Brake Cylinder Gap Adjusting Nut Assembly
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Solution Overview
Problem
Existing brake caliper units in rail vehicles face issues with maintaining a fixed disc release gap due to excessive elastic deformation of the external lever and inappropriate timing of gap adjustments, leading to continuous reduction of the release gap and potential virtual braking.
Innovation Solution
A brake cylinder with a gap adjusting nut assembly and internal lever assembly that includes a groove on the gap adjusting sleeve for easy adjustment of the release gap, and a thrust sleeve spring to recognize excessive elastic deformation of the external lever, preventing unnecessary gap adjustments and ensuring a constant disc gap.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If the external lever is designed to be slender, then the brake caliper unit achieves compact structure and light weight, but the elastic deformation of the external lever becomes excessive causing the disc release gap to be uncontrollable
Solution Approach 1:
A thrust sleeve spring is introduced as an intermediary component between the piston and the gap adjusting mechanism. This spring mediates the force transmission and provides a buffer against excessive elastic deformation of the external lever, allowing the lever to remain slender while maintaining reliable disc release gap control.
Solution Approach 2:
The patent changes the mechanical parameters of the braking system by introducing a compliant element (thrust sleeve spring) that alters the force-displacement characteristics. This allows the external lever to maintain its slender geometry while the spring compensates for elastic deformation through controlled compression and expansion.
2Extent of automation
If the brake regulator performs gap adjustment based on conventional criteria, then the adjustment mechanism operates automatically, but the adjustment timing becomes inappropriate due to unrecognized lever deformation causing continuous gap reduction
Solution Approach 1:
The thrust sleeve spring provides mechanical feedback about the actual braking force and lever deformation state. When the spring is fully compressed, it signals that the external lever has undergone excessive deformation, preventing the brake regulator from initiating unnecessary gap adjustments and maintaining precise disc release gap control.
Solution Approach 2:
The thrust sleeve spring provides beforehand cushioning by compressing in advance during normal braking operations. This pre-compression buffers subsequent force variations and prevents the gap adjusting mechanism from reacting to normal lever deformation, ensuring adjustments only occur when truly necessary.
3Device complexity
If the gap adjusting nut assembly is integrated inside the brake cylinder, then the structure is compact, but the release gap adjustment becomes difficult requiring complete cylinder disassembly
Solution Approach 1:
The gap adjusting nut assembly is segmented from the main brake cylinder body through a removable connection interface. This allows the gap adjusting mechanism to remain integrated during normal operation for compactness, while enabling easy separation for maintenance and adjustment purposes without requiring complete cylinder disassembly.
Solution Approach 2:
The connection between the gap adjusting nut assembly and brake cylinder is made dynamically changeable - fixed during operation for structural integrity and compactness, but easily separable when adjustment is needed. This dynamic configuration optimizes both device complexity and ease of repair.
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 allows for convenient adjustment and maintenance of the release gap without disassembling the brake cylinder, recognizes excessive elastic deformation to avoid unnecessary gap adjustments, and ensures a constant disc gap, thereby preventing virtual braking and maintaining braking efficiency.
Implementation Method 1
a thrust sleeve spring to recognize excessive elastic deformation of the external lever
Implementation Method 2
a gap adjusting spring, and a groove extending along an axial direction of the gap adjusting sleeve is formed on an outer circumferential surface of the gap adjusting sleeve
Data Source
AI summary
The present disclosure relates to a brake cylinder, a brake caliper unit and a rail vehicle. The brake cylinder includes a cylinder block and a cylinder head fixedly sleeved over one end of the cylinder block, the cylinder block being provided therein with a piston, a guide spring, a guide nut, a taper sleeve, an adjusting shaft assembly, a thrust sleeve and a gap adjusting nut assembly; wherein the gap adjusting nut assembly includes a gap adjusting nut, a gap adjusting sleeve and a gap adjusting spring, and a groove extending along an axial direction of the gap adjusting sleeve is formed on an outer circumferential surface of the gap adjusting sleeve, in which groove a release gap adjusting unit is provided. The thrust sleeve spring of the brake cylinder of the present disclosure can recognize excessive elastic deformation of the external lever to prevent the gap adjustment triggered by the excessive elastic deformation of the external lever, ensuring that the release gap of the disc is constant.