Brake Axle Mount Sleeve With Mated Depressions
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Solution Overview
Problem
Conventional heavy-duty vehicle brake systems experience reduced axle life and durability due to stress risers and local mechanical property changes caused by welds between brake assembly brackets and the axle.
Innovation Solution
A brake system component axle mount that eliminates welds by using a sleeve with mated depressions on the axle, creating a mechanical lock and pre-load contact without additional fasteners, thereby stabilizing the brake assembly components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welds are used to attach brake assembly brackets to the axle, then the brake components are securely mounted, but stress risers and local mechanical property changes occur in the axle, reducing its durability and life expectancy
Solution Approach 1:
A sleeve is introduced as an intermediary component between the brake assembly brackets and the axle. The sleeve is disposed about the axle and includes a depression that mates with a depression in the axle to form a mechanical lock. The brake chamber bracket and cam shaft bracket are then attached to the sleeve instead of directly to the axle, eliminating welds on the axle while maintaining secure mounting through the sleeve intermediary.
2Reliability
If welds are used to connect brake brackets to the axle, then the connection is strong and stable, but the welding process creates stress risers that reduce the axle's life expectancy
Solution Approach 1:
The sleeve serves as a mediator that provides a stable mounting surface for the brake brackets without requiring welds on the axle itself. The mechanical lock formed by mated depressions in the sleeve and axle, combined with the sleeve's interference fit, creates a stable connection that avoids the stress risers associated with welding while maintaining connection reliability.
Solution Approach 2:
The mounting system is segmented into distinct components: the axle, the sleeve, and the brake brackets. This segmentation allows the sleeve to bear the mounting loads and protect the axle from stress concentrations, effectively separating the functions of structural support (axle) and component mounting (sleeve).
Data Source
AI summary
A brake system component axle mount for a vehicle axle/suspension system includes an axle having at least one depression formed therein. A sleeve is formed with at least one depression and disposed about the axle so that the axle depression and the sleeve depression matingly engage one another to form a mated pair of depressions. A brake mount assembly is rigidly attached to the sleeve. A method of forming the brake system component axle mount includes providing an axle and disposing a sleeve about the axle. At least one mated pair of depressions is simultaneously formed in the axle and the sleeve. A brake mount assembly is rigidly attached to the sleeve.