Brake Lathe Aligning Joint Control for Fast Runout Compensation
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Solution Overview
Problem
On-car brake lathes face challenges in accurately and efficiently compensating for runout between the brake lathe and the vehicle wheel hub during resurfacing operations, often requiring manual or complex automated adjustments that are time-consuming and prone to errors due to rotational noise and vibrations.
Innovation Solution
A precision runout compensation system that monitors the rotational position of slant discs within an aligning joint, calculates the necessary adjustments to align the wheel coupling rotational axis with the wheel hub, and implements these adjustments with minimal rotational movement, providing real-time feedback on the compensation time required.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual runout compensation procedures are used, then the operator can adjust the alignment, but the process becomes tedious and complex requiring multiple iterations
Solution Approach 1:
The system employs a sensor to detect runout conditions and provides real-time feedback to an automated adjustment mechanism. The sensor monitors the positional relationship between the brake lathe and wheel hub, and the controller automatically adjusts the aligning joint based on this feedback, eliminating the need for manual trial-and-error iterations while maintaining high precision runout compensation.
Solution Approach 2:
The patent replaces the manual mechanical adjustment process with an automated electromechanical system. A sensor detects runout conditions and an automated adjustment mechanism, controlled by a controller, performs the alignment adjustments electronically, substituting the tedious manual mechanical adjustment process with a faster automated system.
2Loss of time
If automated runout compensation mechanisms are used, then adjustment time is reduced, but rotational noise and vibrations cause measurement errors
Solution Approach 1:
The patent introduces an intermediary sensor system that detects runout conditions independently from the rotating components. The sensor is positioned to measure the positional relationship between the brake lathe and wheel hub without being directly affected by rotational noise and vibrations, providing accurate measurement data to the controller for automated adjustment.
Solution Approach 2:
The system separates the measurement function from the adjustment function. The sensor detects runout conditions while the automated adjustment mechanism performs corrections, allowing the measurement process to be isolated from the sources of rotational noise and vibrations. This segmentation enables accurate detection even during automated adjustments.
3Measurement precision
If complex automated adjustment mechanisms are used, then runout compensation accuracy improves, but device complexity increases
Solution Approach 1:
The aligning joint is designed to perform multiple functions: it provides automated adjustment for runout compensation while also maintaining proper alignment during the brake rotor resurfacing operation. This multi-functionality reduces the need for separate complex adjustment mechanisms, as the aligning joint handles both alignment and compensation tasks.
Solution Approach 2:
The system uses the existing structural components of the brake lathe and aligning joint for runout compensation rather than adding separate complex adjustment mechanisms. The sensor detects runout conditions and the controller utilizes the aligning joint's existing degrees of freedom to perform self-adjustment, eliminating the need for additional complex mechanical adjustment devices.
Data Source
AI summary
An on-car brake lathe is provided with a runout compensation system configured to monitor the rotational position of a pair of slant discs within an aligning joint of the on-car brake lathe. The system monitors the amount of runout present between the rotating components of the on-car brake lathe and the wheel hub to which the on-car brake lathe is secured, and calculates a relative rotational position for each slant disc within the aligning joint required to impart a necessary adjustment in the wheel coupling rotational axis to align the on-car brake lathe with the rotational axis of the wheel hub. An adjustment mechanism within the aligning joint is configured to rotationally drive each slant disc to the calculated relative rotational positions with a minimum amount of rotational movement based on the current relative rotational position of each slant disc and the required calculated relative rotational positions.