Disc Brake Actuation Mechanism Vibration Damping
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Solution Overview
Problem
Disc brakes on heavy vehicles experience de-adjustment due to vibration-induced torques, leading to impaired brake function from excessive or insufficient pad-to-rotor air gaps.
Innovation Solution
Incorporating a friction element between the yoke and piston in the disc brake actuation mechanism to provide consistent frictional resistance, inhibiting unwanted rotation and maintaining the desired pad-to-rotor alignment, thus preventing de-adjustment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional wear adjustment mechanism is used without a friction element, then the device complexity is reduced, but vibration-induced torques cause de-adjustment of the disc brake during operation
Solution Approach 1:
A friction element is introduced as an intermediary component between the piston and yoke. This friction element provides controlled frictional resistance that prevents vibration-induced torques from causing de-adjustment, while allowing the wear adjustment mechanism to function properly. The friction element acts as a mediator that filters out harmful vibrations while transmitting necessary adjustment forces.
2Reliability
If additional clips or retaining components are added to prevent de-adjustment, then the reliability improves, but the device complexity and manufacturing costs increase
Solution Approach 1:
The friction element serves multiple functions simultaneously: it provides frictional resistance to prevent vibration-induced de-adjustment, retains the piston on the yoke, and allows controlled movement for wear adjustment. By combining multiple functions into a single component, the need for additional clips or retaining features is eliminated, simplifying manufacturing while maintaining reliability.
3Adaptability or versatility
If the piston is made fully rotatable for wear adjustment, then the adaptability improves, but vibration-induced torques can cause unwanted rotation and de-adjustment
Solution Approach 1:
The friction element modifies the rotational parameter by providing controlled frictional resistance. This allows the piston to rotate sufficiently for wear adjustment while preventing excessive rotation caused by vibrations. The friction element effectively changes the rotational characteristics from fully free to controlled, maintaining both adaptability and reliability.
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 friction element effectively reduces the impact of vibration-induced torques, maintaining consistent brake performance by preventing unwanted de-adjustment and reducing manufacturing costs through a simplified design with fewer components.
Implementation Method 1
a friction element is located between the yoke and the portion of the piston, for providing a predetermined level of resistance to relative rotation of the yoke and portion of the piston
Implementation Method 2
The friction element may be resilient, and is dimensioned such that compression thereof applies a force to a surface of the yoke and a surface of the portion of the piston
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
An actuation mechanism for a disc brake, the actuation mechanism comprising: a non-rotatable yoke to transmit an actuating force from an operating shaft; a piston configured to be driven by the yoke to transmit the actuating force to a brake pad, the piston comprising a portion rotatable with respect to the yoke to cause the piston to extend; and a wear adjustment mechanism for adjusting extension of the piston to account for wear of the brake pad; wherein a friction element is located between the yoke and the portion of the piston, for providing a predetermined level of resistance to relative rotation of the yoke and portion of the piston.