Wrap Spring Assembly With U-Shaped Support for Brake Adjuster Fatigue
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Solution Overview
Problem
Existing disk brake adjusting devices with wrap springs suffer from premature fatigue fractures and variations in switching angles and clearance due to excessive stress and pressure, leading to potential failure and inconsistent braking performance.
Innovation Solution
The introduction of a U-shaped projection in the wrap spring, which acts as an additional radial support, reduces material overload and stress, making the wrap spring more rigid and resistant to bending, while its arrangement on a bead of the intermediate ring and within the thread of the adjusting spindle enhances precision and stability, minimizing play and lateral forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the wrap spring is used without additional radial support, then the structure is simpler, but the wrap spring is subject to excessive stress and pressure leading to fatigue fractures
Solution Approach 1:
The wrap spring is segmented by introducing a U-shaped projection that divides the continuous spring structure into distinct sections. This segmentation provides additional radial support points, reducing the stress concentration on any single section and preventing fatigue fractures while maintaining the overall spring function.
Solution Approach 2:
The U-shaped projection introduces an asymmetric feature to the otherwise symmetric wrap spring structure. This asymmetric element creates a specific radial support configuration that effectively reduces stress and pressure on the spring coils, enhancing durability without significantly increasing complexity.
2Force
If the wrap spring is subjected to high stress, then the radial support function is stronger, but the wrap spring becomes more prone to fatigue fractures
Solution Approach 1:
The U-shaped projection acts as a pre-positioned cushioning element that distributes and reduces the radial support force before it reaches the spring coils. By providing this intermediate support structure, the design prevents excessive stress accumulation that would lead to fatigue fractures, thereby enhancing reliability.
3Manufacturing precision
If the wrap spring has more radial support points, then the switching angle variation is reduced, but the manufacturing complexity increases
Solution Approach 1:
Instead of uniformly increasing radial support throughout the entire wrap spring, the U-shaped projection provides localized radial support at a critical position. This local quality enhancement achieves the necessary switching angle precision without the complexity of adding multiple support points throughout the structure.
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
This configuration significantly reduces the risk of fatigue fractures, maintains precise adjustment, and stabilizes the switching angles, ensuring consistent clearance and improved braking performance by preventing premature failure and maintaining precise control of the adjusting device.
Implementation Method 1
the wrap spring comprises at least one U-shaped projection. The U-shaped projection of the wrap spring serves, in the fitted state in the adjusting device, as additional radial support, thereby significantly reducing the load acting on the wrap spring
Implementation Method 2
reduces material overload and stress, making the wrap spring more rigid and resistant to bending, while its arrangement on a bead of the intermediate ring and within the thread of the adjusting spindle enhances precision and stability, minimizing play and lateral forces
Implementation Method 3
significantly reduces the risk of fatigue fractures, maintains precise adjustment, and stabilizes the switching angles
Data Source
AI summary
The invention relates to a wrap spring for blocking an unwanted rotational movement of a rotary element. The invention further relates to an adjusting device for adjusting the wear of brake pads of a disk brake. An adjusting device comprises a guide sleeve in which a wrap spring is arranged, a grooved ring which encompasses the guide sleeve, wherein the grooved ring is coupled to a closure cap via a torsion spring, and an opening ring encompassing the grooved ring. The invention further relates to a disk brake for a vehicle, in particular for a utility vehicle, wherein the disk brake comprises an adjusting device with a wrap spring.