Disk Brake Integrated Adjustment Device for Wear Compensation
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Solution Overview
Problem
Existing disc brake mechanisms for heavy load trucks are complex, costly, and prone to sealing issues due to multiple components and large openings, leading to cumbersome assembly and uneven brake lining wear.
Innovation Solution
A disc brake mechanism with a simplified structure using a single axial tappet and thrust element, integrated adjustment device, and torque clutch, mounted in parallel to the brake disc's rotary axis, which reduces component count, weight, and assembly complexity while improving sealing and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a complex brake mechanism with multiple single components is used, then the braking force transmission can be achieved, but the assembly process becomes complicated and expensive
Solution Approach 1:
The patent combines multiple single components (actuation member, lever mechanism, thrust piece, brake linings) into an integrated brake mechanism assembly that is pre-assembled as a single unit. This merging eliminates the need for complex on-site assembly of multiple separate components while maintaining the braking force transmission function.
Solution Approach 2:
The brake mechanism is pre-assembled and pre-configured as a complete unit before installation. The lever mechanism, thrust piece, and brake linings are all positioned and connected in advance, allowing for simple installation into the brake caliper housing without requiring complex assembly procedures during installation.
2Ease of manufacture
If multiple openings are provided in the brake caliper housing for component assembly, then the brake mechanism can be assembled, but major sealing problems occur
Solution Approach 1:
By combining all brake mechanism components into a single integrated assembly unit, the patent enables installation through one opening only. This eliminates the need for multiple openings in the brake caliper housing, thereby resolving the sealing problems that would arise from having multiple access points for assembly.
Solution Approach 2:
Instead of providing multiple openings for different components to be inserted separately, the invention inverts the approach by designing a single opening that accommodates the entire pre-assembled brake mechanism unit, thereby maintaining ease of assembly while eliminating sealing issues.
3Ease of manufacture
If a rotatable connection between thrust piece and lever is used, then the lever mechanism can be assembled, but uneven wear occurs at the brake lining
Solution Approach 1:
The patent removes the rotatable connection element (roller element) from between the thrust piece and lever mechanism. By extracting this rotatable component, the invention eliminates the source of uneven brake lining wear while maintaining the ability to assemble the lever mechanism through the single opening.
4Reliability
If a cross bar or yoke is employed in the brake mechanism, then the thrust element can be arranged, but the mechanism becomes bulky and heavy
Solution Approach 1:
The patent eliminates the cross bar or yoke component from the brake mechanism design. By removing this bulky structural element, the invention significantly reduces the weight and size of the brake mechanism while maintaining the functional arrangement of the thrust element through the integrated assembly approach.
Data Source
AI summary
A brake including an adjustable thrust element for applying a brake force to a brake pad and an adjustment device for selectably adjusting the thrust element. The adjustment device includes a shaft having a cylindrical shaft surface, a sleeve having a cylindrical sleeve surface, wherein the shaft and the sleeve are arranged end-to-end, and a torque clutch including a wrap spring that is mounted on the cylindrical shaft surface and mounted on the cylindrical sleeve surface, the shaft including an integral drive pin for selectively rotating the shaft. The brake further includes an operating lever, wherein the drive pin extends radially directly from the shaft surface of the shaft and wherein the operating lever includes a groove that receives the drive pin.