Inverted Park Brake Caliper Layout for Axial Space Reduction
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Solution Overview
Problem
The existing brake systems in commercial vehicles face challenges in spatial optimization, particularly in reducing the axial length of the brake system to accommodate the needs of electrified vehicles with limited axial space.
Innovation Solution
A park brake caliper design that includes an actuation unit with a push rod that can be pre-tensioned by a spring and reversed by pneumatic, hydraulic, or electromechanical forces, allowing for an inverted actuator lever arm placement with an inverted pivot axis. This design enables the caliper to be positioned closer to the axle, reducing the overall axial length.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a conventional combined service and parking brake actuator is used, then both brake functions are integrated in one caliper, but the axial length of the brake system becomes too large for electrified vehicles
Solution Approach 1:
The brake system is segmented into separate service brake and parking brake calipers. The service brake caliper contains only the service brake actuator, while the parking brake caliper contains only the parking brake actuator with inverted lever configuration. This segmentation eliminates the need for a long combined actuator, reducing axial space while maintaining functional integration through coordinated operation of separate units.
Solution Approach 2:
The parking brake caliper employs an inverted lever configuration where the lever arm is positioned below the bridge instead of above it. This inversion allows the parking brake actuator to be oriented with its piston facing toward the axle rather than away from it, enabling compact axial packaging that fits within the limited space of electrified vehicle architectures.
2Adaptability or versatility
If the actuation unit is positioned at 12 o'clock position, then the brake system is conventional and easy to implement, but it collides with other axial components in electrified vehicles
Solution Approach 1:
The parking brake actuator is reoriented from the conventional 12 o'clock position to a 3 o'clock or 9 o'clock position, utilizing the lateral dimension rather than the axial dimension. This dimensional change allows the actuator to be positioned in the lateral space between wheels, avoiding collision with axial components while providing the necessary braking function.
3Volume of moving object
If separate calipers for service and parking brakes are used, then axial space is reduced, but the device complexity increases
Solution Approach 1:
While the brake system uses separate calipers for service and parking brakes, the application units (brake mechanisms) are merged into a common bridge structure that supports both brake pads. This merging of the application unit reduces overall complexity compared to having completely separate brake assemblies, while still achieving axial space reduction through separate actuator positioning.
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 allows for a compact brake system design that saves axial space, enabling the integration of electric drive components and improving the packaging efficiency of the drivetrain, while maintaining effective brake performance.
Implementation Method 1
The push rod is pre-tensioned, further preferably by a spring, in one direction in order to force the bridge to press at least one brake pad against a brake disc
Implementation Method 2
The application unit comprises a brake lever, which is pivotably supported around a pivot axis and which is adapted to rest at the push rod at one side and at the bridge on the other side via an excenter
Implementation Method 3
an application unit with a pivotable brake lever requires enough space for accommodating its functional parts (in particular brake lever and bridge) in the caliper
Implementation Method 4
the bridge is adapted to press at least one brake pad against the brake disc of a utility vehicle
Data Source
AI summary
A park brake caliper for a utility vehicle has an actuating unit, which is adapted to move a push rod, wherein the push rod is pre-tensioned by a tensioning device in one direction, but is adapted to be pressed in the opposite direction by a pneumatic, hydraulic, electromechanical or magnetic force, and an application unit which includes a brake lever, which is pivotably supported around a pivot axis and which is adapted to rest at the push rod at one side and at a bridge on the other side via an excenter. The application unit is adapted to be positioned around an axle of a utility vehicle. The bridge is adapted to press at least one brake pad against a brake disc of the utility vehicle. The lever points downwards towards the axle in all of its positions. A brake system is disclosed, where the park brake caliper and a service brake caliper are radially spaced from each other.