Air Brake Spring Support Assembly With Insertion Depth Indicator
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Solution Overview
Problem
The assembly of spring supports in air brakes for heavy goods and trailer vehicles is complicated by recess depth tolerances, leading to increased production costs due to incorrect insertion and subsequent need for additional correction steps.
Innovation Solution
Incorporating a visual indicator, such as markings or incisions, on the spring support or brake caliper to accurately determine the proper depth of insertion, preventing collision with the brake caliper border and simplifying the assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the recess is made deeper to compensate for tolerances, then the assembly becomes more robust against positioning errors, but the spring support may be pushed too deep and collide with the brake caliper border, requiring additional correction steps
Solution Approach 1:
The patent applies preliminary action by providing visual indicators (markings or incisions) on the spring support or brake caliper before assembly begins. These indicators show the correct insertion depth, allowing the assembler to stop at the proper position without needing to push the spring support too deep and then correct it. This prevents the collision with the brake caliper border from the outset, eliminating additional correction steps while maintaining tolerance compensation.
2Adaptability or versatility
If the recess depth is increased to accommodate tolerance variations, then more components can be accommodated, but the assembly time increases due to the need for additional correction steps
Solution Approach 1:
The patent replaces the mechanical trial-and-error assembly process with a visual guidance system. Instead of relying on physical feedback from collisions or complex mechanical stops, the visual indicators provide immediate visual feedback about insertion depth. This substitution allows the recess to be deeper for tolerance accommodation while eliminating the time-consuming correction steps that would otherwise be necessary.
3Manufacturing precision
If the spring support is pushed deeper into the recess during assembly, then tolerance compensation is improved, but the end of the spring support collides with the brake caliper border preventing proper screwing
Solution Approach 1:
The patent introduces visual indicators as an intermediary element between the spring support and the assembler. These markings or incisions act as a mediator that communicates the correct insertion depth, allowing the assembler to achieve proper positioning accuracy without the spring support end colliding with the brake caliper border. This intermediary guidance system maintains manufacturing precision while preserving assembly ease.
Data Source
AI summary
An air brake (100) includes a brake caliper (40, 41), at least one leaf spring (44, 45), and a spring support (30a-e). The spring support is pushed into a recess (42) of the brake caliper during assembly prior to being fixed to the brake caliper. The spring support (30a) includes a visual indicator in the form of a marking (38a) or the brake caliper includes a visual indicator in the form of an incision. The visual indicator is arranged to indicate the correct depth of insertion of the spring support into the brake caliper.