Floating Ramp Caliper Unit for Brake Drag Reduction

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Solution Overview

Problem

Existing caliper units with ball in ramp (BIR) calipers face issues due to permanent deformation of the low compression spring, which impeded the backward movement of the piston, reducing braking efficiency as the piston cannot move as much as the built-in clearance, leading to insufficient backward rotation of the brake pad and increased drag.

Innovation Solution

A floating ramp is interposed between the high compression spring and the low compression spring, transferring the elastic force of the high compression spring to the operating ramp, reducing the load on the low compression spring and preventing its deformation, allowing the piston to move backward sufficiently and maintaining braking efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Length of moving object

If the low compression spring is used to move the piston backward, then the piston can achieve built-in clearance movement, but the low compression spring is easily and permanently deformed

Engineering Contradiction:

Improvepiston backward movement distanceVSAvoidlow compression spring durability

Core Design Contradiction:

Length of moving objectVSReliability

Solution Approach 1:

The floating ramp acts as an intermediary component between the high compression spring and the low compression spring. It transfers the elastic force from the high compression spring to the operating ramp, thereby reducing the load on the low compression spring and preventing its permanent deformation while still enabling the piston to achieve the required built-in clearance movement.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The spring system is segmented into two distinct compression springs with different functions: the high compression spring provides the primary restoring force through the floating ramp, while the low compression spring provides additional force for built-in clearance. This segmentation allows each spring to operate within its optimal force range, preventing the low compression spring from being overloaded and deformed.

Inventive Principle:

Principle #1Segmentation

2Reliability

If the low compression spring is permanently deformed, then the spring length is reduced, but the piston cannot move backward as much as the built-in clearance

Engineering Contradiction:

Improvelow compression spring integrityVSAvoidpiston backward movement distance

Core Design Contradiction:

ReliabilityVSLength of moving object

Solution Approach 1:

The floating ramp serves as a mediator that transfers force from the high compression spring to the operating ramp, ensuring that the low compression spring is not overloaded and maintains its original length, thereby enabling the piston to achieve the full built-in clearance movement.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The high compression spring acts in advance to provide the primary restoring force through the floating ramp before the low compression spring is engaged. This preliminary action prevents the low compression spring from being permanently deformed and ensures sufficient piston backward movement is achieved.

Inventive Principle:

Principle #10Preliminary action

3Reliability

If the operating ramp reversely rotates, then the mechanism may malfunction, but the piston backward movement is impeded

Engineering Contradiction:

Improveoperating ramp rotation controlVSAvoidpiston backward movement

Core Design Contradiction:

ReliabilityVSLength of moving object

Solution Approach 1:

The floating ramp acts as an intermediary that transfers the elastic force of the high compression spring to the operating ramp in a controlled manner, preventing reverse rotation of the operating ramp while ensuring the piston can move backward the full built-in clearance distance.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 floating ramp design ensures the piston can move backward as much as the built-in clearance, reducing drag and preventing reverse rotation of the operating ramp, thereby enhancing braking performance by minimizing low compression spring deformation and maintaining efficient brake pad movement.

Implementation Method 1

a high compression spring supported by the cylinder and configured to restore the pushrod to an original position, and a floating ramp interposed between the high compression spring and the operating ramp to transfer elastic force of the high compression spring to the operating ramp

Methodology Applied

Scientific EffectElastic force: Elasticity

Implementation Method 2

a low compression spring configured to further move the pushrod backward

Methodology Applied

Scientific EffectSpring force: Spring

Data Source

PatentUS9726242B2Caliper unit for vehicle

Publication Date: 2017.08.08 HYUNDAI MOTOR CO LTD

AI summary

A caliper unit may include a piston configured to linearly reciprocate in a cylinder, a pushrod configured to move along with the piston, an operating ramp configured to linearly move the pushrod in one direction, a high compression spring supported by the cylinder and configured to restore the pushrod to an original position, and a floating ramp interposed between the high compression spring and the operating ramp to transfer elastic force of the high compression spring to the operating ramp.