Brake Mounting Bracket Assembly Without Axle Welding
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Solution Overview
Problem
Existing brake component mounting systems for heavy-duty vehicles with mechanical leaf spring axle/suspension systems require welding brackets to the axle, leading to increased stress susceptibility and the need for thicker axle walls, which increase weight and cost.
Innovation Solution
A clamp assembly that allows for the rigid mounting of a brake chamber and cam shaft assembly on or adjacent to the axle without welding, using a combination of U-bolts, top and bottom axle seats, and integrated brake component mounting brackets to secure the components in place.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If brake component mounting brackets are welded to the axle, then the brake components are securely mounted, but the axle wall thickness must be increased to withstand welding stress, which increases weight and manufacturing cost
Solution Approach 1:
The mounting system is divided into separate components: the clamp assembly (with U-bolts and axle seats) attaches to the axle, while the brake component mounting bracket attaches to the clamp assembly. This segmentation eliminates the need for welding brackets directly to the axle, allowing thinner wall thickness while maintaining mounting stability.
Solution Approach 2:
The clamp assembly acts as an intermediary between the axle and the brake component mounting bracket. It provides a stable mounting surface for the bracket without requiring direct welding to the axle, thus protecting the axle from welding-induced stress concentrations.
2Reliability
If brake component mounting brackets are welded to the axle, then secure mounting is achieved, but stress susceptibility increases at the weld locations
Solution Approach 1:
The clamp assembly serves as a mediator that distributes mounting loads across multiple attachment points (U-bolts securing both leaf springs and bracket) rather than concentrating stress at weld locations on the axle.
Solution Approach 2:
The welding operation is extracted from the axle-bracket connection and relocated to the clamp assembly-bracket connection. This removes the harmful welding stress from the axle structure while maintaining secure mounting through mechanical fastening.
3Reliability
If thicker wall axles are used to accommodate welding, then mounting stability is improved, but manufacturing cost increases
Solution Approach 1:
By segmenting the mounting system into a clamp assembly and a separate bracket, the invention allows the use of thinner, less expensive axles while achieving the required mounting stability through the distributed attachment system.
Solution Approach 2:
The welding process is replaced with a mechanical fastening system (U-bolts, nuts, and clamping action) that achieves equivalent or superior mounting stability without requiring increased axle wall thickness, thereby reducing manufacturing cost.
Data Source
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AI summary
An integrated brake component mounting bracket for a mechanical spring axle/suspension system of a heavy-duty vehicle includes an axle seat that is disposed on and is rigidly connected to an axle of the vehicle. An air chamber mounting bracket is rigidly connected to the axle seat, and a cam shaft assembly mounting bracket is rigidly connected to the axle seat. A brake air chamber of a brake system is attached to the air chamber mounting bracket, and a cam shaft assembly of the brake system is mounted to the cam shaft assembly mounting bracket. The integrated brake component mounting bracket thus provides mounting of the brake air chamber and the cam shaft assembly on the axle seat, which reduces the number of components that are welded to the axle and enables the use of a thinner-wall axle, desirably reducing the weight and cost associated with the axle/suspension system.