Radial Disc Brake Caliper Layout With External Traction Drive
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Solution Overview
Problem
Existing radial disc brakes face challenges in manufacturing complexity, weight, and operational reliability due to their multi-part design, requiring numerous screws and seals, which complicates assembly and increases weight, contradicting weight minimization demands, especially in commercial vehicles.
Innovation Solution
The radial disc brake is redesigned with a single-piece lever dome and caliper housing, guiding the traction mechanism outside the lever dome, simplifying assembly and eliminating the need for separate connections and seals, while allowing for easier adjustment of chain play through innovative guideways and cover plates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the brake caliper is constructed in multiple parts (separate lever dome and caliper housing), then the lever can be guided around the chain drive, but the assembly complexity increases due to numerous screws and sealing measures
Solution Approach 1:
The patent merges the lever dome and caliper housing into a single integrated component. The lever dome is no longer a separate part that needs to be connected to the caliper housing with screws and seals, but is instead formed as one piece with the caliper housing, eliminating the need for separate connection elements and sealing measures.
2Ease of operation
If the brake caliper is constructed in multiple parts, then the lever can be guided around the chain drive, but the manufacturing time and cost increase
Solution Approach 1:
The integration of the lever dome and caliper housing into a single component eliminates the assembly step of connecting these parts, thereby reducing manufacturing time and increasing productivity.
3Reliability
If the lever dome is connected to the caliper housing as a separate part, then the chain drive can be enclosed, but the weight of the brake caliper increases
Solution Approach 1:
By forming the lever dome and caliper housing as a single integrated component, the patent eliminates the weight of separate connection elements (screws, seals) while maintaining the protective function of enclosing the chain drive within the unified structure.
4Ease of manufacture
If threaded holes are made in the caliper housing to connect the lever dome, then the lever dome can be attached, but the machining complexity and time increase
Solution Approach 1:
The integration of the lever dome and caliper housing eliminates the need for machining threaded holes in the caliper housing for connection purposes, as the parts are formed as one piece. This significantly reduces machining complexity and increases manufacturing productivity.
5Reliability
If seals are provided and installed to protect the interior of the brake caliper, then the chain drive is protected, but the assembly complexity and time increase
Solution Approach 1:
The integrated design of the lever dome and caliper housing eliminates the need for separate seals and sealing measures, as the unified structure inherently protects the chain drive interior without requiring additional sealing components or installation steps.
Data Source
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AI summary
A disc brake for a utility vehicle with - an application device, which is positioned in a receiving space of a brake caliper (1) having a caliper housing (2) and a lever dome (3) arranged thereon, having - a pivotable brake lever, which is provided with at least one eccentric portion and a lever arm (6) which adjoins the latter, extends approximately parallel to the axis of rotation of the brake disc and projects into the lever dome (3), - two brake plungers which are mounted axially adjustably in a bridge and, during braking, lie against a brake pad, - a readjustment device for compensating for a wear-induced change in an air gap, - a synchronizing device connected functionally to the brake plungers and having a traction mechanism drive (7), is designed in such a manner that the traction mechanism drive (7) is arranged outside the lever dome (3), wherein the strands (8) of the traction mechanism drive (7) are guided around a partial region of the lever dome (3).