tensile driving mechanism has a tension means (7) that meshes in a force-transmitting manner with driving gears (6) which are effectively connected to the adjusting spindles (3) for conjoint rotation therewith. Each driving gear (6) includes at least one form-fitting element (10) which engages with an outer axial guide of the associated adjusting spindle (3).