Disk Brake Carrier Axle Integration
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Solution Overview
Problem
Existing disc brake systems require multiple assembly steps and components, making them complex and difficult to maintain, especially when wear occurs, as they often involve a heavy brake carrier with unnecessary parts and lack efficient mounting mechanisms.
Innovation Solution
A disc brake design featuring a brake carrier directly welded to the axle body with a simplified assembly process, utilizing a one-piece or two-piece brake carrier and a lining shaft with guide surfaces for radial and tangential guidance of brake pads, along with replaceable threaded bushings and wear plates for easy maintenance, reduces the number of parts and assembly steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a multi-part brake carrier system is used with separate brake carrier parts and support arms, then the brake caliper can be mounted and guided, but the number of parts increases and assembly steps become complex
Solution Approach 1:
The patent merges the brake carrier parts and support arms into a single integrated brake carrier component. This unified structure eliminates the need for separate brake carrier parts that need to be screwed together and removes the external support arms, directly reducing the number of parts and simplifying the assembly process while maintaining all necessary functions for mounting and guiding the brake caliper.
Solution Approach 2:
The integrated brake carrier serves multiple functions simultaneously: it provides the mounting structure for the axle body, incorporates the sliding guide elements for brake caliper guidance, and integrates the support functions previously requiring separate support arms. This multi-functionality reduces the overall component count while maintaining operational capabilities.
2Strength
If the brake carrier is made as a one-piece structure with integrated support arms, then structural integrity is improved, but the weight increases
Solution Approach 1:
The patent segments the brake carrier into functional zones rather than using a solid one-piece structure. By creating a hollow or cavity-containing structure with strategically placed walls and ribs, the design maintains structural integrity for mounting and guiding functions while removing unnecessary material to reduce weight.
Solution Approach 2:
The brake carrier features local reinforcement where structural strength is needed (at mounting points and guide element locations) while having reduced material density in non-critical areas. This localized quality distribution maintains structural integrity at essential points while minimizing overall weight through strategic material placement rather than uniform thickness throughout.
3Force
If traditional brake pad mounting is used where all brake pads are attached to the brake carrier, then the brake carrier structure must support all braking forces, but this increases the load on the brake carrier
Solution Approach 1:
The patent segments the brake pad mounting arrangement by allowing some brake pads to be mounted on the brake caliper rather than all pads being attached to the brake carrier. This distribution of brake pad locations divides the braking force transmission paths, reducing the total load that must be supported by the brake carrier structure while maintaining effective braking capability.
Data Source
Figure 1~3
Figure 4~7
Figure 8
AI summary
The invention relates to a disk brake which comprises a brake anchor plate (3) which extends in an essentially transversal manner in relation thereto and which is arranged directly on the axle body (1), in addition to a brake caliper which is arranged therein. Said brake anchor plate (3a, 3b) comprises receiving elements (21) for securing the brake anchor plate, a lining shaft (10) for receiving a brake pad which is arranged counter to a brake disk of the disk brake. Said brake pad comprises guiding surfaces (11, 12) which are arranged on the lining shaft (10) and which guide the brake pad in a radial and tangential manner. The aim of the invention is to produce a disk brake which can be mounted on an axle body, which consists of a few individual parts, and can be mounted in a few steps. In said type of disk brake, each additional brake pad is arranged in a receiving element of the brake caliper.