Disk Brake Quick Contact Wedge Mechanism
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Solution Overview
Problem
Existing disc brake systems face challenges in quickly applying brake pads to the disc due to excessive clearance, which affects response times and energy efficiency, especially during emergency braking, and existing solutions either reduce clearance too much or fail to eliminate idle stroke completely.
Innovation Solution
A disc brake system with a quick-application device featuring a position-changeable intermediate element, such as a threaded bushing or rotating wedge, that generates a pre-stroke by altering its position during actuation, reducing the required actuation stroke through a self-locking mechanism and wedge configuration, thereby ensuring rapid pad application and energy savings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If a conventional adjustment device is used to reduce clearance, then the brake pad contact with the disc is improved, but the response time is still insufficient due to remaining idle stroke
Solution Approach 1:
The quick-application device performs a preliminary action by generating a pre-stroke that partially closes the clearance before the main braking action occurs. When the brake rotary lever is actuated, the intermediate element changes position to move the brake pad toward the disc, reducing the idle stroke that would otherwise remain even with conventional adjustment devices.
Solution Approach 2:
The invention introduces a dynamic intermediate element (threaded bushing or rotating wedge) that can change its position during brake actuation. This dynamic component allows the system to adapt the brake pad position in real-time, enabling the pre-stroke function that reduces response time without permanently altering the clearance setting.
2Loss of time
If the clearance is reduced to minimize idle stroke, then response time improves, but the risk of pad rubbing increases
Solution Approach 1:
The dynamic intermediate element allows the system to temporarily reduce clearance during braking while automatically restoring the original clearance setting when the brake is released. This dynamic adjustment enables pre-stroke for faster response without permanently reducing clearance to the point where pad rubbing occurs during normal operation.
Solution Approach 2:
The pre-stroke mechanism performs a preliminary movement that closes only the necessary portion of the clearance during braking, leaving sufficient clearance (at least 0.4 mm) to prevent pad rubbing. This selective preliminary action achieves response time improvement without creating the harmful condition of excessive clearance reduction.
3Reliability
If a self-locking mechanism is used to maintain position, then reliability improves, but device complexity increases
Solution Approach 1:
The invention uses a threaded bushing or rotating wedge as an intermediary element between the brake rotary lever and the brake pad adjustment mechanism. This intermediate element provides the self-locking function through its threaded or wedge geometry, maintaining the pre-stroke position reliably without requiring additional complex locking mechanisms or actuators.
Solution Approach 2:
The self-locking mechanism is inherent in the design of the intermediate element itself (threaded bushing or rotating wedge), which automatically maintains its position through friction and geometric locking. The element serves its own locking function without requiring external assistance, simplifying the overall device while improving reliability.
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 effectively reduces the brake cylinder stroke by up to 50% and maintains a minimum clearance to prevent pad rubbing, enhancing response times and energy efficiency while ensuring reliable operation.
Implementation Method 1
The quick-applying device (13) has an intermediate element (36, 22, 22') that can be changed in position and has at least one wedge-shaped configuration
Implementation Method 2
The threaded bushing (36) has a rotary drive connection with the brake rotary lever (4) and an output connection with the adjusting spindle (6)
Data Source
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AI summary
A preferably pneumatically actuated disk brake (1), in particular for a motor vehicle, comprises a brake application mechanism with a rotary brake lever (4) that acts on a transverse member inside which at least one readjustment spindle is arranged that acts on a brake lining on the brake application side, further comprising a readjustment device and a quick contact device (13); the quick contact device (13) causes an advancing movement that is superimposed on an actuation of the brake disk (1) during a brake slack compensation phase. The quick contact device (13) includes an intermediate element, the position of which can be adjusted and which has at least one wedge shape.