Steel Wire Bow Spring Radial Suspension Design
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing disk brake systems with radial suspension mechanisms face issues of space constraints, complex mounting and maintenance, reduced brake disk diameter, and vulnerability to corrosion, as well as potential spring leg fractures leading to loss of functionality.
Innovation Solution
A steel wire bow spring with a changing rotational direction in three-dimensional space, asymmetrical configuration, and a central U-bow design that integrates the friction lining wear sensor, allowing for automatic correct mounting and redundant spring action, eliminating the need for separate fastening means and optimizing space usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional shaped spring is used for radial suspension of the friction lining, then the friction lining can be radially suspended, but the spring takes up a large amount of space and reduces the brake disk diameter which can be utilized
Solution Approach 1:
The spring design transitions from a planar configuration to a three-dimensional bow shape with changing rotational direction, allowing the spring to achieve the required suspension function while occupying less radial space and enabling larger brake disk diameters
Solution Approach 2:
The wear sensor is integrated into the spring structure by incorporating a receptacle for the sensor into the spring body, eliminating the need for separate mounting space and reducing overall component footprint
2Reliability
If a traditional shaped spring is used for radial suspension, then the spring can support the friction lining, but the construction complicates mounting and maintenance
Solution Approach 1:
The spring design features self-aligning characteristics where the changing rotational direction and asymmetrical configuration automatically guide correct mounting orientation, eliminating the need for complex alignment procedures during installation and maintenance
Solution Approach 2:
The spring employs asymmetrical configuration in relation to its longitudinal axis, which provides inherent directional identification and ensures correct mounting orientation without requiring additional marking or complex alignment procedures
3Reliability
If a traditional shaped spring is used, then radial suspension is achieved, but the spring is positioned in a manner which is unfavorable in terms of corrosion
Solution Approach 1:
The three-dimensional bow configuration with changing rotational direction positions the spring windings in a manner that improves drainage and reduces water trapping, thereby enhancing corrosion resistance compared to traditional planar spring designs
4Reliability
If separate fastening means are used to attach the wear sensor to the spring and rear plate, then secure attachment is achieved, but the construction becomes more complex and requires additional components
Solution Approach 1:
The spring structure is merged with the sensor mounting function by incorporating a receptacle directly into the spring body, eliminating the need for separate fastening means such as pins, rivets, or screws between the spring, rear plate, and sensor
Solution Approach 2:
The spring serves multiple functions simultaneously: providing radial suspension, integrating sensor mounting, and eliminating the need for separate fastening components, thereby reducing overall system complexity
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 enables simple, space-saving integration of the wear sensor, facilitates error-free mounting, and allows for larger brake disk diameters while ensuring continued spring functionality even if one spring leg breaks, with improved elastic durability and reduced risk of corrosion.
Implementation Method 1
a steel wire bow spring which serves by way of spring legs for the radially elastic support of the friction lining on a housing guide rail of a brake caliper
Data Source
AI summary
A friction lining with a wire bow spring including leg springs for the radially clastic support of the friction lining on a housing bridge of a brake caliper, wherein the back plate has a receptacle for a friction-lining wear sensor, and wherein a steel wire bow spring is a symmetrical to at least one longitudinal axis, and the wire bow spring is symmetrical to an imaginary transverse axis arranged rotated by a 90° with respect to the longitudinal axis, wherein the steel wire bow has a central U-bow for the friction-lining wear sensor, and wherein the U-bow is designed to be open at the top, the friction-lining wear sensor is accommodated integrated in the central U-bow and the U-bow is substantially larger than the friction-lining wear sensor, and therefore the friction-lining wear sensor can be mounted in the radial direction in the receptacle in the back plate.