Brake Adjuster Sleeve Extraction Using Sealing Lip Engagement
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Solution Overview
Problem
Current methods for replacing the adjuster unit in disc brake assemblies are complex and require multiple aftermarket kits, making the process time-consuming and inefficient.
Innovation Solution
A device comprising an insert with an engaging section and an actuator that transmits extraction force to the sleeve of the adjuster unit, allowing for efficient removal of the unit by engaging the inner sealing lip and moving the sleeve away from the brake assembly, with optional features like a threaded bar and cup for enhanced extraction and insertion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional methods are used to replace the adjuster unit, then the process is reliable, but it requires multiple aftermarket kits and is time-consuming
Solution Approach 1:
The invention merges multiple extraction functions into a single integrated device. The extractor comprises an insert with an engaging section that combines both the groove for engaging the inner sealing lip and the inner volume for receiving the proximal end of the shaft, eliminating the need for multiple separate kits and tools.
Solution Approach 2:
The insert is designed as a multi-functional component that can engage with different parts of the adjuster unit (sleeve and shaft) and work with various actuator types (bar actuator, threaded bar with nut). This universal design allows a single device to handle multiple extraction scenarios without requiring additional specialized tools.
2Device complexity
If a simple extraction tool is used, then the device complexity is reduced, but the extraction force transmission may be insufficient
Solution Approach 1:
The insert acts as an intermediary component between the actuator and the adjuster unit parts. The groove in the engaging section serves as a mediator to efficiently transmit the extraction force from the actuator to the inner sealing lip of the sleeve, ensuring sufficient force transmission while maintaining a relatively simple device structure.
Solution Approach 2:
The design allows the adjuster unit's own components (inner sealing lip of the sleeve and proximal end of the shaft) to serve as part of the extraction mechanism. The groove engages with the existing inner sealing lip, and the inner volume receives the shaft's proximal end, utilizing the adjuster unit's own structure to facilitate its own removal without requiring complex external extraction tools.
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
Facilitates faster and simpler extraction and installation of the adjuster unit, reducing the need for multiple kits and improving maintenance efficiency.
Implementation Method 1
By engaging the groove in the insert, the inner sealing lip efficiently transfers the extraction force from the actuator, which is operatively coupled to the insert, to the sleeve
Data Source
AI summary
A device (100) for extracting an adjuster unit (20) of a brake assembly (25), which includes a shaft (22), a gear (24), and a sleeve (26), includes an insert (102) configured to be partially inserted between the peripheral wall (26a) of the sleeve (26) and a proximal end (22a) of the shaft. The insert (102) includes an engaging section (104) for engaging the sleeve (26) and an inner volume (106) for receiving the proximal end of the shaft (22). An actuator (108) is operatively coupled to the insert (102) and transmits an extraction force (F) so as to move the insert (102) and at least the sleeve (26) away from the brake assembly. The sleeve (26) has a sealing lip (26b) extending radially inwards from the peripheral wall of the sleeve (26), and the insert (102) includes a groove (107) configured to engage the sealing lip.