Symmetrical Pad Spring Design for Disc Brake Assembly
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Solution Overview
Problem
The existing disc brake assembly process is hindered by poor workability due to asymmetrical pad springs that complicate the assembly and increase costs by requiring separate support members for each caliper side, leading to increased weight and complexity.
Innovation Solution
A symmetrical pad spring design is implemented, with claw portions engaging the connector part in a way that biases brake pads in the rotor rotational outlet direction, reducing assembly complexity and allowing for common parts usage across caliper sides, thus improving workability and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an asymmetrical pad spring design is used to bias brake pads, then the braking function is achieved, but the assembly workability deteriorates and device complexity increases
Solution Approach 1:
The pad spring is designed with asymmetry in its functional configuration - the claw portions are positioned at different locations relative to the brake pad center, with one claw engaging the connector part while the other engages the brake pad. This asymmetrical engagement arrangement achieves the necessary braking bias while maintaining symmetrical overall shape for easier manufacturing and assembly.
Solution Approach 2:
The pad spring serves multiple functions simultaneously: it biases the brake pads against the rotor, prevents rattling of the brake pads, and provides structural support through its爪 portions engaging with both the connector part and brake pad. This multi-functionality reduces the need for separate components, improving assembly workability.
2Reliability
If separate support members are used for each caliper side, then the braking performance is optimized, but the device complexity and weight increase
Solution Approach 1:
The pad spring integrates multiple support functions into a single component that spans across the caliper. The spring body connects the connector part to the brake pad, combining what would traditionally require separate support members on each side. This merging reduces component quantity and simplifies the overall brake assembly.
Solution Approach 2:
The single pad spring component performs the support and biasing functions for the brake pad, replacing what would traditionally require separate support members. This universal component handles multiple mechanical functions simultaneously, reducing device complexity while maintaining braking performance.
3Ease of manufacture
If a symmetrical pad spring design is used, then the manufacturing cost is reduced and assembly is simplified, but the ability to bias brake pads effectively may be compromised
Solution Approach 1:
The pad spring employs a symmetrical overall shape for ease of manufacturing, but incorporates asymmetrical engagement features - the claw portions are positioned differently to engage the connector part and brake pad. This allows the spring to maintain manufacturing simplicity while achieving effective brake pad biasing through its asymmetrical functional configuration.
Solution Approach 2:
The pad spring has different local properties - the overall symmetrical shape provides manufacturing simplicity, while the locally asymmetrical爪 portions provide effective brake pad biasing. This local differentiation allows the component to satisfy both manufacturing cost requirements and braking performance requirements simultaneously.
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 symmetrical pad spring design enhances assembly efficiency, stabilizes the pad spring posture, reduces weight, and allows for common parts usage, effectively addressing the challenges of assembly complexity and cost in existing disc brake systems.
Implementation Method 1
a pad spring that is engaged with the connector part by a pair of claw portions facing each other, is installed on the caliper main body, and biases the brake pads in a rotor rotational outlet direction and inward in the rotor radial direction
Data Source
AI summary
A disc brake includes a caliper main body configured to have a pad assembling space that is disposed across over a disc rotor and opens toward an approximate middle thereof in a rotor radial direction and a connector part that crosses the pad assembling space in a rotor axial direction, and a pad spring that is engaged with the connector part of the caliper main body by a pair of claw portions facing each other, is installed on the caliper main body, and biases the brake pads in a rotor rotational outlet direction and inward in the rotor radial direction. The pad spring has a symmetrical shape with respect to the center in a longitudinal direction thereof, and the pair of claw portions are engaged with the connector part in a state in which the center in the longitudinal direction is offset in a rotor rotational direction with respect to the center in the rotor rotational direction of the brake pads.