Single Air Disc Brake Tappet Geometry for Uniform Pad Force
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Solution Overview
Problem
In air disc brake systems, the use of a single tappet leads to uneven distribution of braking force due to the moment created between the brake pad drag force and abutment force, resulting in uneven wear of the inner brake pad, which existing solutions often address with complex and costly methods.
Innovation Solution
A single air disc brake tappet with features that mimic multiple tappets, including tapered and angled designs, and a backing plate with recesses and raised surfaces that mate with the tappet, to distribute braking force more evenly and compensate for the unequal force distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single tappet is used in the air disc brake system, then the device complexity is reduced and manufacturing cost is lowered, but the braking force distribution becomes uneven and brake pad wear becomes non-uniform
Solution Approach 1:
The single tappet is segmented into multiple contact points through raised features on its surface. These raised features create multiple localized contact zones with the brake pad backing plate, effectively dividing the force application into several points. This segmentation allows a single tappet to achieve the force distribution benefits traditionally requiring multiple separate tappets, thereby reducing device complexity while maintaining uniform braking force distribution.
Solution Approach 2:
The tappet incorporates raised features with specific local geometries and positions designed to create optimal force distribution at contact points. The raised features have varying heights and positions that locally adjust the force application characteristics. This local quality modification enables the single tappet to compensate for the moment created by brake pad drag force, achieving uniform braking force distribution without requiring multiple tappets.
2Ease of manufacture
If a single tappet is used to simplify the brake system, then ease of manufacture is improved, but uneven wear of the inner brake pad occurs due to moment between drag force and abutment force
Solution Approach 1:
The single tappet is segmented into multiple contact points through raised features on its surface. These raised features create multiple localized contact zones with the brake pad backing plate, effectively dividing the force application into several points. This segmentation allows a single tappet to achieve the force distribution benefits traditionally requiring multiple separate tappets, thereby reducing device complexity while maintaining uniform braking force distribution.
Solution Approach 2:
The tappet design modifies geometric parameters such as the height, position, and shape of raised features to optimize force distribution. By changing these physical parameters, the tappet compensates for the moment created by brake pad drag force, ensuring uniform pressure distribution across the brake pad surface. This parameter optimization maintains reliability and uniform wear characteristics while keeping the system simple and easy to manufacture.
Data Source
AI summary
The following embodiments relate to a single air disc brake tappet with features that mimic multiple tappets. In one embodiment, an air disc brake tappet is provided comprising: a support member; and a plate coupled with support member, wherein the plate comprises a plurality of raised features that mimic a plurality of air disc brake tappets. In another embodiment, an air disc brake pad assembly is provided comprising: a friction material; and a backing plate coupled with the friction material, wherein the backing plate comprises at least one recess shaped and positioned to receive a plurality of raised features of an air disc brake tappet, wherein the plurality of raised features mimics a plurality of air disc brake tappets. Other embodiments are provided.