Spiral Torsion Spring in Disc Brake Caliper
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Solution Overview
Problem
The existing disc brake designs are in need of optimization to improve functional reliability and dimensioning, particularly in minimizing the size and weight of the brake caliper while ensuring the structural integrity and preventing overload during braking.
Innovation Solution
A pneumatically or electromechanically actuable disc brake design that incorporates a spiral torsion spring instead of a helical spring, with the spiral spring being wound from a spring plate and featuring hooks or angled portions for fastening, allowing for a more compact structure and reduced diameter, which is connected to a ball ramp coupling to compensate for wear-induced changes in the air gap between the brake pad and disc through axial displacement of control spindles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a helical torsion spring is used in the ball ramp coupling, then the coupling can be switched under load and overload protection is provided, but the spring has large diameter and structural height which increases the size of installation openings in the brake caliper
Solution Approach 1:
The patent changes the geometric parameters of the torsion spring from a helical configuration to a spiral configuration. This parameter change reduces both the diameter and structural height of the spring, allowing for smaller installation openings in the brake caliper while maintaining the overload protection function of the ball ramp coupling.
Solution Approach 2:
The patent employs a spiral spring with curved geometry instead of a helical spring. The spiral configuration provides the necessary torsional flexibility and overload protection while occupying less space, thereby reducing the required installation opening size in the brake caliper structure.
2Reliability
If a helical torsion spring is used in the ball ramp coupling, then the coupling can be switched under load, but the spring has large structural height which increases the overall size of the brake caliper
Solution Approach 1:
The patent changes the geometric parameters of the torsion spring from a helical configuration to a spiral configuration. This parameter change significantly reduces the structural height of the spring, allowing for a more compact brake caliper design while maintaining the overload protection function.
3Ease of manufacture
If larger installation openings are provided in the brake caliper to accommodate a helical spring, then the spring can be installed, but the stiffness of the brake caliper is reduced
Solution Approach 1:
The patent changes the geometry of the torsion spring to a spiral configuration, which reduces the required installation opening size. This allows the brake caliper to maintain its structural integrity and stiffness without requiring large openings, thereby resolving the contradiction between ease of installation and structural strength.
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 use of a spiral spring results in a more compact and lightweight brake caliper with improved reliability, allowing for precise adjustment and reduced installation space requirements, leading to enhanced performance and reduced fuel consumption.
Implementation Method 1
The spiral spring is wound from a spring plate and has hooks or angled portions formed on the ends for fastening
Implementation Method 2
The central drive input element is connected to a drive input spindle via a ball ramp coupling, and the ball ramp coupling has a drive output disc, which engages into the drive input element
Data Source
AI summary
A pneumatically or electromechanically actuatable disc brake as a wear adjustment adjustment device, which is positioned in a caliper, and is actuatable by a brake lever, includes a central drive element. The central drive element is connected to a drive spindle by way of a ball ramp coupling and the ball ramp coupling has a drive output disc, which engages in the drive element, and a coupling ring, with the ends of a torsion spring being connected to either the disc or the ring. The torsion spring is a helical spring, preferably composed of a wound spring plate.