Sliding Brake Caliper Structure for Lower Braking Deformation
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Solution Overview
Problem
Brake calipers for commercial vehicles face challenges in reducing tension during braking processes to increase lifespan while maintaining high rigidity and brake torque, as existing designs lead to deformation and stiffness limitations.
Innovation Solution
The brake caliper features a reciprocal section with parallel tensile struts and a locking lid, along with an interface for a stirring brake lever, optimizing the length ratio of the clamping section to tensile struts to reduce deformation and enhance stiffness, allowing for the use of high-strength casting materials without additional material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If the tension struts are made longer to reduce deformation and stress during braking, then the service life of the brake caliper is increased, but the overall stiffness of the brake caliper is reduced
Solution Approach 1:
The patent applies parameter changes by optimizing the length ratio of the clamping section to the tension struts within a specific range (0.45-0.55), and by selecting appropriate wall thicknesses for the tension struts. This allows the design to achieve reduced stress and deformation during braking while maintaining sufficient overall stiffness for the required braking torque.
Solution Approach 2:
The patent employs composite materials by using high-strength cast materials for the brake caliper body combined with specifically designed tension struts having optimized wall thicknesses. This composite approach enables the structure to achieve both flexibility for stress reduction and sufficient stiffness for braking performance.
2Ease of manufacture
If the tension struts are made thinner to reduce material usage and cost, then manufacturing cost is reduced, but the stress resistance during braking is decreased
Solution Approach 1:
The patent applies parameter changes by optimizing the wall thickness of the tension struts within specific ranges (first tension strut: 8-12mm, second tension strut: 6-10mm). This allows the design to use thinner, more cost-effective struts while maintaining sufficient stress resistance through the optimized geometric parameters and material selection.
3Length of moving object
If the clamping section is made shorter to reduce overall caliper length, then space constraints are better satisfied, but the deformation during braking is increased
Solution Approach 1:
The patent applies parameter changes by optimizing the length ratio of the clamping section to the tension struts within a specific range (0.45-0.55). This allows the design to achieve a compact overall length while maintaining controlled deformation during braking through the balanced proportioning of the clamping section relative to the tension struts.
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 reduces tension and deformation during braking, increases the lifespan of the brake caliper, and maintains high rigidity and brake torque, while enabling the use of less costly, high-strength materials.
Implementation Method 1
allows for greater deformation of the tension rods during a braking process, which leads to a reduction of the stresses occurring in the brake caliper
Data Source
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AI summary
The invention relates to a brake caliper, in particular a sliding caliper, of a disk brake of a utility vehicle, which brake caliper comprises: a brake application portion (23), which extends around a holding space for holding at least one brake application device; a caliper back (21); two tie bars (22), which run substantially parallel and at a distance to one another and connect the brake application portion (23) to the caliper back (21); a closure cover, which closes the holding space; an interface (26) for mounting a pivotable brake lever on the side of the brake application portion (23) facing away from the closure cover, wherein: a mounting opening (27) for inserting and removing brake pads is formed between the brake application portion (23), the caliper back (21) and the tie bars (22); the ratio of the length (d2) of the brake application portion (23) to the sum (a2) of the length of the brake application portion (23) and the length of a tie bar (22) is between 0.4 and 0.3.