Brake Actuator Segmentation Prevents Spring Buckling
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Solution Overview
Problem
Conventional pneumatic brake actuators for heavy equipment vehicles face issues with reliable locking and unlocking of brakes due to over-compression of air in the spring chamber, leading to buckling of compressive springs and inefficient brake operation.
Innovation Solution
A brake actuator design that includes a piston dividing the spring brake housing into a spring chamber and a pressure chamber, with an actuator rod valve allowing air flow between these chambers, maintaining constant air pressure and preventing over-compression, using a caging bolt head with radial air flow holes and a pilot lip seal to control air flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If compressed air is supplied to the pressure chamber to unlock the parking brake, then the brake can be unlocked, but the air pressure in the spring chamber increases causing over-compression and buckling of the compressive spring
Solution Approach 1:
The brake actuator housing is divided into separate pressure chamber and spring chamber by a piston, allowing independent pressure control. The actuator rod with air flow holes provides selective communication between chambers, segmenting the pressure control to prevent spring chamber over-pressurization while maintaining brake unlocking capability.
Solution Approach 2:
The actuator rod serves as an intermediary component between the pressure chamber and spring chamber. It contains air flow holes that allow controlled pressure equalization, acting as a mediator to transfer pressure effects without direct chamber communication, thereby preventing harmful pressure buildup in the spring chamber.
2Force
If the compressive spring is compressed to provide strong braking force, then the braking force increases, but the volume of the spring chamber decreases causing pressure increase that prevents proper brake operation
Solution Approach 1:
The housing is segmented into pressure chamber and spring chamber separated by a piston. This segmentation allows the spring to be compressed for braking force generation while the piston prevents direct transmission of spring chamber pressure increases to the spring, maintaining proper pressure conditions for brake operation.
Solution Approach 2:
The system changes the physical parameters of the chambers by introducing a piston that can move between positions. When the spring compresses, the piston moves to accommodate volume changes, thereby controlling pressure parameters and preventing harmful pressure buildup while maintaining the required compressive force.
3Force
If the pressure in the spring chamber increases due to spring compression, then the spring force increases, but the brake cannot be unlocked or unlocks very slowly
Solution Approach 1:
The actuator rod with air flow holes acts as an intermediary pressure equalization path. During brake unlocking, it allows controlled air flow between chambers to balance pressure differences, enabling the spring force to be applied effectively without creating pressure barriers that would slow down the unlocking process.
Solution Approach 2:
The system dynamically changes pressure parameters between chambers through the movable piston and air flow holes. This allows the spring force parameter to be optimized for braking while the pressure parameter in the spring chamber is controlled to prevent unlocking delays, achieving both high force and fast response.
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
Ensures smooth locking and unlocking of brakes, preventing over-compression and buckling of the compressive spring, maintaining constant air pressure, and enhancing operational reliability.
Implementation Method 1
a strong compressive spring which is able to forcibly apply a braking force if the air is eliminated
Implementation Method 2
the compressed air allows to expand the pressure chamber and to move the diaphragm and to move the pressure plate toward the opposite ends of the spring brake actuator housing
Data Source
AI summary
Disclosed is a brake actuator which is able to adjust the operational states of a brake connection to the lower end of a push rod disposed movable upward or downward while passing through the lower end of a service brake housing in such a way that a diaphragm moves upward or downward a pressure plate in response to the elastic force of a compressive spring in a spring chamber and the adjustment of an air pressure in a pressure chamber.