Disc Brake Thrust Member Structure for Easier Forging
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Solution Overview
Problem
The formation of engagement protruding portions on the thrust member of disc brakes by forging results in significant plastic deformation, increasing manufacturing costs and complexity, particularly as the piston size increases.
Innovation Solution
A disc brake design that includes a piston with internal engaging portions and a fixing mechanism to restrict the rotation and axial movement of the thrust member, eliminating the need for radially protruding engagement features, thereby simplifying manufacturing and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the engagement protruding portion is formed by forging to allow the thrust member to move axially while being nonrotatable, then the functional requirements are met, but the amount of plastic deformation increases significantly, leading to increased manufacturing cost and complexity
Solution Approach 1:
The invention divides the thrust member into multiple components: a body portion and a separate engagement portion. The engagement portion is formed with engagement protrusions that extend radially outward, while the body portion is formed separately. This segmentation allows the engagement portion to be attached to the body portion through welding or other joining methods, reducing the overall plastic deformation required during forging and lowering manufacturing complexity and cost.
Solution Approach 2:
The invention applies different formation methods to different parts of the thrust member. The engagement portion, which requires radial protrusions, is formed separately with localized material addition or attachment, while the body portion is formed by conventional forging. This local differentiation reduces the total amount of plastic deformation needed and simplifies the manufacturing process.
2Force
If the piston size increases to meet braking performance requirements, then the braking capability is improved, but the amount of plastic deformation of the thrust member increases, making manufacturing more difficult and costly
Solution Approach 1:
By segmenting the thrust member into a body portion and a separately formed engagement portion, the invention enables the engagement portion to be optimized for larger pistons without proportionally increasing the complexity of the entire component. The separate formation of the engagement portion allows for scalable design that accommodates larger piston sizes while maintaining manufacturing feasibility.
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
The design allows for easier and less costly production of the thrust member, reduces the number of manufacturing steps, and maintains effective braking performance by ensuring the thrust member is non-rotatable and axially movable relative to the piston.
Implementation Method 1
The rotary-to-linear motion conversion mechanism includes a screw member and a linearly movable member. The screw member receives rotation of the electric actuator transmitted to the screw member. The linearly movable member is threadably engaged with the screw member, and is linearly moved by the rotation of the screw member to thrust the piston.
Data Source
AI summary
A disk brake includes: a piston, which has a bottomed cylindrical shape, and is configured to press braking members against a braked member; a thrust member configured to thrust the piston through rotation of a rotary member configured to be driven by an electric machine; a rotation stopping member configured to restrict rotation of the thrust member relative to the piston; an engaging portion, which is on an inner side of the piston, and is configured to restrict rotation of the rotation stopping member through engagement; and a fixing member configured to restrict movement of the rotation stopping member in an axial direction relative to the piston.