Brake Coupling Ring Resolves Plunger Rotation Stress
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Solution Overview
Problem
The existing braking force transmission arrangement suffers from rotational misalignment of the pressure plunger relative to the traverse, leading to excessive stress and potential cracking of the bellows seal due to the strong form-fitting connection between the coupling ring and pressure elements, causing the plunger to rotate when the brake is applied, especially under asymmetrical conditions.
Innovation Solution
The coupling ring is designed to have a low-friction, non-form-fitting arrangement between the pressure elements, allowing the second pressure element to rotate freely about its longitudinal axis, with radially resilient areas protruding into annular grooves to maintain axial alignment and prevent permanent twisting, utilizing a metal strip formed into a ring with tabs for cost-effective production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the coupling ring is designed with a strong form-fitting connection to the pressure elements, then the longitudinal connection strength is improved, but the pressure plunger rotates relative to the traverse during brake operation
Solution Approach 1:
The coupling ring is segmented with radially resilient portions that can deflect independently, allowing the connection to accommodate rotational movements while maintaining longitudinal strength. The segmentation enables different parts of the coupling ring to handle different types of stresses separately.
Solution Approach 2:
The coupling ring transitions from a rigid form-fitting connection to a flexible connection with controlled friction. By changing the friction parameter and allowing slight rotational movement, the system prevents stress accumulation while maintaining adequate connection strength for longitudinal forces.
2Reliability
If the pressure plunger is tightly secured in the traverse hole, then the connection reliability is improved, but the bellows seal becomes overstressed and develops cracks
Solution Approach 1:
The coupling ring acts as an intermediary element between the pressure plunger and the traverse. It provides a low-friction interface that allows the pressure plunger to rotate independently, preventing the transmission of rotational stress to the bellows seal while maintaining axial connection reliability.
Solution Approach 2:
The coupling ring is designed to be dynamically adaptable, allowing controlled rotational movement when stress is applied. This dynamic behavior prevents stress accumulation in the bellows seal by enabling the pressure plunger to self-align during brake operation.
3Stability of the object's composition
If the coupling ring prevents rotation of the pressure plunger, then the seal alignment is maintained, but the connection requires considerable effort to assemble and disassemble
Solution Approach 1:
The coupling ring has different friction characteristics in different directions: low friction to allow rotation during operation, but sufficient friction and mechanical engagement to prevent excessive movement during assembly. The radially resilient portions provide local flexibility where needed while maintaining overall connection stability.
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
This solution prevents the accumulation of rotational misalignment and stress on the seal, ensuring the seal remains undisturbed over time, maintaining its sealing integrity and preventing cracks, even after prolonged brake operation.
Implementation Method 1
at least one radially resilient portion of the coupling ring protrudes into the other annular groove
Implementation Method 2
the coupling ring is arranged without a form fit and with little friction relative to the first and/or the second pressure element
Data Source
Figure 1~3
Figure 4~7
Figure 5~6
AI summary
The braking force transmission arrangement has a locked pressurized element having a cylindrical hole (21) and is movable in brake housing. A couple ring (24) is provided, which is arranged opposite to two pressurized elements (5,8) in form fit-free and friction-poor manner, and latter pressurized elements are rotated around its longitudinal axis (A) along the former pressurized element.