Pad Spring Coating Layout for Accurate Disc Brake Clearance Inspection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing disc brake pad spring clearance inspection method is prone to erroneous determinations due to the insulating resin coating, which can prevent electrical short circuits from occurring even when the desired clearance is not secured, leading to inaccurate inspection results.
Innovation Solution
The pad spring features a locking portion with a thinner coating film thickness in regions opposed to the disc rotor and protruding portions that approach the disc rotor, allowing for increased electrical conductivity and accurate clearance inspection through electrical short circuits at the closest points.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a resin coating is applied to the locking portions of the pad springs, then the insulating property is improved, but the measurement precision of the clearance inspection deteriorates
Solution Approach 1:
The resin coating is applied with different thicknesses to different regions of the locking portion. Specifically, the coating thickness is controlled to be thinner in the region opposed to the disc rotor compared to other regions. This local differentiation allows the coating to provide insulation where needed while maintaining electrical conductivity in the region critical for clearance inspection, thereby resolving the contradiction between insulating property and measurement precision.
2Device complexity
If the locking portion is positioned close to the disc rotor, then the structural compactness is improved, but the reliability of clearance inspection deteriorates due to potential contact
Solution Approach 1:
The locking portion is designed with differentiated resin coating thickness across its surface. The region opposed to the disc rotor has a thinner coating that allows electrical contact to be detected, while other regions have thicker coating for insulation. This enables the locking portion to be positioned close to the disc rotor for structural compactness while maintaining inspection reliability through the selectively conductive coating pattern.
Solution Approach 2:
The resin coating acts as an intermediary layer between the locking portion and the disc rotor. By controlling the coating thickness to be thinner in the region opposed to the disc rotor, the coating serves as a mediator that allows electrical contact detection when clearance is insufficient, while still providing insulation in other regions. This intermediary approach resolves the contradiction between structural compactness and inspection reliability.
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 ensures accurate clearance inspection by securing electrical short circuits between the pad spring and the jig portion, enhancing the inspection accuracy and preventing erroneous determinations.
Implementation Method 1
the resin coating is applied to the locking portions of the pad springs, and hence, even when the contact occurs between the locking portion and the jig portion corresponding to the disc rotor due to, for example, a defect, an electrical short circuit may not occur due to an insulation property provided by the resin coating
Implementation Method 2
the locking portion includes a coating film having a thinner coating film thickness in at least a part of a region opposed to a disc rotor than a coating film thickness in other region
Data Source
AI summary
Protruding portions protruding in a direction of approaching a disc rotor are integrally formed in a locking plate portion of a pad spring. Moreover, an insulating resin coating is formed on a front surface side (surface in a region opposed to an outer peripheral surface of the disc rotor) of the locking plate portion. The coating film formed on the front surface of the locking plate portion flows downward by its own weight before the coating material is solidified. As a result, the coating film formed on bottom surfaces (front surfaces of protrusions) of the protruding portions is thinner in film thickness than that of the coating film in other region.