Guided Brake Disc Retraction for Low-Friction Fast Locking
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Solution Overview
Problem
Existing braking systems face challenges with overheating due to inadequate cooling, uneven pad wear leading to offsets and reduced braking efficiency, and require compression springs that are susceptible to damage and corrosion, which do not allow for minimal residual friction between brake discs and lining discs to achieve quick braking.
Innovation Solution
A brake device with a guiding support and pusher elements that enable axial displacement of brake discs relative to the lining disc, allowing for minimal separation distance without residual friction, using a floating coupling and elastic damping gaskets to reduce wear and improve cooling through fluid flow and heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If compression springs are used to separate brake discs from lining discs, then the brake discs can be kept separated to reduce residual friction, but the springs are susceptible to damage and corrosion, reducing reliability
Solution Approach 1:
The patent removes the compression springs from the system entirely, replacing them with a mechanical guide structure. The guide supports with grooves directly guide the brake discs axially, eliminating the need for separate spring elements that were causing reliability issues through damage and corrosion.
Solution Approach 2:
The guide supports act as intermediary elements between the brake discs and the housing. The grooves in the guide supports provide the separation function previously achieved by springs, but through a more robust mechanical guidance structure that is resistant to damage and corrosion.
2Productivity
If brake discs are moved axially towards the lining disc to achieve braking, then braking capacity is improved, but the separation distance must be large enough to allow rotation without residual friction
Solution Approach 1:
The brake discs are pre-positioned in the retracted state during normal rotation, maintaining minimal separation from the lining disc. This preliminary positioning allows the discs to be already close to the optimal braking position, requiring only minimal axial movement when braking is initiated, thus reducing Time to lock.
Solution Approach 2:
The system dynamically adjusts the axial position of the brake discs based on operating conditions. During normal rotation, the discs maintain a minimal separation distance; during braking, they move axially to contact the lining disc. The guide supports enable this dynamic positioning through their groove structure.
3Temperature
If the brake disc continuously rotates with the wheels, then the braking system can be activated on demand, but cooling is limited to natural convection, causing overheating
Solution Approach 1:
The brake disc is segmented into multiple sections with radial grooves that allow cooling fluid to penetrate and flow through the disc structure. This segmentation enables internal cooling passages that facilitate efficient heat removal while maintaining the continuous rotation capability of the brake disc.
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 configuration reduces the 'Time to Lock' (TTL) by minimizing the braking distance, enhancing energy efficiency, reducing wear, and improving active safety with reduced energy consumption and minimal residual friction, while maintaining robustness and cooling efficiency.
Implementation Method 1
elastic damping gaskets to reduce wear and improve cooling through fluid flow and heat dissipation
Implementation Method 2
improve cooling through fluid flow and heat dissipation
Implementation Method 3
by means of friction between the brake pads and the disc, the braking of the wheels and consequently of the vehicle takes place
Data Source
Figure 1A~1D
Figure 2
Figure 3A~3B
AI summary
The invention relates to a brake device attachable on a rotating shaft, which comprises a guiding support (1) comprising at least one transmitting guide (2), a first casing (3), a first pusher element (13, 17, 18) movable in the axial direction, a lining disc (5) located between a first brake disc (6) and a second brake disc (7). The first casing (3) comprises a drive system configured to, when activated, move the first pusher element (13, 17, 18), in the axial direction, towards the lining disc (5), pushing the first brake disc (6) towards the first lining (52), wherein the drive system is configured to, when deactivated, retract the first pusher element (13, 17, 18), moving in an opposite direction to the direction of pushing on the first disc brake (6), in the axial direction.