Disc Hydraulic Anti-lock Brake with Nested Pistons
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Solution Overview
Problem
Existing braking systems, including drum brakes and ABS, face issues such as large space occupation, complex structure, poor heat dissipation, high cost, and low safety, which hinder their widespread adoption for effectively managing braking inertia, especially in high-speed and heavy-duty applications.
Innovation Solution
A disc hydraulic anti-lock brake system that integrates service and parking braking capabilities, utilizing a support with passages, pistons, a core tube, and an elastic member to alternately increase and decrease pressure on the brake disc, facilitated by a brake release system and anti-lock system, allowing for efficient deceleration and anti-lock functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If drum brakes or pneumatic ABS systems are used, then braking capability is achieved, but device complexity and cost increase
Solution Approach 1:
The patent combines service braking and parking braking functions into a single integrated brake assembly. The support structure houses both braking mechanisms share common components like the brake disc, mounting brackets, and hydraulic fluid passages, eliminating the need for separate drum brake and ABS systems while maintaining both braking capabilities.
Solution Approach 2:
The first piston serves multiple functions: it performs service braking by pressing the service brake pad against the brake disc, and it performs anti-lock braking by controlling hydraulic pressure release. This multi-functional design eliminates the need for separate braking systems, reducing overall device complexity while maintaining comprehensive braking capability.
2Reliability
If traditional braking systems are used, then braking function is provided, but space occupation increases
Solution Approach 1:
The second piston is nested within the first piston, with the second piston's cylinder bore positioned inside the first piston's structure. This nested arrangement allows the parking brake mechanism to occupy the same spatial envelope as the service brake, significantly reducing the overall space required for the braking system while maintaining both functions.
Solution Approach 2:
The patent utilizes the axial dimension along the piston stroke direction to accommodate multiple braking functions. The first piston extends axially for service braking, while the second piston is positioned concentrically within it for parking braking. This dimensional arrangement allows both systems to coexist in a compact footprint without requiring additional lateral space.
3Reliability
If existing ABS systems are used, then anti-lock braking is achieved, but cost and safety factor worsen
Solution Approach 1:
The anti-lock braking function is achieved through the automatic operation of the drain valve that responds to wheel speed sensor signals. The system self-regulates hydraulic pressure by opening or closing the drain valve based on detected wheel deceleration, eliminating the need for complex external ABS control units and making the system more cost-effective while maintaining safety.
4Reliability
If drum brakes are used, then braking is achieved, but heat dissipation and braking performance deteriorate
Solution Approach 1:
The patent employs hydraulic pressure transmission through brake fluid to actuate both the first and second pistons. The hydraulic system efficiently transmits force from the master cylinder to the brake pads, providing superior braking performance compared to mechanical drum brakes while the exposed brake disc design enables effective heat dissipation through direct air contact and rotational cooling.
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 system effectively realizes service and parking braking while preventing wheel lock, enhancing safety and reducing the impact of braking inertia, with a simpler and more cost-effective design compared to existing solutions.
Implementation Method 1
an elastic member provided between the second piston and a bottom of the second hole; wherein the elastic member may be a spring or gas
Implementation Method 2
the first cavity is in communication with a service brake valve through the first passage and a first pipeline; the second cavity is able to be in communication with a parking brake valve through the channel, the core tube, the second passage and a second pipeline
Implementation Method 3
a brake pad provided on the brake pad base; a brake disc provided with a counting gear ring and a mounting portion
Data Source
Figure 1
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AI summary
A disc hydraulic anti-lock brake and a brake system. The disc hydraulic anti-lock brake comprises a support (400) provided with a first opening (415), a core tube (502), a first passage (406), a second passage (412), a third passage (409) and a brake pad base; a first piston (501) provided in the first opening (415), with a first cavity being communicated with the first passage (406) and a service brake valve, and the first piston (501) being provided with a second opening (504); a second piston (506) provided in the second opening (504), with a second cavity (508) being communicated with the core tube (502), the second passage (412) and a parking brake valve; an elastic member (505) provided between the second piston (506) and the bottom of the second opening (504); a brake release system provided with a pump (315) and an unloading valve (322); a brake disc (900) provided with a counting gear ring and a mounting portion; and an anti-lock system provided with a counting sensor, a motor (309), and a liquid drainage valve (310). A liquid inlet of the liquid drainage valve (310) is communicated with the first cavity by means of the third passage (409). ccoridng to the brake, the support (400) is provided with the first opening(416) and the second opening (417), and the first piston (601) and the second piston (701) are provided in the first opening (416) and the second opening (417), respectively. The brake system can achieve service braking, parking braking and anti-lock braking, and is easy to achieve.