Sheet Metal Brake Caliper Design for Heavy Vehicle Cost Reduction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing brake calipers for heavy commercial vehicles face high process costs due to the sand casting method, material inefficiency, and structural limitations, leading to increased weight and cost disadvantages, particularly in areas with low mechanical loads.
Innovation Solution
A brake caliper design utilizing a base plate, intermediate plate, housing shell, and housing cover, where the intermediate plate and base plate are cut from semi-finished flat materials, and the saddle frame is formed from sheet metal, allowing for optimal material utilization and reduced post-processing, with components joined using laser welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If sand casting process is used to produce brake caliper, then the brake caliper can be manufactured with sufficient strength, but the process costs are high due to melting costs, sand removal, targeted cooling, and cleaning
Solution Approach 1:
The brake caliper is divided into multiple components (housing, caliper frame, application device) that are manufactured separately and then joined together. This segmentation allows each component to be optimized for its specific function and manufactured using appropriate processes, reducing overall manufacturing costs while maintaining strength requirements.
Solution Approach 2:
The invention changes the manufacturing parameters from traditional sand casting to alternative processes such as laser cutting and joining. This parameter change eliminates melting costs, sand removal, and extensive cleaning operations while maintaining the structural integrity and strength of the brake caliper components.
2Productivity
If lost mold casting is used, then brake caliper can be produced, but a casting model is required which incurs additional costs and is subject to abrasive wear requiring replacement
Solution Approach 1:
The invention extracts and eliminates the casting model requirement from the manufacturing process. By using alternative manufacturing methods such as laser cutting and joining pre-fabricated components, the process removes the need for expensive, wear-prone casting models entirely, reducing both initial costs and ongoing maintenance expenses.
3Ease of manufacture
If cast brake caliper is produced, then the brake caliper can be manufactured, but minimum wall thicknesses are required which result in material not being fully utilized in terms of strength
Solution Approach 1:
The invention applies local quality by allowing different wall thicknesses in different areas of the brake caliper components. The laser cutting and joining process enables precise control of material distribution, providing thicker sections where strength is needed and thinner sections where loads are lower, thereby fully utilizing material strength properties.
4Ease of manufacture
If cast brake caliper is produced, then the brake caliper can be manufactured, but machining process is required to produce ready-to-install brake caliper
Solution Approach 1:
The invention applies preliminary action by pre-fabricating components with their final shapes and dimensions using laser cutting and forming processes. The components are prepared in advance with precise geometries, eliminating or minimizing the need for subsequent machining operations to achieve ready-to-install conditions.
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 design enables cost-effective and efficient production with optimized material strength and weight reduction, increasing payload capacity while eliminating the need for a costly casting model and minimizing machining costs.
Implementation Method 1
components joined using laser welding
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to a brake caliper (1) for a disk brake, said brake caliper having a caliper frame (2) which is designed to extend over an edge of a brake disk and which comprises a casing for accommodating an application mechanism for applying the disk brake. The casing comprises a base plate (15), an intermediate plate (7), a housing shell (12')inter connecting the base plate (15) and the intermediate plate (7), and a housing cover (12). The caliper frame (2) is cut from sheet metal and shaped and the housing cover (12) is integrally formed with the caliper frame (2).