Pad Return Spring Attachment for Disc Brake Drag Prevention
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Solution Overview
Problem
Current vehicle disc brake systems face challenges in reducing manufacturing costs and assembly complexity, particularly in attaching pad return springs to the back plate of friction pads, while also ensuring proper alignment and wear detection.
Innovation Solution
The design includes pad return springs with a back plate attachment portion formed by bending a strip-shaped plate, featuring engagement protrusions and grooves for easy attachment, and a wearing detection portion integrated with the spring to reduce parts and assembly effort, with varying spring forces on the disc entrance and exit sides to prevent dragging and ensure correct assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional attachment methods are used for pad return springs, then reliability is maintained, but manufacturing cost increases and assembly complexity increases
Solution Approach 1:
The pad return spring and attachment portion are merged into a single integrated component. The attachment portion is formed as an integral part of the pad return spring body through bending the strip-shaped plate, eliminating the need for separate attachment components and reducing assembly steps while maintaining secure attachment through the engagement protrusion and groove design
Solution Approach 2:
The physical state and configuration of the attachment portion are changed by bending the strip-shaped plate into specific geometric forms (engagement protrusion and connection piece). This parameter change transforms the flat strip into a three-dimensional attachment structure that provides both secure engagement and proper spring function
2Reliability
If multiple separate components are used for pad return spring attachment, then attachment reliability is improved, but device complexity increases and assembly work increases
Solution Approach 1:
Multiple attachment elements (engagement protrusion, connection piece, and attachment holes) are merged into a single integrated attachment portion structure that is formed by bending the strip-shaped plate. This reduces the number of separate components from multiple discrete parts to a unified structure, simplifying the overall device while maintaining reliable attachment
Solution Approach 2:
The attachment portion serves multiple functions simultaneously: it provides secure mechanical engagement through the protrusion and groove interface, maintains proper spacing through the connection piece geometry, and enables assembly through integrated attachment holes. This multi-functionality reduces the need for separate specialized components
3Reliability
If pad return spring is attached to back plate, then pad separation function is achieved, but assembly work increases
Solution Approach 1:
The attachment portion is designed to attach to the back plate through self-aligning engagement features. The engagement protrusion fits into the corresponding groove on the back plate, and the attachment holes are positioned to align with back plate mounting holes, allowing the component to serve its own alignment and attachment functions without requiring additional fixtures or complex assembly procedures
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 simplifies the attachment process, reduces manufacturing costs, and enhances the vehicle disc brake's functionality by preventing pad dragging and providing effective wear detection, thereby improving brake performance and reliability.
Implementation Method 1
Each pad return spring urges the corresponding friction pad toward an opposite side to the disc rotor when braking is released
Data Source
AI summary
Each pad return spring includes a lug piece attachment portion that is attached to a corresponding lug piece, and a pad return portion. The lug piece attachment portion of each pad return spring includes a first piece that is disposed on a first surface, on a disc rotor side, of the corresponding lug piece, a second piece that is disposed on a second surface, on the opposite side to the disc rotor side, of the corresponding lug piece, and a connection piece that connects the first piece and the second piece. The lug piece attachment portion of each pad return spring has a substantially U shape in section. The lug piece attachment portions are formed with engagement claw portions, and the lug pieces are formed with engagement grooves.