Disk Brake Guide Rail Damping Bushing
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Solution Overview
Problem
Disc brakes in commercial vehicles experience rattling noises and reduced operational reliability due to radial mobility in the fixed bearing, which also leads to corrosion and dirt ingress impairing sliding properties, necessitating an improvement in wear and vibration resistance with minimal design and manufacturing complexity.
Innovation Solution
A disc brake design where the guide rail is held under slight pretension with a radially elastically deformable section acting as a damping bushing, featuring a metallic inner shell with an elastically deformable layer, and a damping ring, which adjusts pressing forces and provides progressive damping behavior to prevent rattling and enhance service life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a play-free sliding bearing is implemented between the guide rail and guide sleeve, then radial mobility is reduced, but manufacturing tolerances cannot be compensated and the structure becomes more complex
Solution Approach 1:
The guide sleeve is constructed as a composite structure with an inner metallic shell and an outer elastomer layer. The metallic shell provides structural strength and radial stability, while the elastomer layer provides damping and compensates for manufacturing tolerances. This composite design resolves the contradiction by achieving both radial stability and tolerance compensation without increasing structural complexity.
Solution Approach 2:
The elastomer layer's material parameters (viscoelastic properties, damping characteristics) are specifically selected to provide radial damping while accommodating manufacturing tolerances. The material parameters are tuned to ensure the guide sleeve maintains sufficient radial stability while absorbing dimensional variations from assembly tolerances.
2Ease of operation
If the guide sleeve is made of brass for good sliding properties, then sliding performance is improved, but dirt particles still ingress and impair sliding properties
Solution Approach 1:
The guide sleeve combines a metallic shell (providing structural integrity) with an outer elastomer layer (providing protection). The elastomer layer acts as a barrier that prevents dirt particles from reaching the sliding surface, while the underlying metallic structure maintains good sliding properties through proper material selection and surface treatment.
3Force
If the elastic layer is compressed under large braking torque, then the plain bearing contacts the guide rail outside the elastic layer, but damage to the layer or socket may occur
Solution Approach 1:
The elastomer layer's material parameters (hardness, elasticity, compressive strength) are specifically selected to allow compression under large braking torques without permanent deformation or damage. The material is chosen to maintain its functional properties even when compressed, enabling the bearing to transition to contact with the guide rail outside the elastic layer while preventing damage to the layer or socket structure.
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
The solution effectively reduces rattling noises and improves operational reliability by compensating manufacturing tolerances and enhancing wear resistance, allowing the disc brake to function more smoothly and reliably, especially under increased radial forces.
Implementation Method 1
the guide rail has a radially elastically deformable section, in particular consisting of a damping bushing with a metallic inner shell, which serves as a carrier for an elastically deformable layer
Implementation Method 2
the damping bushing has progressive damping behavior in the radial direction of loading, which preferably differs over sub-areas
Implementation Method 3
When a correspondingly large braking torque is introduced, the elastic layer is compressed to such an extent that the plain bearing also comes to rest on the guide rail outside of the elastic layer
Implementation Method 4
the guide sleeve lies slidably on the elastic layer as a sliding bearing
Data Source
Figure 1~2
Figure 3~4
Figure 5~7
AI summary
The invention relates to a disk brake, particularly for a commercial vehicle, comprising a brake caliper (1), which is provided with a brake disk and fixed to a brake carrier (5) by means of two fastening elements such that it can be axially displaced in relation to the brake disk (1). The fastening elements each comprise a guiding bar (3), which is connected to the brake carrier (5) in a fixed manner. For the axial displacement of the brake caliper (1), one of the guiding bars is guided in a plain bearing designed as a movable bearing and the other in a plain bearing designed as fixed bearing such that the guiding bar (3) of the fixed bearing comprises an elastically deformable section in the radial direction on the outer circumference. The associated bearing rests against the deformable section at least in some sections.