Radial Disc Brake Caliper Layout With External Traction Drive
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Solution Overview
Problem
Conventional radial disc brakes require multiple parts and screws for assembly, leading to complex sealing requirements, high weight, and increased assembly variations, which complicates the process and increases costs.
Innovation Solution
Guiding the traction mechanism strands outside the lever dome allows for a one-piece cast construction of the lever dome and caliper housing, simplifying assembly, reducing weight, and eliminating the need for separate components and seals, with adjustable guides and a cover plate for easy access and tension adjustment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the brake caliper is formed in multiple parts (caliper housing and separate lever dome), then the lever can be guided around the chain drive, but the assembly complexity increases, weight increases, and sealing requirements become more complex
Solution Approach 1:
The patent merges the lever dome and caliper housing into a single one-piece cast component. This eliminates the need for separate parts and their associated connections, seals, and assembly steps, while still providing the necessary structure to guide the lever arm around the chain drive through the integrated design of the single component.
2Ease of operation
If the lever dome is connected to the caliper housing as a separate part, then the lever can be accommodated, but the weight of the brake caliper increases
Solution Approach 1:
By combining the lever dome and caliper housing into one integrated casting, the patent eliminates the weight of additional fastening components (screws, bolts) and reduces the overall material usage compared to two separate parts. The single-piece construction provides the same lever arm accommodation function with reduced weight.
3Ease of manufacture
If multiple screws are used to connect the lever dome to the caliper housing, then the parts can be assembled, but the assembly time increases and productivity decreases
Solution Approach 1:
The one-piece cast construction eliminates the need for multiple screws and fastening operations entirely. The lever dome and caliper housing are manufactured as a single integrated component, removing all associated assembly steps, sealing requirements, and fastening hardware, thereby dramatically increasing assembly speed and productivity.
4Ease of operation
If the brake caliper is formed in multiple parts, then the lever can be guided around the chain drive, but the sealing requirements increase to protect the interior
Solution Approach 1:
By forming the lever dome and caliper housing as a single integrated casting, the patent eliminates the interface between these two parts. This removes the need for seals, gaskets, or any sealing measures at the junction, while the integrated design still provides the necessary pathway for the lever arm to guide around the chain drive.
Data Source
AI summary
A disc brake for a utility vehicle includes an application device, which is positioned in a receiving space of a brake caliper having a caliper housing and a lever dome arranged thereon. The application device has a pivotable brake lever, which is provided with at least one eccentric portion and a lever arm which adjoins the latter, the lever extending approximately parallel to the axis of rotation of the brake disc and projecting into the lever dome. Two brake plungers are mounted axially adjustably in a bridge and, during braking, lie against a brake pad. A readjustment device compensates for a wear-induced change in an air gap. A synchronizing device is connected functionally to the brake plungers and has a traction mechanism drive. The traction mechanism drive is arranged outside the lever dome, wherein strands of the traction mechanism drive are guided around a partial region of the lever dome.