Brake Adjuster Blocking Device for Spindle Jamming Prevention
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Solution Overview
Problem
Pneumatically actuated disc brakes in commercial vehicles face challenges in automatic wear adjustment and manual reset of adjusting spindles, leading to potential jamming during pad replacement due to lack of mechanical turn-back delimitation, making it difficult to ensure proper adjustment and prevent jamming.
Innovation Solution
An adjusting device with a clutch ring and a deformable or displaceable blocking element that forms a tangential stop, preventing rotational movement of the adjusting spindle and allowing for easy manual reset without high friction force, ensuring the spindle does not jam and maintaining automatic adjustment functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual reset of adjusting spindle is performed without blocking device, then adjusting device can be inserted and removed easily, but spindle may become jammed during resetting
Solution Approach 1:
The blocking device is activated in advance during the manual reset operation to prevent the harmful effect of jamming before it occurs. When the adjusting spindle is rotated to reset the brake pad position, the blocking device engages to prevent excessive rotation that would cause the spindle to jam, thus applying counter-action beforehand to eliminate the potential harm.
Solution Approach 2:
The blocking device converts the potential harmful effect of unrestricted spindle rotation (jamming) into a beneficial mechanical stop that defines the correct reset position. The blocking element's engagement creates a positive mechanical delimitation that ensures the spindle is reset to the proper position, transforming what could be a damaging unlimited rotation into a controlled, beneficial positioning mechanism.
2Reliability
If blocking device is added to prevent jamming, then spindle jamming is prevented, but device complexity increases
Solution Approach 1:
The blocking device is segmented into separate functional elements: a blocking element that can be inserted or removed, and a corresponding blocking receptacle or engagement feature on the adjusting spindle. This segmentation allows the blocking function to be added independently without redesigning the entire adjusting device, maintaining simplicity while providing the necessary jamming prevention.
Solution Approach 2:
The blocking device acts as an intermediary element between the operator and the adjusting spindle. Rather than requiring the operator to directly control the spindle rotation, the blocking device mediates the interaction by providing a mechanical stop that automatically prevents excessive rotation, thus simplifying the overall system control while maintaining reliability.
3Manufacturing precision
If mechanical turn-back delimitation is provided, then proper adjustment can be ensured, but friction force increases during operation
Solution Approach 1:
The blocking device is designed to be dynamic rather than fixed, allowing it to engage and disengage as needed. During normal brake operation, the blocking device is disengaged to minimize friction and allow smooth spindle rotation. During manual reset operations, it is engaged to provide the necessary mechanical delimitation for precise positioning, thus dynamically adapting to operational requirements.
Solution Approach 2:
The blocking device provides delimitation only when needed during manual reset operations, rather than continuously during all operations. This partial action approach ensures precise adjustment positioning when resetting brake pads, while avoiding the increased friction that would result from continuous engagement during normal braking operations.
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 solution effectively prevents spindle jamming during manual reset and ensures consistent automatic adjustment by providing a mechanical turn-back delimitation, allowing for smooth operation without high force expenditure, thus addressing the limitations of prior art.
Implementation Method 1
A blocking device, in particular a blocking element, is arranged between the adjusting device (1) insertable into the adjusting spindle (25) and the adjusting spindle (25). The blocking element (5) forms a stop in the tangential direction with regard to the direction of rotation for the adjusting spindle (25).
Implementation Method 2
The adjusting device (1) has a clutch ring (8) for coupling to a spring sleeve (14)
Data Source
AI summary
A wear adjustor is provided for adjusting the wear of brake pads and the brake disc of a pneumatically operated disc brake having a brake application device that can be actuated via a rotary lever. The wear adjustor is able to be inserted into an adjusting spindle of the brake application device. The wear adjustor includes a clutch ring for coupling to a spring sleeve that is in engagement with the adjusting spindle. A blocking device is disposed between the adjusting spindle and the wear adjustor. The blocking device forms a stop for the adjusting spindle in the tangential direction relative to the rotating direction.