Floating Caliper Disk Brake Automatic Resetting Mechanism
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing disc brake designs for commercial vehicles face issues with brake pad wear and overheating due to constant friction during non-braking conditions, leading to reduced service life and increased maintenance costs.
Innovation Solution
A disc brake design featuring a resetting device positioned opposite the application device, with a compression spring assembly and adjustment mechanism to maintain even force distribution and compensate for wear and deformation, ensuring minimal system rigidity and effective automatic resetting of the brake caliper.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the brake caliper is held in a fixed position during braking, then braking force is maintained, but the brake linings continue to rub against the brake disc after braking, causing overheating and excessive wear
Solution Approach 1:
The restoring device automatically returns the brake caliper to its initial position after braking without external intervention. The spring mechanism self-activates when braking force is released, pulling the caliper away from the brake disc and eliminating the need for manual resetting or additional actuation systems.
Solution Approach 2:
The brake caliper undergoes periodic positioning: during braking it is pressed against the disc to generate friction, and after braking it is automatically restored to the initial position. This periodic action ensures the brake linings are in contact with the disc only when braking force is applied, preventing continuous rubbing and overheating.
2Ease of operation
If a restoring device is integrated into the guide rail to automatically return the brake caliper, then the brake caliper can be reset, but the guide rail structure becomes more complex requiring special production measures
Solution Approach 1:
The restoring device is segmented into distinct functional components: a separate spring element, a mounting bracket, and connection points on the caliper and carrier. This modular segmentation allows each component to be manufactured independently using standard processes, avoiding the need to modify the guide rail structure while still achieving automatic resetting functionality.
Solution Approach 2:
The restoring device acts as an intermediary mechanism between the brake caliper and the brake carrier. Rather than modifying the guide rail directly, the spring-based restoring device mediates the resetting action, connecting the caliper to the carrier in a way that simplifies the overall structure compared to integrating the restoring function directly into the guide rail.
3Extent of automation
If the restoring element is formed from a leaf spring to pull the brake pad out of contact, then automatic resetting is achieved, but the retraction distance varies greatly due to wear
Solution Approach 1:
The spring element is designed with specific mechanical parameters (coil diameter, wire diameter, number of coils, material properties) that provide a consistent restoring force and displacement characteristic. These parameters are carefully selected to ensure the spring extends by a predetermined, constant amount regardless of brake pad wear, maintaining precise retraction distance throughout the service life of the brakes.
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 design extends the service life of brake pads and discs by minimizing friction during non-braking conditions, reducing wear and overheating, and maintaining consistent brake performance through adjustable clearance compensation.
Implementation Method 1
a compression spring (8), with which the brake caliper (1) is automatically brought into a starting position
Data Source
Figure 1
Figure 2
Figure 3~5
AI summary
The invention relates to a disk brake, in particular for a utility vehicle, comprising a brake caliper (1) that reaches over a brake disk (5) and is designed as a floating caliper, the brake caliper being fastened to a stationary brake carrier (2), a brake application device, by means of which an associated, action-side brake lining (3) can be pressed against the brake disk (5) during braking, and at least one restoring device (6) having a restoring element, by means of which restoring device the brake caliper (1) can be brought into an initial position after displacement and release of the brake as a result of braking, is designed in such a way that the restoring device (6) is retained both in the brake caliper (1) and in the brake carrier (2) on the side of the brake disk (5) facing the brake application device (22).