Integrated Brake Carrier Structure for Low-Complexity Assembly
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Solution Overview
Problem
Existing brake carrier units for motor vehicles are heavy, require significant assembly effort, and are prone to errors due to numerous components and vulnerable connection points, which increases installation space requirements and susceptibility to dirt and liquids.
Innovation Solution
A carrier unit with a one-piece design integrating an expanding wedge unit, featuring a first flange section for chassis fixation, a second flange section for brake cylinder attachment, and a guide section for force transmission, which reduces weight, assembly complexity, and vulnerability to contaminants by eliminating additional interfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If brake carriers are designed with multiple separate components and adapter elements, then the braking system can be assembled with various brake types, but the weight increases and assembly work increases
Solution Approach 1:
The patent combines the brake carrier, expanding wedge unit, and adapter elements into a single integrally cast brake carrier unit. This merging eliminates the need for separate components and their connections, thereby reducing weight while maintaining adaptability through integrated design features for different brake types.
2Adaptability or versatility
If multiple adapter elements and connection points are used, then the braking system can accommodate different brake configurations, but the assembly work and susceptibility to errors increase
Solution Approach 1:
The patent integrates multiple functions into a single brake carrier unit structure, combining the carrier, expanding wedge unit, and adapter elements. This reduces the number of separate components and connections from multiple separate parts to one integrated unit, thereby reducing assembly work and susceptibility to errors.
3Adaptability or versatility
If additional adapter elements are provided for attaching the brake cylinder, then the braking system can be adapted to different configurations, but the installation space required increases
Solution Approach 1:
The patent integrates the adapter elements directly into the brake carrier unit structure, eliminating the need for separate adapter components. This merging allows the brake cylinder to be mounted directly to the integrated adapter features on the brake carrier, thereby reducing the overall installation space required while maintaining adaptability to different configurations.
4Adaptability or versatility
If multiple connection points and interfaces are provided, then the braking system can be assembled with various components, but the vulnerability to dirt and liquids penetration increases
Solution Approach 1:
The patent creates a single integrated brake carrier unit with an enclosed expanding wedge unit, eliminating multiple external connection interfaces. The integral design means there are no separate joints or gaps between components where dirt and liquids could penetrate, while the integrated adapter features still provide compatibility with various brake components.
5Ease of manufacture
If the expanding wedge unit is attached separately to the brake carrier, then the components can be manufactured and assembled independently, but the weight and assembly effort increase
Solution Approach 1:
The patent integrates the expanding wedge unit directly into the brake carrier as a single integrally cast component. This eliminates the weight of separate components and their connection hardware, while the integral manufacturing process achieves the weight reduction goal despite requiring a single-cast production method.
Data Source
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AI summary
The present invention relates to a support unit (2), comprising a first flange section (22), a second flange section (24) and a guiding section (26), wherein the first flange section (22) has a first engagement geometry (23) for securing the support unit (2) to a chassis, wherein the second flange section (24) has a second engagement geometry (25) for securing a brake cylinder, wherein the guiding section (26) is arranged adjacent to the second flange section and has a guiding geometry (27) for guiding a guide element (4) along a guide axis, wherein an expansion wedge unit (8) is provided adjacent to the guiding section (26), and wherein the expansion wedge unit (8) has a housing (82) which is formed as one piece with the guiding section.