Disk Brake Cylindrical Roller Holder Integration

Solution Overview

Problem

Existing disk brake technologies face challenges in cost-effective manufacturing and precise assembly, with complex assembly processes and potential functional issues due to misalignment of components, particularly with the cylindrical roller and lever, leading to increased costs and reduced reliability.

Innovation Solution

A disk brake design featuring a cylindrical roller holder with cage return guides that allows for preassembly of the lever as a complete unit, eliminating the need for bridge installation and ensuring precise positioning of the cylindrical roller, using bearing lugs and a separate cylindrical roller holder to secure and align components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the cylindrical roller is fastened to the bridge using bearing lugs and bearing shell, then the roller is axially and radially secured, but the assembly process becomes complicated and costly

Engineering Contradiction:

Improvesecuring of cylindrical rollerVSAvoidassembly process

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines the cylindrical roller holder with the bridge into a single integrated component. The holder is formed as one piece with the bridge, eliminating the need for separate bearing lugs, bearing shells, and multiple fastening operations. This merging reduces assembly complexity while maintaining the securing function through the integrated structure that provides both axial and radial constraints.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The integrated cylindrical roller holder serves multiple functions simultaneously: it provides the bridge structure, contains the cylindrical roller, provides axial and radial securing, and eliminates the need for separate bearing components. This multi-functionality reduces the number of parts and assembly steps while maintaining all necessary securing functions.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If the cylindrical roller is fastened to the bridge using bearing lugs and bearing shell, then the roller is axially and radially secured, but manufacturing costs increase

Engineering Contradiction:

Improvesecuring of cylindrical rollerVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent combines the cylindrical roller holder with the bridge into a single integrated component. The holder is formed as one piece with the bridge, eliminating the need for separate bearing lugs, bearing shells, and multiple fastening operations. This merging reduces assembly complexity while maintaining the securing function through the integrated structure that provides both axial and radial constraints.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent extracts the unnecessary intermediate components (separate bearing lugs, bearing shells, and fastening elements) from the assembly, keeping only the essential bridge and integrated holder structure. This extraction eliminates redundant parts and simplifies manufacturing while maintaining the required securing function.

Inventive Principle:

Principle #2Taking out (Extraction)

3Reliability

If the cylindrical roller is fastened to the bridge using bearing lugs and bearing shell, then the roller is axially and radially secured, but exact positioning with respect to the lever is not ensured

Engineering Contradiction:

Improvesecuring of cylindrical rollerVSAvoidpositioning of cylindrical roller

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The patent combines the cylindrical roller holder with the bridge into a single integrated component. The holder is formed as one piece with the bridge, eliminating the need for separate bearing lugs, bearing shells, and multiple fastening operations. This merging reduces assembly complexity while maintaining the securing function through the integrated structure that provides both axial and radial constraints.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The integrated holder design incorporates the positioning function directly into the bridge structure during manufacturing. The precise positioning of the cylindrical roller relative to the lever is built into the holder geometry from the start, eliminating the need for complex assembly and adjustment operations to achieve exact positioning.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS7673722B2Disc brake for a vehicle, in particular a commercial vehicle

Publication Date: 2010.03.09 KNORR BREMSE SYSTEME FUER NUTZFAHIZEUGE GMBH

AI summary

A disk brake for a vehicle, in particular a commercial vehicle, including an application device, which is used to apply a brake lining to a brake disk by at least one or two actuating spindles running parallel and at a distance from one another in a bridge. The application device has an anti-friction roller, which is supported on a pivotable lever of the application device. The disk brake is configured in such a way that the anti-friction roller is fixed as a separate component radially and axially on the lever and is held by an anti-friction roller holder that is fixed to the lever. The anti-friction roller holder is provided with cage return guides, which, when the lever is pivoted back into an initial position, likewise press the journal bearings into an initial position.