Disk Brake Lever-Roller Assembly for Secure Bridge Fixation
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Solution Overview
Problem
The existing disc brake clamping devices for commercial vehicles face issues with the secure fixation of rolling rollers, leading to potential brake failures due to axial displacement and particle contamination, which complicates assembly and increases production costs.
Innovation Solution
A clamping device design that secures the rolling roller to the bridge using a securing element, such as a clamping sleeve or dowel pins, to prevent axial, radial, and rotational movement, allowing for pre-assembly as a structural unit and simplifying installation, while eliminating the need for complex machining and specialized assembly measures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the roller is secured to the bridge using flattened sections and support surfaces, then axial and rotational displacement is prevented, but the design complexity increases and machining costs rise
Solution Approach 1:
The patent replaces flat surfaces with spherical geometry. The roller features a spherical outer surface, and the bridge contains a corresponding spherical recess. This curved surface design simplifies manufacturing compared to precision flat surfaces while effectively preventing axial, radial, and rotational displacement of the roller through the spherical constraint geometry.
2Adaptability or versatility
If the roller is kept as a loose component, then assembly flexibility is maintained, but assembly process becomes complicated and requires additional aids
Solution Approach 1:
The spherical roller is pre-positioned into the spherical recess of the bridge during bridge manufacturing, creating a pre-assembled unit. This preliminary action eliminates the need for complex assembly aids and special procedures during final brake assembly, while the spherical design maintains natural alignment and positioning flexibility.
3Strength
If hardened steel is used for the roller, then friction resistance is improved, but manufacturing costs increase
Solution Approach 1:
The patent employs a composite material system where a steel roller core provides structural strength, overlaid with a DU (double metal) bearing material layer. This composite structure delivers the friction resistance and wear properties of hardened materials while using less expensive base materials, reducing overall manufacturing cost compared to fully hardened steel.
4Ease of operation
If the roller is freely rotating, then smooth operation is achieved, but particle contamination occurs that reduces bearing service life
Solution Approach 1:
The patent introduces a DU bearing material layer as an intermediary between the steel roller and the bearing shell. This intermediate layer prevents direct metal-to-metal contact and particle generation, while still allowing smooth rotation. The DU material acts as a mediator that maintains operational smoothness while eliminating the harmful particle contamination effect.
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 enhances the service life of the clamping device, simplifies assembly, reduces production costs, and eliminates the need for hardened steel, thereby improving safety and cost efficiency in the manufacturing process.
Implementation Method 1
a roller bearing in the form of a roller secured axially and radially between the brake lever and the bridge is arranged
Implementation Method 2
the brake lever is smoothly mounted on the inner wall of the brake caliper
Implementation Method 3
a bearing shell is formed in the brake lever, which is coated with a suitable plastic, resulting in a so-called DU bearing
Implementation Method 4
the at least one roller is virtually connected to the bridge by a locking element, ensures not only the fixation of the roller relative to the bridge in axial, radial, and rotational directions
Data Source
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AI summary
Disclosed is a brake application mechanism for a disk brake in a utility vehicle, comprising a pivotable brake lever that is supported on an inner wall of a brake caliper and, indirectly, on a bridge (8) which is movably disposed in the brake caliper and which suports at least one brake pad, wherefor an axially and radially secured antifriction roll (8) is disposed between the brake lever and the bridge (8). The disclosed brake application mechanism is designed such that the antifriction roll (9) rests on the bridge (13) in such a way as to be prevented from rotating and sliding.