Sliding Caliper Disc Brake Reset Mechanism for Residual Drag Torque
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Solution Overview
Problem
Commercial vehicle disc brakes experience residual grinding torques due to brake pad wear, leading to increased fuel consumption and reduced service life of brake components, with existing restoring devices facing reliability issues in compressed air-actuated systems due to component tolerances and deformations.
Innovation Solution
A disc brake design featuring a spreading device that synchronously resets both brake pads and the caliper upon release, using expanding elements that act against the application direction to create gaps between the brake pads and the disc, ensuring consistent spring force transmission and minimizing oblique wear through central or symmetric contact with the pad carrier plates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a restoring device is arranged in the guide rail to reset the brake caliper, then the brake caliper can be restored to initial position, but the device complexity increases and reliability decreases due to component tolerances and deformations in compressed air-actuated systems
Solution Approach 1:
The patent combines the restoring device with the existing application device (brake actuator), using the same pneumatic cylinder and piston mechanism to perform both braking and restoring functions. The application device is designed to be displaceable in the axial direction, allowing it to push the brake pad against the disc during braking and return to initial position during restoration, thereby eliminating the need for a separate restoring device in the guide rail.
Solution Approach 2:
The application device serves dual functions: it acts as both the braking actuator and the restoring mechanism. By making the application device displaceable axially, it can perform the restoration function alongside its primary braking function, reducing overall device complexity and improving reliability by minimizing the number of additional components that could introduce tolerances and deformations.
2Duration of action of stationary object
If the brake caliper remains in displaced position after brake release, then the brake structure is simple, but residual grinding torques increase fuel consumption and reduce service life
Solution Approach 1:
The patent introduces dynamic displacement of the application device in the axial direction, allowing the brake caliper to automatically transition between braking and non-braking positions. During braking, the application device is displaced axially to push the brake pad against the disc; during non-braking, it returns to initial position, creating dynamic separation between the brake pad and disc, thereby eliminating residual grinding torques and reducing energy loss.
3Reliability
If spreading elements act on brake pads to create gaps, then residual grinding torques are prevented, but the device complexity increases
Solution Approach 1:
The patent merges the spreading function with the application device by incorporating spreading elements into the brake pad assembly that is already integrated with the displaceable application device. The spreading elements are positioned to act on the brake pad in conjunction with the axial displacement of the application device, creating gaps between the brake pad and disc during non-braking without requiring a separate spreading mechanism.
Solution Approach 2:
The application device performs multiple functions simultaneously: it acts as the braking actuator, the restoring mechanism, and the spreading device. By making the application device displaceable axially and integrating spreading elements into this single component, the patent eliminates the need for separate restoring and spreading devices, thereby reducing overall device complexity while maintaining reliable operation.
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
The solution effectively extends the service life of brake pads and the brake disc, reduces operating costs, and ensures reliable operation by maintaining consistent spring forces and minimizing wear, thus preventing residual grinding torques and improving overall brake performance.
Implementation Method 1
The spreading device has resilient spreading elements that can be displaced in the axial direction towards one another and away from one another
Implementation Method 2
Each brake pad (3) has a lining carrier plate (4) and a friction lining (5) fastened to it on its side facing the brake disc (2)
Data Source
Figure 1
Figure 1a
Figure 2
AI summary
The invention relates to a disk brake (100), comprising a brake caliper (1), which reaches over a brake disk (2), is designed as a sliding caliper, is fastened to a stationary brake bracket (6) and has a central opening (41) over the brake disk (2), further comprising two brake pads (3), which are arranged in the brake caliper (1) and can be moved in opposite directions and each have a backing plate (4) and a friction lining (5) fastened thereto and of which an action-side brake pad can be pressed against the brake disk (2) by an application device by means of at least one brake piston, and at least one restoring device, by means of which the brake caliper (1) can be returned after displacement and release of the brake caused by braking, wherein the restoring device has a spreading device (8), which acts on the brake pads (3) lying opposite each other and acts in the same way against each particular application direction and has resilient spreading elements that act on the respective backing plates (4). The spreading device (8) is arranged in the central opening (41), wherein the spreading elements act directly or indirectly outside of the friction linings (5) on one side in the center region or at at least two contact regions of the brake pads (3) arranged at a distance from each other with respect to the center, wherein the contact regions each have a contact surface and a bearing surface, on which the spreading elements are movably arranged. The invention further relates to a corresponding brake pad set.