Floating Disc Brake Caliper Axial Guide Pin
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Solution Overview
Problem
Existing disc brake callipers face challenges in achieving both lightness and rigidity, as increased rigidity typically leads to increased thickness and mass, which can result in deformation and incorrect thrust distribution during braking.
Innovation Solution
A floating calliper design featuring a monobloc or paired half-body calliper body with lateral and central bridges, using axial and radial attachment pins to distribute braking forces, and a single guide pin for axial sliding, preventing rotation and allowing lighter material usage, such as aluminium alloys.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the calliper body thickness is increased to achieve necessary rigidity, then deformation is prevented, but the calliper mass increases
Solution Approach 1:
The calliper body is divided into multiple functional zones with different thicknesses: thicker regions at the ends for rigidity and thinner regions in the middle for weight reduction. This segmentation allows the calliper to achieve necessary stiffness while minimizing mass, directly resolving the contradiction between strength and weight.
Solution Approach 2:
Different portions of the calliper body have different thickness characteristics - the end portions are thicker to provide rigidity and resistance to deformation, while the central portion is thinner to reduce overall mass. This local variation in quality optimizes both strength and weight requirements simultaneously.
2Weight of moving object
If the calliper body is made lighter to reduce non-suspended masses, then vehicle performance improves, but the calliper body may deform under braking forces
Solution Approach 1:
The calliper body is divided into multiple functional zones with different thicknesses: thicker regions at the ends for rigidity and thinner regions in the middle for weight reduction. This segmentation allows the calliper to achieve necessary stiffness while minimizing mass, directly resolving the contradiction between strength and weight.
Solution Approach 2:
The calliper body utilizes aluminium alloy material that provides high strength-to-weight ratio, allowing the component to be lighter while maintaining sufficient rigidity to withstand braking forces without deformation.
3Manufacturing precision
If multiple pins are used to connect the calliper body to the bracket, then positioning accuracy improves, but device complexity increases
Solution Approach 1:
The invention extracts and eliminates the attachment pin from the connection mechanism, leaving only the guide pin. This simplification reduces device complexity while maintaining adequate positioning accuracy through the remaining guide pin and the self-aligning properties of the floating calliper design.
Solution Approach 2:
Instead of using multiple pins for both guidance and attachment functions, the invention inverts the approach by using a single guide pin for guidance and allowing the calliper body to self-position and attach through the braking forces and floating mechanism, thereby simplifying the connection mechanism.
Data Source
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AI summary
Floating calliper for disc brake (4) comprising a calliper body (8) and a bracket (12), the bracket comprising means of attachment (36) of the calliper to a support, the calliper body (8) sliding in relation to the bracket (12) in an axial direction (X-X) and comprising means of coupling (80) between the calliper body (8) and the bracket (12), suitable to permit the relative sliding. The bracket (12) extends only on the inner side (16) of the calliper (4) and delimits a first seat (38) housing at least a first brake pad (40).The coupling means comprise a guide pin (84) and an attachment pin (88), the guide pin (84) enabling the relative sliding of the calliper body (8) and the attachment pin (88) angularly blocking the calliper body (8) preventing its rotation, so that the calliper body (8) is axially guided solely by the guide pin (84).