Railway Disk Brake Caliper Return Mechanism Design
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Solution Overview
Problem
The existing floating caliper type disk brake for railway vehicles faces challenges in achieving a stable caliper return operation due to manufacturing variations and dimensional tolerances, leading to inconsistent caliper return force and pad drag issues.
Innovation Solution
A disk brake design incorporating a caliper return mechanism with a spring accommodating member, slide bearings, and compression spring members, which elastically bias the caliper to maintain consistent pad clearance and prevent drag, allowing for easy adjustment of return force and amount without additional machining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If retraction rubber rings are used to pull the caliper away from the rotor after braking release, then pad drag is prevented, but the caliper return force becomes inconsistent due to manufacturing variations and dimensional tolerances
Solution Approach 1:
The invention changes the parameter of the return mechanism from elastic rubber rings to a mechanical spring system with adjustable preload and stiffness. This allows precise control of the return force magnitude and characteristics, compensating for manufacturing variations and ensuring consistent caliper return operation regardless of dimensional tolerances in other components.
Solution Approach 2:
The invention introduces a dynamic adjustment capability to the return mechanism through the adjustable spring preload and stiffness. This allows the system to adapt to different operating conditions and wear states, maintaining reliable caliper return operation throughout the service life of the brake system.
2Object-generated harmful factors
If the caliper return force is increased to prevent pad drag, then starting torque increases, but braking performance may be compromised
Solution Approach 1:
The invention enables precise adjustment of the spring preload and stiffness parameters to optimize the return force. This allows the return force to be increased sufficiently to prevent pad drag and reduce starting torque, while being controlled to an appropriate level that does not compromise braking performance. The adjustable parameters provide fine-tuning capability to achieve the optimal balance between these competing requirements.
3Reliability
If a complex adjustment mechanism is added to modify the return force, then caliper return operation can be optimized, but device complexity increases
Solution Approach 1:
The invention segments the return mechanism into modular components: the spring assembly, the mounting structure, and the adjustment mechanism. This modular design allows for easy installation, maintenance, and adjustment of the return force parameters without affecting other parts of the brake system, thereby optimizing caliper return operation while managing device complexity through functional separation.
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 ensures stable caliper return operation and prevents pad drag, maintaining consistent pad clearance and reducing starting torque, while allowing for easy adjustment of return force and amount, thus enhancing braking performance.
Implementation Method 1
a compression spring member which is accommodated in the spring accommodating member and elastically biases the base portion
Data Source
AI summary
A disk brake includes a floating caliper, a pair of brake pads, a driving piston and a caliper return mechanism. The floating caliper includes a base portion which is slidably supported via a guide pin to a support and a pair of pressing arms which extend from the base portion to pinch a disk rotor. The brake pads are provided in tip portions of the pressing arms so as to face side surfaces of the disk rotor. The driving piston is provided on one of the pressing arms so as to drive one of the brake pads toward one of the side surfaces. The caliper return mechanism is arranged in at least one of both end portions of the guide pin on a side opposite to the driving piston side so as to elastically bias the base portion to the side opposite to the driving piston side.