Floating Caliper Disc Brake for Residual Drag Torque Release
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Solution Overview
Problem
Floating caliper disc brakes experience residual drag torque due to the inability to actively detach the second pad from the brake disc after a braking event, leading to increased pad wear, energy consumption, and pollutant emissions.
Innovation Solution
A floating caliper disc brake design with independently actuable pistons allows for selective and sequential rearward movement to position the caliper body and pads relative to the brake disc, ensuring complete detachment and minimizing residual drag torque.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the second pad is fixed to the caliper body without active positioning capability, then the structure is simple, but residual drag torque cannot be eliminated
Solution Approach 1:
The actuation system is segmented into two independent pistons: a first piston for actuating the first pad and a second piston for positioning the second pad. This segmentation allows independent control of each pad, enabling the second pad to be actively detached from the disc to eliminate residual drag torque while maintaining structural manageability through modular actuation components.
Solution Approach 2:
The second piston acts as an intermediary positioning mechanism between the caliper body and the second pad. By introducing this intermediate actuating element, the system gains the capability to actively control the position of the second pad relative to the disc, enabling complete detachment and elimination of residual drag torque without requiring complete redesign of the caliper structure.
2Loss of energy
If independently actuable pistons are added to actively position the caliper body, then residual drag torque is eliminated, but device complexity increases
Solution Approach 1:
The second piston serves multiple functions: it positions the second pad relative to the disc, enables active detachment to eliminate residual drag torque, and works in coordination with the first piston for sequential actuation. This multi-functionality justifies the added complexity by providing comprehensive control over pad positioning and detachment.
Solution Approach 2:
The actuation system transitions from a static, passive configuration to a dynamic, actively controllable system. The independently actuable pistons enable real-time adjustment of pad positions, allowing the caliper to adapt its configuration to eliminate residual drag torque while maintaining braking performance when needed.
3Reliability
If sequential and selective piston actuation is implemented, then pad detachment is complete, but control complexity increases
Solution Approach 1:
The control system implements preliminary positioning of the second pad using the second piston before the main braking action. This preliminary action ensures the second pad is correctly positioned and can be completely detached when needed, improving reliability of pad detachment while managing control complexity through a structured two-stage actuation sequence.
Solution Approach 2:
The sequential and selective actuation of the two pistons implies a controlled process where the state of each piston can be monitored and adjusted. This feedback mechanism ensures complete pad detachment by verifying the position of each piston and pad, enhancing reliability while keeping control complexity manageable through systematic state management.
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 reduces pad wear, energy consumption, and pollutant emissions while maintaining brake performance by eliminating residual drag torque and optimizing pad alignment.
Implementation Method 1
only the position of the first pad on the piston side can be controlled to a given extent by the configuration and positioning of the elastic seal and its housing in the caliper body, which positions the (unbiased) piston elastically relative to the caliper (roll-back effect)
Implementation Method 2
one or more first and second friction pads supported by the supporting bracket and/or the caliper body on the first and second sides of the brake disc
Data Source
Figure 1~2
Figure 3~4
Figure 5~9C
AI summary
A floating disc brake (1) with a supporting bracket (2), a caliper body (3) connected to the supporting bracket (2) in a sliding manner, a first friction pad (12) on the first side (6) of the caliper body (3), a second friction pad (13) on the second side (8) of the caliper body (3) and fixed to the caliper body (3), a first piston (15) connected to the first friction pad (12) and a second piston (16) can freely rest on the first friction pad (12) forming a positioning surface (17) which can abut against a resting surface (18, 18') of the supporting bracket (2), wherein the first piston (15) and the second piston (16) can be actuated independently of each other so that a rearward movement of the first piston (15) towards the first side (6) detaches the first pad (12) from the brake disc (11), and a rearward movement of the second piston (16) towards the first side (6), with the positioning surface (17) abutting against the resting surface (18, 18') moves the caliper body (3) together with the second pad (13) towards the second side (8) and detaches the second pad (13) from the brake disc (11).