Brake Caliper Wear Compensation via Vibrating Threaded Sleeve
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Solution Overview
Problem
Conventional brake caliper devices suffer from reduced braking effectiveness due to pad wear over time, requiring regular maintenance and replacement.
Innovation Solution
A brake caliper device with a caliper actuator unit that includes an actuating member, a bolt member, and a threaded sleeve, which, when driven by an external force, causes axial vibration to push the pads toward the brake disk, automatically compensating for pad wear by rotating relative to the bolt member and providing a travel stroke.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional brake caliper devices are used without automatic compensation, then the structure is simple, but the braking effectiveness deteriorates over time due to pad wear
Solution Approach 1:
The brake caliper device automatically compensates for pad wear through the threaded sleeve rotating relative to the bolt member, which adjusts the pad position without external intervention. This self-adjusting mechanism maintains braking effectiveness without requiring manual maintenance or complex external systems.
Solution Approach 2:
The device transitions from a static pad position to a dynamic adjustment system where the threaded sleeve can rotate along the bolt member to change the pad position automatically. This dynamic mechanism allows the system to adapt to pad wear while maintaining relatively simple overall structure.
2Productivity
If manual maintenance and replacement is used for pad wear, then the device structure remains simple, but the maintenance time and operational downtime increase
Solution Approach 1:
The automatic compensation mechanism continuously adjusts for pad wear during normal operation, eliminating the need for manual maintenance interventions. This keeps the brake system productive without downtime while avoiding the time loss associated with manual maintenance schedules.
3Reliability
If automatic pad wear compensation mechanism is added, then the braking effectiveness is maintained, but the device complexity increases
Solution Approach 1:
The caliper actuator unit incorporates a dynamic adjustment mechanism where the threaded sleeve rotates relative to the bolt member to automatically adjust pad position. This dynamic element maintains braking effectiveness while adding minimal structural complexity compared to fully automated systems.
4Ease of operation
If the threaded sleeve rotates relative to the bolt member to push the pad, then the travel stroke for wear compensation is achieved, but the mechanical complexity of the actuator increases
Solution Approach 1:
The rotation of the threaded sleeve relative to the bolt member creates a mechanical action that pushes the pad forward automatically. This mechanical vibration and rotational movement provides the travel stroke needed for wear compensation while keeping the actuator mechanism relatively simple through straightforward mechanical components.
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 device maintains effective braking performance by automatically adjusting for pad wear, extending the interval between maintenance and replacement, ensuring consistent braking efficiency.
Implementation Method 1
the actuating member is capable of vibrating axially to cause an axial vibration of the bolt member
Data Source
AI summary
A brake caliper device is adapted to be used with a brake disk, and includes a main body unit, first and second pads, and a caliper actuator unit. The caliper actuator unit includes an actuating member, a bolt member that abuts against the actuating member, and a threaded sleeve that is threadedly engaged to the bolt member. When the actuating member is driven by an external force, the actuating member is capable of vibrating axially to cause an axial vibration of the bolt member, which prompts the threaded sleeve to rotate relative to the bolt member for pushing the first pad toward the brake disk, thereby automatically providing a travel stroke that compensates for pad wear.