Utility Vehicle Disk Brake Air Gap Control for Pad Wear
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Solution Overview
Problem
Existing braking systems for commercial vehicles face challenges in achieving short brake actuation times and maintaining desired braking performance with small, economical electric motors, while also dealing with high complexity and reduced braking effectiveness as brake pads wear out.
Innovation Solution
A braking device with a brake pad wear sensor and control unit that adjusts clearance based on wear, allowing the system to maintain constant braking force with lower drive power by shifting the contact point into a more efficient working area of the non-linear gear, and optionally adjusting for temperature effects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the brake pads are worn down, then the brake clearance decreases and braking performance deteriorates, but increasing the clearance to compensate requires additional adjustment mechanisms and control systems
Solution Approach 1:
The brake system automatically adjusts its own clearance through a self-regulating mechanism. The non-linear transmission element's geometry is designed such that as the brake pads wear and clearance decreases, the mechanical interaction between transmission elements automatically increases the effective clearance compensation without requiring external sensors or active control systems.
Solution Approach 2:
The patent changes the geometric parameters of the non-linear transmission element to compensate for wear. By designing the transmission element with specific curvature and profile characteristics, the system transforms the wear-induced clearance change into a beneficial effect where the transmission ratio automatically adjusts to maintain constant braking force.
2Reliability
If a larger electric motor is used to maintain braking force with worn pads, then braking performance is maintained, but energy consumption and system weight increase
Solution Approach 1:
The non-linear transmission element is designed with varying transmission ratios that compensate for pad wear. As pads wear and clearance changes, the transmission ratio automatically adjusts to maintain constant output force, eliminating the need for increased drive power and reducing energy consumption throughout the brake pad lifecycle.
3Reliability
If complex sensor and control systems are implemented to adjust clearance, then braking performance is maintained, but manufacturing cost and assembly complexity increase
Solution Approach 1:
The system uses passive mechanical elements whose geometry inherently provides the compensation function. The non-linear transmission element's profile is designed to automatically adjust clearance effects through mechanical interaction alone, eliminating the need for sensors, controllers, and complex adjustment mechanisms, thereby simplifying manufacturing and assembly.
4Speed
If the brake clearance is kept small for responsive braking, then actuation time is reduced, but braking performance deteriorates as pads wear and stiffness increases
Solution Approach 1:
The non-linear transmission element is designed with a transmission ratio that varies with position and wear state. This allows the system to maintain small effective clearance for fast actuation while the transmission geometry compensates for wear-induced stiffness changes, preserving braking performance throughout the pad lifecycle.
Data Source
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AI summary
The invention relates to a brake device (102), particularly a utility vehicle disk brake, comprising a brake disk (106), at least one brake pad (104, 104'), a transmission member (114) coupled to the brake pad (104, 104') and used to press the at least one brake pad (104, 104') against the brake disk (106), a drive for producing a drive variable, a non-linear gear (110) which is operatively connected to the drive and the transmission member (114) and used for the non-linear transmission of the drive variable to the transmission member (114), and an adjusting unit (120) for adjusting an air gap (108) between the transmission member (114) and the brake disk (106). According to the invention, the device comprises a brake pad wear sensor for detecting the degree of wear of the at least one brake pad (104, 104'), and a control unit which is connected to the sensor in a signal-conducting manner and is designed to modify the air gap (108) according to the wear of the brake pad (104, 104') determined by the sensor.