Disk Brake Lever Arm Transmission Layout for Bearing Space
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Solution Overview
Problem
Existing disc brake designs face challenges in maximizing installation space for bearings while maintaining effective braking force transmission, as the space required for transmission mechanisms compromises the size and length of the brake lever's application shaft, leading to reduced bearing forces.
Innovation Solution
The disc brake design positions the first gear element of the gear coupling at the inner end of the lever arm, allowing for a larger space for the application shaft's bearings, and uses a drive element with a connecting link that describes an arc or varies in angle to optimize movement transmission, minimizing unnecessary play and enhancing stability against vibrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the transmission mechanism is positioned in the conventional location, then the gear coupling can be implemented, but the space for the application shaft bearings is reduced, leading to smaller bearing surface area and higher specific bearing forces
Solution Approach 1:
The first gear element is positioned at the inner end of the lever arm in the plane of pivoting movement, utilizing the two-dimensional space at the lever arm's inner end rather than consuming axial space along the application shaft. This dimensional repositioning allows the transmission mechanism to coexist with larger bearing surfaces without compromising either function.
Solution Approach 2:
The lever arm is divided into functional zones: the inner end area houses the transmission mechanism while the outer end area maintains the application shaft and bearings. This spatial segmentation allows both the transmission and bearing functions to operate independently with optimized space allocation for each.
2Force
If the application shaft length is reduced to accommodate the transmission, then the transmission can be integrated, but the bearings have less surface area to transmit braking forces, increasing specific bearing forces
Solution Approach 1:
The transmission mechanism is relocated to the inner end of the lever arm in the pivoting plane, utilizing radial and transverse space rather than axial space. This preserves the full axial length of the application shaft available for bearings, maintaining large bearing surface areas for effective braking force transmission while keeping specific bearing forces low.
3Area of stationary object
If the gear coupling is positioned to maximize bearing space, then bearing surface area is increased, but the transmission mechanism must be positioned in an area where application forces are not transmitted
Solution Approach 1:
The first gear element is positioned at the inner end of the lever arm within the pivoting plane, a location that experiences rotational movement but not direct application forces. This positioning allows the transmission mechanism to function effectively through the lever's pivoting motion while the application shaft and bearings maintain their full size for force transmission.
Solution Approach 2:
Different regions of the lever arm are assigned different functional qualities: the inner end area is optimized for transmission with the gear coupling, while the outer end area is optimized for force transmission with the application shaft and bearings. Each region is designed for its specific function without compromising the other.
Data Source
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AI summary
The invention relates to a disk brake for a vehicle, preferably a utility vehicle, comprising a brake caliper, which reaches around a brake disk and brake pads on both sides of the brake disk, a brake application device (5), which can be actuated by means of a force element, preferably a pneumatic force element, an adjusting device (20) for compensating the brake-pad wear and the brake-disk wear, which is arranged on an adjustment axis (L) extending in the brake application direction and is provided with a drive element (27) that can be rotated about the adjustment axis (L), a brake lever, which is part of the brake application device (5) and which is composed of a brake application shaft (11), which is supported with respect to the brake caliper and with respect to a pressure piece (8) working against one of the brake pads, and of a lever arm (12), which can be pivoted with the brake application shaft (11) and the pivoting center line of which extends at a right angle to the brake application shaft (11) and which is provided with a support (16) for the force element in the region of the outer end (12A) of the lever arm, wherein the brake lever (10) has, in extension of the lever arm (12) in the inward direction, a clearance (40), through which the adjustment axis (L) extends, and a transmission, which couples the brake lever (10) to the drive element (27) and is composed of a first transmission element (31) on the brake lever (10) and a second transmission element (32) on the drive element (27), which second transmission element interacts with the first transmission element. In order to provide installation space for the brake application shaft, the first transmission element (31) is arranged at the inner end (12B) of the lever arm (12) in the plane (E) defined by the pivoting motion (S) of the lever arm (12).