Utility Vehicle Disk Brake Lever Positioning
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing disk brake designs for utility vehicles lack precise positioning of the brake lever, leading to operational reliability issues and reduced service life due to potential lateral misalignment and uncontrolled loading of components during braking operations.
Innovation Solution
A disk brake and brake caliper design that incorporates a ring-shaped securing element with slots in the brake lever and caliper head, ensuring permanent positioning of the brake lever and minimizing lateral displacement, thereby enhancing operational reliability and service life by providing a positive guidance mechanism.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional brake lever support design is used, then the structure is simple, but the brake lever positioning is imprecise leading to lateral misalignment
Solution Approach 1:
A positioning element is introduced as an intermediary component between the brake lever and the caliper head. This positioning element features a receptacle with a bottom surface that engages with the brake lever, providing precise lateral positioning while maintaining structural simplicity through modular design
Solution Approach 2:
The brake caliper structure is segmented into functional components: the caliper head, the positioning element as a separate component, and the brake lever. This segmentation allows the positioning function to be independently optimized while keeping the overall structure manageable and manufacturable
2Reliability
If the brake lever is not precisely positioned, then the structure is simpler, but operational reliability decreases due to uncontrolled loading
Solution Approach 1:
The positioning element serves as a mediator that ensures reliable brake lever positioning without requiring complex guidance mechanisms. The receptacle geometry provides automatic centering and lateral positioning, ensuring controlled loading paths while maintaining structural simplicity
Solution Approach 2:
The positioning element's receptacle is designed to self-align and self-position the brake lever through its geometric configuration. The bottom surface of the receptacle automatically provides lateral positioning when the brake lever is installed, eliminating the need for additional adjustment mechanisms
3Duration of action of stationary object
If lateral displacement of the brake lever is allowed, then the design is more flexible, but friction and wear increase reducing service life
Solution Approach 1:
The positioning element acts as a mediator that permits easy installation through its receptacle design while simultaneously preventing lateral displacement during operation. The receptacle's geometric constraints ensure the brake lever maintains proper alignment, reducing friction and wear on contact surfaces
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 ensures precise positioning of the brake lever, reducing friction and wear, and significantly improving the functional reliability and service life of the brake components by preventing lateral misalignment and uncontrolled loading.
Implementation Method 1
corresponding friction forces must be overcome
Implementation Method 2
a ring-shaped securing element with slots in the brake lever and caliper head, ensuring permanent positioning of the brake lever
Implementation Method 3
which is, at least over the pivoting range, of circular-arc-shaped form corresponding to the curvature of the receptacle
Data Source
AI summary
A disk brake for a utility vehicle is provided. A brake caliper of the disk brake includes a receiving chamber configured to receive a brake application device with a pivotable brake lever. The brake lever is supported at one end on a bridge supporting at least one brake piston and at the other end on a wall of the brake caliper forming a caliper head. A pivot bearing is provided for supporting the brake lever on the caliper head or the bridge. The pivot bearing includes a receptacle having a circular-arc-shaped cross-section and has a pivoting body configured to be located in the receptacle. The brake lever is retained in such a way that the brake lever is secured against displacement transversely to the pivoting direction of the brake lever by at least one securing element arranged in the region of the pivoting body extending axially on both sides of the securing element. The securing element protrudes radially in relation to the pivoting body at least in some regions and engages in a slot of the caliper head or of the bridge having a circular arc shape in the pivoting direction of the brake lever.