External Synchronization Mechanism for Monobloc Disc Brakes
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Solution Overview
Problem
The existing disc brake designs with radial brake configurations cannot be manufactured as monobloc calipers due to the protruding shape of the brake rotary lever, which affects weight distribution and installation, leading to complex interfaces and reduced robustness.
Innovation Solution
A synchronization mechanism is arranged outside the brake caliper housing within a sealed cover, allowing the brake rotary lever to be mounted similarly to axial brakes, with synchronizing elements like chains or gears routed around the lever housing, enabling a compact and robust monobloc caliper design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the brake rotary lever protrudes from the clamping section in radial brake configuration, then the synchronization mechanism can be arranged outside the caliper housing, but the caliper cannot be manufactured as monobloc due to complex interfaces and reduced robustness
Solution Approach 1:
The synchronization mechanism is relocated from the traditional position inside the caliper housing to an external position on the clamping section. This spatial reconfiguration allows the brake rotary lever to protrude without creating complex internal interfaces, enabling monobloc caliper manufacturing while maintaining synchronization functionality.
2Ease of operation
If the brake rotary lever protrudes from the clamping section, then the synchronization mechanism can be mounted externally, but the weight distribution and installation conditions are adversely affected
Solution Approach 1:
The caliper is divided into functionally independent components: the monobloc clamping section containing the synchronization mechanism, and the separately mountable brake rotary lever. This segmentation allows optimized weight distribution and simplified installation while maintaining structural integrity and braking performance.
3Volume of moving object
If the synchronization mechanism is arranged inside the caliper housing, then the design is compact, but radial brake configurations cannot be manufactured as monobloc due to the protruding brake rotary lever
Solution Approach 1:
The synchronization mechanism is extracted from the internal caliper housing space and positioned externally on the clamping section. This extraction eliminates the conflict between the protruding brake rotary lever and monobloc manufacturing requirements, while the overall caliper volume remains compact through optimized external arrangement.
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 achieves cost savings, improved robustness, simplified installation, weight reduction, and enhanced installation conditions by allowing a monobloc caliper with fewer cast parts and reduced interfaces, while maintaining the braking performance.
Implementation Method 1
The synchronizing element 13 is a chain or roller chain or a toothed belt and interacts with the synchronizing wheels 14, 15 as a wrap-around gear
Implementation Method 2
The synchronizing element 13 is a chain or roller chain or a toothed belt and interacts with the synchronizing wheels 14, 15 as a wrap-around gear
Data Source
AI summary
A disc brake, for a motor vehicle, has a brake caliper with a clamping section, which is equipped with a clamping device with a brake rotary lever, at least two threaded pistons, an adjustment device, and a driver device. A synchronization mechanism for synchronizing the rotational movements of the threaded pistons is arranged outside of the housing of the brake caliper within a sealed cover on the clamping section of the brake caliper. The synchronization mechanism has at least one synchronizing element and two synchronizing wheels, a first synchronizing wheel of which is coupled to one threaded piston and a second synchronizing wheel of which is coupled to the other threaded piston. The synchronization mechanism is arranged on the clamping section of the brake caliper (3) so as to be guided about a lever housing of the brake rotary lever. The lever housing protrudes from the clamping section of the brake caliper.