Rotatable Disc Brake Lever for Spatial Adaptation
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Solution Overview
Problem
Disc brakes for heavy load vehicles face challenges in adapting to different spatial constraints and require a cost-effective and easy-to-assemble actuation mechanism that can be adjusted to various positions.
Innovation Solution
A disc brake design featuring a rotatable brake lever with a force-redirecting device and angular connecting means, allowing the actuator's position to be adjusted relative to the caliper, and a rod for mounting components in functional cooperation, enabling adaptation to diverse spatial constraints.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a fixed actuator position is used in the brake caliper, then the assembly structure is simple, but the brake system cannot adapt to different spatial constraints in various vehicle types
Solution Approach 1:
The brake lever is designed to be rotatable around a pivot bearing, allowing it to change its angular position dynamically. This enables the actuator to adapt to different spatial constraints in various vehicle types while maintaining a relatively simple overall structure, as the rotation capability is achieved through the pivot bearing rather than a complex repositioning mechanism
Solution Approach 2:
The force-redirecting device serves multiple functions: it transmits the input force from the actuator to the brake lever, redirects the force direction to match the optimal braking direction, and accommodates different actuator positions through the rotatable brake lever design. This multi-functionality reduces the need for separate components for each function, thereby limiting the increase in device complexity
2Reliability
If a complex actuation mechanism with multiple components is used, then the brake system can achieve precise force transmission, but the assembly process becomes difficult and manufacturing costs increase
Solution Approach 1:
The force-redirecting device is integrated with the brake lever assembly, where the brake lever itself acts as the force-redirecting element. This merging of functions reduces the number of separate components that need to be assembled, simplifying the assembly process while maintaining reliable force transmission from the actuator to the brake disc through the unified lever structure
Solution Approach 2:
The pivot bearing serves as an intermediary element that facilitates the rotation of the brake lever while maintaining a reliable connection between the actuator and the thrust element. This intermediary component enables smooth force transmission through the rotating lever without requiring complex mounting mechanisms, thereby improving ease of manufacture while ensuring force transmission reliability
3Adaptability or versatility
If the brake lever is fixed in position, then the manufacturing process is simpler, but the system cannot be adjusted to different angular positions for different vehicle configurations
Solution Approach 1:
The brake lever is designed with rotational capability around a pivot bearing, allowing it to be adjusted to different angular positions dynamically during assembly or operation. This dynamic positioning capability enables adaptation to different vehicle configurations without requiring a complex fixed-position adjustment mechanism, as the rotation itself provides the necessary flexibility
Solution Approach 2:
The actuation mechanism is segmented into the rotatable brake lever and the fixed pivot bearing, allowing the lever to be positioned independently at different angles while the bearing remains stationary. This segmentation enables angular position adjustability without complicating the overall structure, as each segment has a defined function and the rotation interface is standardized through the pivot bearing
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 provides a high degree of variability in actuator positioning, facilitating easy assembly and cost-effective manufacturing while ensuring reliable brake operation across different vehicle types.
Implementation Method 1
a brake lever (4) being rotatable around a pivot bearing (5) for introducing the clamping force from an actuator
Implementation Method 2
a force-redirecting device (35) is arranged between the actuator and the brake caliper for transmitting an input force from the actuator to the brake lever
Implementation Method 3
a thrust element (9) for transmitting the amplified clamping force onto the brake disc
Data Source
AI summary
A disc brake, in which a force-redirecting device is arranged between an actuator and the brake caliper for transmitting an input force from the actuator to a brake caliper of the brake actuation mechanism.