Rotatable Disc Brake Lever for Spatial Adaptation
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Solution Overview
Problem
Disc brakes for heavy load trucks face challenges in adapting to different spatial constraints across various vehicles, such as cross-road trucks and low-floor buses, due to fixed actuation mechanisms that do not easily accommodate varying external positions of actuators and chassis configurations.
Innovation Solution
A disc brake design featuring a rotatable brake lever with an amplification mechanism, supported by a non-displaceable rod within the caliper housing, allowing angular adjustment to accommodate different spatial constraints. The lever is configured to direct clamping force perpendicularly to the brake disc axis, with a recessed design for improved rigidity and reduced material usage, and a mounting brace for secure assembly and disassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a fixed actuation mechanism is used, then the brake structure is simple and stable, but it cannot adapt to different spatial constraints in various vehicles
Solution Approach 1:
The brake lever is designed to be rotatable around the rod axis, transforming a static fixed-position mechanism into a dynamic adjustable one. This allows the lever to be mounted at different angular positions to accommodate various spatial constraints in different vehicle types, while the core mechanism structure remains relatively simple
Solution Approach 2:
The rod-supported amplification mechanism serves multiple functions: it provides mechanical advantage for force amplification, acts as a pivot axis for the brake lever, and enables angular adjustment to different positions. This multi-functionality reduces the need for additional components to achieve adaptability
2Strength
If the brake lever is made with thick walls for rigidity, then structural strength is improved, but manufacturing cost and weight increase
Solution Approach 1:
The rod acts as a structural support that counterbalances the need for thick lever walls. By providing external support through the rod connection, the lever can be designed with thinner walls while maintaining sufficient rigidity and strength, thereby reducing manufacturing cost and weight
3Adaptability or versatility
If the clamping force is directed axially to the brake disc, then the actuation mechanism is simplified, but adaptability to different vehicle configurations is reduced
Solution Approach 1:
The brake lever's rotatable design allows the direction of clamping force to be dynamically adjusted. By changing the angular position of the lever around the rod, the force transmission direction can be optimized for different vehicle configurations while maintaining the same core actuation mechanism structure
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
Enables easy assembly, cost-effective manufacturing, and adaptable installation in diverse vehicle configurations, ensuring reliable torque transmission and stability while minimizing weight, thus enhancing the disc brake's adaptability and performance across different spatial constraints.
Implementation Method 1
an amplification mechanism comprising a brake lever being rotatable around a pivot bearing for introducing a clamping force from an actuator
Implementation Method 2
a rod, which rod is supported in the housing of the brake caliper so as to be not displaceable in axial direction
Implementation Method 3
transmitting the amplified clamping force onto the brake disc
Data Source
Figure 1
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AI summary
The present invention relates to a disc brake comprising a brake actuation mechanism (3), the components of which are mounted in functional cooperation in the brake caliper (1) by means of a rod (20), in which a brake lever (4) is configured so that the clamping force from the actuator is substantially directed radially to the axis of the brake disc upon brake actuation, and in which the brake lever (4) is further configured to be mounted at different angular positions around the axis of the rod (20).