Commercial Vehicle Disk Brake Guide Bush Wedge Clamping
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Solution Overview
Problem
The production and installation of disc brakes for commercial vehicles are hindered by high costs due to the need for multiple variants of guide bushes and screws, resulting from production-related tolerances and complex machining processes.
Innovation Solution
A disc brake design utilizing a standardized, seamless steel tube guide bush with a wedge sleeve that enables the use of the same screws for different inserts, achieving cost optimization through material savings and simplified manufacturing, where the wedge sleeve creates a self-locking clamping effect and radially expands the guide bush to secure it within the brake carrier.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple variants of guide bushes and screws are used to compensate for production-related tolerances, then the reliability and fit of the assembly is improved, but the production costs and inventory complexity increase significantly
Solution Approach 1:
The patent applies parameter changes by modifying the geometric parameters of the guide bush and screw components. Specifically, the guide bush is designed with a conical outer surface and the screw head with a matching conical surface, creating a tapered interference fit that compensates for production tolerances through the wedge effect, eliminating the need for multiple variants.
Solution Approach 2:
The patent employs asymmetry by using a conical (asymmetric) interface between the guide bush and screw instead of a cylindrical (symmetric) interface. This asymmetric tapered design creates a self-centering and self-compensating mechanism that accommodates production tolerances while maintaining reliable assembly fit.
2Manufacturing precision
If complex machining processes are applied to guide bushes to achieve precise tolerances, then the manufacturing precision is improved, but the production time and cost increase
Solution Approach 1:
The patent changes the geometric parameters of the guide bush, specifically implementing a conical outer surface instead of a cylindrical one. This parameter change allows the component to self-adjust to production tolerances through the wedge effect during assembly, reducing the need for high-precision machining while maintaining functional requirements.
Solution Approach 2:
The conical design of the guide bush and screw interface enables the components to self-adjust and self-center during assembly. The wedge effect automatically compensates for dimensional variations, eliminating the need for complex post-machining adjustments or specialized assembly procedures.
3Ease of manufacture
If through-holes are introduced in guide bushes for screw passage, then the assembly process is simplified, but material is wasted and manufacturing complexity increases
Solution Approach 1:
The patent applies the nesting principle by integrating the screw passage function directly into the solid structure of the guide bush. The screw passes through the guide bush in a nested configuration without requiring a separate through-hole, thereby eliminating material waste while maintaining assembly simplicity.
Solution Approach 2:
The patent merges the functions of the guide bush structure and the screw passage into a single integrated component. The guide bush is designed as a solid piece with the screw passing through it, combining structural support and fastening functions without requiring separate holes or additional manufacturing steps.
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 significantly reduces production and storage costs by allowing a single version of guide bushes and screws, simplifying inventory management and assembly, while maintaining effective centering and clamping of the guide bush within the brake carrier.
Implementation Method 1
a self-locking clamping effect is achieved which, when a certain radial clamping force is reached
Implementation Method 2
leads to a radial expansion of the guide bush, which means that it is pressed against the wall of the mounting hole of the brake carrier
Data Source
Figure 1
Figure 2~3
AI summary
The invention relates to a disk brake for a commercial vehicle, comprising a brake caliper, which surrounds a brake disk and which is retained on a stationary brake carrier (1) by means of guide bushings (3), which are fastened to the brake carrier by means of screws (4) and are arranged parallel to and at a distance from each other and form plain bearings, the brake caliper being retained in such a way that the brake caliper can be moved in a brake-application direction, wherein said disk brake is designed in such a way that each guide bushing (3) is wedged together with the associated screw (4).