Floating Caliper Parking Braking via Elastic Reaction Piston
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Solution Overview
Problem
Existing floating calipers for disc brakes lack reliable parking braking capabilities, as they fail to maintain a gripped configuration on the disc for an indefinite time after the user's action is released, compromising compactness and rigidity.
Innovation Solution
A floating caliper design that integrates a sliding mechanism with elastic reaction elements and hydraulic actuators, allowing for increased pressure to engage parking brakes, combined with an electric locking system and detection means to ensure reliable locking and release of the braking position.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a floating caliper design is used to reduce overall dimensions, then compactness is improved, but parking braking reliability deteriorates
Solution Approach 1:
The braking function is segmented into two independent systems: service braking through hydraulic pressure on the action piston, and parking braking through mechanical engagement of the locking element with the reaction piston. This segmentation allows each system to be optimized for its specific function while maintaining the compact floating caliper structure.
Solution Approach 2:
The reaction piston acts as an intermediary element between the elastic reaction element and the brake pad. It receives the parking braking force from the elastic reaction element and transmits it to the brake pad through the locking mechanism, enabling reliable parking braking without compromising the compact floating caliper design.
2Strength
If a floating caliper design is used to achieve high rigidity, then braking response is improved, but parking braking capability deteriorates
Solution Approach 1:
The caliper design incorporates dynamic elements including the movable action piston for service braking and the spring-loaded reaction piston with locking mechanism for parking braking. This dynamic design maintains rigidity during service braking while enabling reliable parking braking through the elastic reaction element that can store and release energy as needed.
Solution Approach 2:
The elastic reaction element is pre-loaded to store energy that will be used for parking braking. The locking element is positioned to engage with the reaction piston when needed, allowing the system to maintain rigidity during normal operation while having the capability for reliable parking braking when required.
3Reliability
If parking braking is added to the floating caliper, then parking braking reliability is improved, but device complexity increases
Solution Approach 1:
The service braking and parking braking systems are merged into a single integrated caliper assembly. The reaction piston and locking mechanism are combined within the same structure as the action piston, allowing both braking functions to be performed by one device without requiring separate systems, thus limiting the increase in complexity.
Solution Approach 2:
The reaction piston serves multiple functions: it provides the braking force during service braking through hydraulic pressure, stores energy in the elastic reaction element, and engages with the locking element for parking braking. This multi-functionality reduces the need for additional components, limiting the increase in device complexity while achieving reliable parking braking.
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 maintains compactness and rigidity while enabling reliable parking braking by ensuring the caliper can maintain a gripped configuration indefinitely, with reduced failure risk and efficient operation through precise control of the locking mechanism.
Implementation Method 1
at least one elastic reaction element (60), for example a helical spring or a set of cup springs, suitable for operating permanently on said inner pad (30) in thrust towards the braking surface of the disc
Implementation Method 2
a second body (70) which supports the outer pad (34) and has at least one pressure chamber (72) supplied with pressurised oil from a hydraulic circuit
Implementation Method 3
at least one action piston (90), translatable along an action axis (W) parallel to the disc axis (Z) and hydraulically actuatable to operate with a braking action on the outer pad (34)
Implementation Method 4
the locking element (112) is shaped so as to have, along said engagement direction (J), at least one disengagement portion (114) and at least one engagement portion (116), protruding radially with respect to the first, so that, by translation of the locking element from the disengagement position to the engagement position, the engagement portion (116) structurally interferes with the piston (90), locking it in the parking position
Implementation Method 5
The inner half-caliper (10) comprises a first pad (30) or inner pad carrying a first friction material (32) facing the disk from one side, while the outer half-caliper (12) includes a second pad (34) or outer pad carrying a second friction material (36), facing the disk from the other side
Data Source
AI summary
A floating caliper (2) for a disc brake comprises a first half-caliper (10), which houses a reaction piston (50), a second half-caliper (12), which houses an action piston (90) and locking means for locking the action piston (90) in a preset parking position. The reaction piston (50) is elastically yielding when the braking action acting on it exceeds a preset parking action threshold which corresponds to said parking position wherein the locking means lock the action piston (90).