Utility Vehicle Disk Brake Bearing Shell Clamping
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Solution Overview
Problem
The existing disc brake systems for commercial vehicles face issues with the service life of the application device due to flexing of the support material in the DU bearing, leading to high repair costs and downtime, especially due to the difficulty in accessing and replacing the bearing shell.
Innovation Solution
The bearing shell is practically clamped in the pivoting direction of the brake lever, preventing flexing and deformation, and is designed with stop edges that secure it against displacement, allowing for precise guidance of the roller and simplifying production and attachment processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the bearing shell is held in the receptacle by one-sided clamping using cage return links riveted to the brake lever, then the bearing shell can be attached without complex anti-rotation devices, but the support material flexes during pivoting movements causing reduced service life
Solution Approach 1:
The patent changes the attachment method from one-sided clamping with cage return links to a two-sided clamping arrangement using stop edges on the receptacle that engage with corresponding features on the bearing shell. This parameter change in the attachment mechanism prevents support material flexing during pivoting movements while maintaining ease of manufacture by avoiding complex anti-rotation devices.
2Reliability
If the bearing shell is securely clamped in the pivoting direction with stop edges, then support material flexing is prevented and service life is extended, but the device complexity increases due to additional stop edge features
Solution Approach 1:
The receptacle is designed with stop edges that serve multiple functions: they clamp the bearing shell in the pivoting direction, prevent support material flexing, and provide precise guidance for the roller. By making the receptacle multi-functional, the patent extends service life without proportionally increasing device complexity.
3Ease of operation
If DU plain bearings with sliding additives are used, then sufficient sliding properties are achieved, but the manufacturing and attachment processes become more complex and costly
Solution Approach 1:
The patent changes the bearing material parameters by using DU plain bearings without sliding additives, which are simpler and less costly to manufacture. The improved clamping arrangement with stop edges compensates for the reduced lubricity, maintaining sufficient sliding properties while simplifying manufacturing and attachment processes.
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
This configuration significantly extends the service life of the disc brake, reduces repair costs, and allows for the use of plain bearings without sliding additives, achieving high load absorption with inexpensive materials.
Implementation Method 1
a plastic coating to ensure sufficient sliding properties
Implementation Method 2
The bearing shell is practically clamped in the pivoting direction of the brake lever, preventing it from moving beyond its original dimension
Data Source
Figure 1
Figure 2~3b
Figure 4a~5
AI summary
A disk brake for a utility vehicle having a brake caliper spanning a brake disk on the vehicle side, in which brake caliper a clamping means is arranged which has a pivotable brake lever (5) engaging in at least one bridge carrying a brake plunger, which at the same time is directly or indirectly supported at the inner side of a wall of the brake caliper, wherein the contact area of the bridge at the brake lever (5) or of the brake lever (5) at the brake caliper is configured as a pivot bearing comprising a bearing shell (10) cross-sectionally configured as an arc forming a part of a pivot bearing and a bearing shell (10) placed in a seating (13), which disk brake is configured such that the bearing shell (10) stops in the pivoting direction of the brake lever (5) with its opposite longitudinal borders at the stop edges, which longitudinally limit the trough-like seating (13).