Description:Technical field of the invention

[0002] The present invention relates to a braking designed for two-wheeler vehicles. The invention particularly relates to a cable operated disc brake system that utilizes a mechanical mechanism operated by a control cable. The innovative system generates variable output force, resulting in highly efficient braking for two-wheeler vehicles.

Background of the invention

[0003] Braking systems are crucial for ensuring the safety and control of two-wheeler vehicles. There are various types of brake systems, including electromagnetic, frictional, hydraulic, air, drum and disc brakes. These systems work by absorbing energy from a moving system, typically through friction, in order to bring motion to a stop. Disc brakes and drum brakes are the two primary classifications based on their working principles. Disc brakes are directly connected to the front wheels, while drum brakes are mounted on the rear wheels. Conventional drum brakes, although cost-effective, lacks the desired performance and responsiveness. In contrast, hydraulic disc brakes offer superior performance but often come with a higher cost, making them less accessible to a wider market.

[0004] Among the different brake systems, hydraulic disc brakes are widely used. Hydraulic disc brake system comprises a brake rotor and brake pads that rotate with the wheel, clamped by pressure from pistons. By utilizing incompressible fluid, such as brake fluid, the hydraulic brake system transfers forces to engage the brake pads against the rotors, thereby decelerating the vehicle effectively.
[0005] However, hydraulic disc brake systems come with certain limitations. One of the drawbacks is the potential messiness associated with the managing of hydraulic fluids. In the event of leakages, addressing them can be challenging and may even pose fire hazards. Moreover, the maintenance of hydraulic systems can be costly due to the complexity and multitude of components involved.

[0006] In order to overcome the drawbacks of the existing systems, several technologies were developed over the decades to provide a lower maintenance and cost-effective braking system with improved performance.

[0007] The Patent Application No TWI545052B entitled, “Brake system and apparatus” discloses a braking system comprises a brake pad that is connected to a slider assembly capable of linear movement within a guide. The slider assembly and guide are linked to a first brake. Additionally, a second brake actuator is connected to the slider assembly, guide, and a second brake. When the first brake is engaged, the slider assembly is pressed against a rotating braking surface. As a result, the friction between the brake pad and the rotating braking surface causes the slider assembly to move within the guide, subsequently activating the second brake actuator. The second brake actuator then engages the second brake. Conversely, when the first brake is released, the slider assembly disengages from the rotating braking surface, causing the second brake actuator to release and subsequently disengage the second brake.

[0008] The Patent Application No US9126653B2 entitled, “Straddle type vehicle brake system and straddle type vehicle” discloses a device that links the front disc and rear drum to enhance the braking performance and safety of a two-wheeler vehicle. It includes a shell, brake connecting rod, rear inhaul cable, front inhaul cable, steering rod, balancer, and connecting rod. The device effectively distributes brake force between the front disc brake and rear drum brake, improving brake efficiency and reducing braking distance. It also helps alleviate vehicle sideslip and drift, maintaining the centre of gravity during braking. This enhances overall drive safety and reduces the reliance on advanced driving skills.

[0009] The Patent Application No CN201124920Y entitled, “Hydraulic associated braking system for motorcycle” discloses a hydraulic combined braking system specifically designed for motorcycles. This advanced system incorporates various key components, including the left and right braking main pump assemblies, the braking distribution delay valve assembly, the front and rear braking calliper assemblies, and the braking oil pipe. By effectively controlling the initial braking time of both the front and rear wheels, this innovative system ensures a well-balanced distribution of braking forces. It achieves this by sensing the input pressure from the braking main pumps through the valves. The result is significantly improved braking stability and enhanced safety for motorcycles, as the system optimizes the coordination between the front and rear braking mechanisms.

[0010] None of the prior arts provide any solution that bridges the gap between the limitations of conventional drum brakes and the high costs associated with the hydraulic disc brakes. Thus, there is a need for an innovative approach that addresses the challenges faced by the manufacturers and the end-users. The objective is to develop a practical and cost-effective braking system that offers optimal performance while ensuring accessibility to a wide range of users.
Summary of the Invention
[0011] The invention relates to a cable-operated disc brake system comprising several components that work together to enable efficient and reliable braking. The system includes a floating caliper that houses the internal mechanisms and monitors reaction forces during braking. A caliper cap provides additional protection and security for the internal components. The system incorporates a cam lever, an upper cam, and a lower cam to transfer load and stroke, adjust mechanical advantage, and convert rotational motion into linear movement. A plurality of spherical rollers within the upper cam and the lower cam enables the fine-tuning of the braking system. An adjuster enables precise adjustment of a piston position to compensate for brake pad wear. The piston transfers the load to engage the brake pads with the disc rotor, and a spring aids in the piston retraction after the release of the brakes. Plurality of mounting bolts ensure secure attachment of the caliper and caliper cap, while a dust cap protects the system against any water or dust ingress. Together, these interconnected components facilitate the operation of the cable-operated disc brake system, converting the applied force into an effective braking system.

[0012] When the brakes are applied, the front brake lever is depressed, and the braking force is transferred to the cam lever through a control cable. The rotation of the cam lever engages the upper cam, which pushes the lower cam axially. This movement synchronizes with the piston, causing one brake pad to make contact with the disc rotor, generating a clamping force for the effective braking. A spring allows the piston retraction upon release of the brake. A dust cover protects the system from dust and debris. The process helps to efficiently converts the user's applied force into the necessary movements and the clamping force for the purpose of reliable braking.

Brief Description of drawings

[0013] Figures 1a- 1k illustrate cross-sectional views of different components of the system, in accordance with the embodiments of the present invention.

[0014] Figure 2 illustrates a cross-sectional view of the system, in accordance with the embodiments of the present invention.

Detailed description of the invention

[0015] In order to describe and point out the subject matter of the claimed invention, the following definitions are provided for specific terms, which are used in the following written description more clearly and concisely.

[0016] Figure 1a-1k illustrates a cross-sectional view of different components of the system (100) for operating disc brake in accordance with the different embodiments of the present invention. The system (100) comprises a caliper (101) as shown in [Figure-1a] that houses all the components within the mechanism and monitors the reaction forces during braking.

[0017] Further, the system (100) comprises an additional component known as a caliper cap (102), as shown in [Figure-1b], specifically designed to enclose and protect the mechanisms located within the caliper. By securely enclosing the mechanisms, the caliper cap (102) ensures the longevity and optimal performance of the cable-operated disc brake.

[0018] Further, the system (100) is equipped with another essential component, a cam lever (103) as shown in [Figure-1c]. The cam lever (103) serves as a mechanism to transfer the load and stroke from the control cable to the brake system. Through its design, the cam lever (103) multiplies the load and stroke to a predetermined value, effectively enhancing the force exerted on the brake pads for efficient braking.

[0019] Furthermore, the system (100) comprises an upper cam (104) as shown in [Figure-1d] that works in conjunction with the cam lever (103). The upper cam (104) converts the rotational motion generated by the cam lever (103) into a linear axial movement of the lower cam (105). The lower cam is shown in [Figure-1e]. To achieve variable Mechanical Advantage (M.A.), the upper cam (104) features a variable contact radius. This variability allows for precise adjustment and optimization of the braking force exerted on the disc rotor. The lower cam (105) is mated with the upper cam (104) to facilitate the conversion of rotational movement into linear motion through the use of three wedges. Similar to the upper cam (104), the lower cam (105) incorporates a variable radius slot along its wedge surfaces, providing variable Mechanical Advantage (M.A.) throughout its operation. This adjustability ensures the brake system can adapt to varying braking requirements.

[0020] Yet another crucial component of the system (100) assembled between the upper cam and lower cam wedges is the plurality of spherical rollers (106) as shown in [Figure-1f]. The spherical rollers (106) move within the slots of both upper cam (104) and lower cam (105), thereby altering the contact radius. By adjusting the contact radius, the spherical rollers (106) enable fine-tuning of the braking system, allowing for precise control and modulation of the braking force.

[0021] The system (100) further includes an adjuster (107) as shown in [Figure-1g], and a piston (108) as shown in [Figure-1h]. The adjuster (107) is specifically designed to adjust the position of the piston (108) in relation to brake pad wear. Over time, as the brake pads wear down, the adjuster (107) allows for precise adjustments to compensate the changes in brake pad thickness. By ensuring optimal positioning of the piston (108), the adjuster (107) helps maintain consistent braking performance and enhances the overall longevity of the brake system.

[0022] The piston (108) plays a crucial role in the cable-operated disc brake system (100) by transferring the load from the cams to the brake pads. When engaged, the piston (108) applies the necessary force to bring the brake pads into contact with the disc rotor, resulting in an effective braking.

[0023] The system (100) incorporates a spring (109) as shown in [Figure-1i] that assists in the piston's (108) return after the brake is released. When the brake is no longer applied, the spring (109) helps in restoring the initial position of the piston (108). By exerting force in the opposite direction, the spring (109) ensures that the brake pads disengage from the disc rotor, allowing for smooth rotation and preventing any unwanted friction. The spring's (109) role in retraction contributes to the overall efficiency and functionality of the cable-operated disc brake.

[0024] The system (100) further comprises a plurality of mounting bolts (110) as shown in [Figure-1j] to ensure structural integrity and secure attachment of the components. The mounting bolts (110) are specifically designed to join the caliper (101) and the caliper cap (102) together. By firmly connecting these components, the mounting bolts (110) provide stability and strength to the brake assembly. Their presence ensures that the caliper (101) and caliper cap (102) remain securely fastened, allowing for consistent and reliable operation of the cable-operated disc brake system (100).

[0025] The system (100) further comprises a protective component known as a dust cap (111) as shown in [Figure-1k]. The dust cap (111) serves a crucial role in safeguarding the brake mechanism from potential damage caused by water and dust ingress. By preventing the entry of external elements, the dust cap (111) helps to maintain the integrity of the internal components. It contributes to the long-term reliability and performance of the system (100) by reducing the risk of contamination and potential wear and tear. Further, the dust cap (111) ensures that the system (100) remains well-protected and operates optimally under various environmental conditions.

[0026] Referring now to Figure 2, a cross sectional view of the system (100) of cable operated disc brake is depicted, wherein the system (100) comprises interconnected components that work seamlessly to facilitate the operation of the cable-operated disc brake. The floating caliper (101) houses the mechanisms and monitors the reaction forces, while the caliper cap (102) encloses and secures the internal components. The cam lever (103) transfers the load and stroke, which is further converted by the upper cam (104) into a linear axial movement of the lower cam (105) thereby adjusting mechanical advantage through variable contact radius and slots. The spherical rollers (106) within the upper cam (104) and lower cam (105) vary the contact radius, while the adjuster (107) adjusts the precise piston (108) position to compensate the brake pad wear. The piston (108) efficiently transfers load to engage the brake pads with the disc rotor, while the spring (109) aids in piston retraction after brake release. The plurality of mounting bolts (110) ensure a secure attachment between the caliper (101) and caliper cap (102), and the dust cap (111) provides protection against water and dust, preserving the integrity of the brake mechanism. Together, these interconnected components synergistically enable reliable and efficient operation of the cable-operated disc brake system (100).

[0027] In an embodiment, when a user applies the brakes using the cable-operated disc brake system (100), the front brake lever is depressed, initiating the transfer of braking force and stroke through the control cable. The cam lever (103) is activated by this motion, resulting in its rotation. As the cam lever (103) rotates, it engages with the upper cam (104), which subsequently pushes the lower cam (105) in an axial direction. This axial movement of the lower cam (105) is synchronized with the movement of the piston (108). Consequently, one of the brake pads is brought into contact with the disc rotor. The clamping force required for effective braking is then generated as the force is transmitted to the brake pads, enabling them to firmly grip the disc rotor. The spring (109) facilitates the retraction of the piston (108) back to its original position when the brake is released. Additionally, the dust cap (111) fixed on the cam lever (103) protects the system (100) from dust and debris, ensuring optimal performance. Through this process, the cable-operated disc brake system (100) efficiently converts the user's applied force into the necessary movements and clamping force for reliable braking.

[0028] The present invention discloses a system (100) that effectively converts the force exerted by the user into the precise movements and clamping force essential for reliable braking. This efficient conversion ensures that the braking mechanism operates effectively, delivering the desired level of performance and safety. Additionally, the system (100) is designed with the objective of maintaining optimal performance and extending the lifespan of the brake system by effectively preventing the entry of dust and debris.

Reference Numbers:

Components Reference Numbers
System 100
Caliper 101
Caliper Cap 102
Cam Lever 103
Upper Cam 104
Lower Cam 105
Spherical Roller 106
Adjuster 107
Piston 108
Spring 109
Mounting Bolts 110
Dust Cap 111
, Claims:We Claim:
1. A cable-operated disc brake system, the system (100) comprising:
a. a cam lever (103) rigidly connected to an upper cam (104) wherein the upper cam (104) is connected with a lower cam (105) featuring a plurality of variable-radius grooves along its wedge surfaces, by means of a plurality of spherical rollers (106) positioned within the grooves, forming an interconnected mechanism for converting rotational motion of the cam lever (103) into linear axial movement of the lower cam (105).
2. The system (100) as claimed in claim 1, wherein the cam lever (103) is linked to a user-operated brake lever through a control cable for facilitating the transfer of braking force from the user-operated brake lever to the cam lever (103) whenever the user-operated brake lever is depressed.
3. The system (100) as claimed in claim 1, wherein the internal components of the system (100) are housed within a floating caliper (101), which is further protected by a caliper cap (102) to safeguard against external agents of corrosion and erosion.
4. The system (100) as claimed in claim 1, wherein the varying contact radius of the plurality of spherical rollers (106) placed on the variable-radius grooves of the lower cam (105), facilitate the adjustment and optimization of the braking force exerted on the disc rotor thereby enabling the system (100) to achieve a variable Mechanical Advantage (M.A.) throughout the operation.
5. The system (100) as claimed in claim 1, wherein the lower cam (105) moves in the axial direction along with a piston (108) disposed between the lower cam (105) and brake pads, thereby transferring the load from the cam lever (103) to the brake pads, facilitating effective engagement of the brake pads with the disc rotor, and ensuring efficient braking.
6. The system (100) as claimed in claim 1, wherein the plurality of variable- radius grooves between the lower cam (105) and the upper cam (104) are designed to accommodate the movement of a plurality of spherical roller (106) enabling fine-tuning of the system (100) and facilitating control of the braking force.
7. The system (100) as claimed in claim 1, wherein the piston’s (108) position in response to the brake pad wear is adjusted by an adjuster (107) assembled with the lower cam (105), utilizing a fastening mechanism to maintain the contact gap between the disk rotor and brake pads, thereby enabling the system (100) to achieve the optimum braking force.
8. The system (100) as claimed in claim 1, wherein the piston’s (108) retraction after the release of the brake pad is assisted by a spring (109), assembled between the piston (108) and the caliper (101), thereby facilitating the disengagement of the brake pads from the disc rotor for smooth rotation and aiding the return of the piston (108) to its original position.

9. The system (100) as claimed in claim 1, wherein the structural integrity of the system (100) is ensured by securely attaching the floating caliper (101) and the caliper cap (102) using a plurality of mounting bolts (110).
10. The system (100) as claimed in claim 1, wherein the system (100) incorporates a dust cap (111) as a protective measure to safeguard the brake mechanism from external agents of corrosion and erosion.