Pneumatic Brake Cylinder Piston Vulcanized Sealing Ring
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Solution Overview
Problem
Pneumatic brake cylinders in rail vehicles have high production and mounting costs due to the need for specialized machining of pistons for press-fit sealing rings and the requirement for separate sealing ring replacement during reconditioning, which is labor-intensive and costly.
Innovation Solution
A pneumatic brake cylinder design where the sealing ring is vulcanized onto the piston, allowing for the piston to be exchanged as a whole unit, eliminating the need for separate sealing ring replacement and reducing production and mounting costs by using a deep-drawn steel piston with a loose fit and sliding blocks to prevent rotation of the piston tube, thus eliminating the need for a rigid connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the sealing ring is connected to the piston via a press fit, then the sealing function is improved, but the production cost and mounting cost increase due to specialized machining and separate replacement requirements
Solution Approach 1:
The sealing ring is vulcanized directly onto the piston, merging two previously separate components (piston and sealing ring) into a unified assembly. This eliminates the need for separate press-fit connections and specialized machining operations, reducing production costs while maintaining sealing effectiveness through the bonded interface.
Solution Approach 2:
The mechanical press-fit connection is replaced with a chemical bonding process (vulcanization). Instead of relying on mechanical interference and specialized machining, the sealing ring is bonded to the piston through vulcanization, eliminating the need for complex machining operations and reducing manufacturing complexity.
2Reliability
If the sealing ring is connected to the piston via a press fit, then the sealing function is improved, but the mounting cost increases due to separate replacement during reconditioning
Solution Approach 1:
By vulcanizing the sealing ring onto the piston, the two components become a unified assembly that is exchanged as one unit during reconditioning. This eliminates the labor-intensive process of separately removing and replacing the sealing ring, reducing mounting costs while ensuring the sealing function is restored with the new piston assembly.
Solution Approach 2:
The brake cylinder is segmented into replaceable modules, with the piston (including the vulcanized sealing ring) as a discrete exchangeable unit. This modular approach allows the piston assembly to be quickly removed and replaced during reconditioning without affecting other components, simplifying the repair process.
3Ease of repair
If the piston is exchanged as a whole unit, then the mounting cost is reduced, but the piston structure becomes more complex with vulcanized sealing ring
Solution Approach 1:
The complex mechanical press-fit connection requiring specialized machining is replaced with a simpler vulcanization process. Although vulcanization adds a chemical bonding step, it eliminates the need for complex precision machining operations, ultimately simplifying the overall manufacturing process and reducing the skill level required for assembly.
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 design significantly reduces production and mounting costs by simplifying the assembly and reconditioning process, as the entire piston can be easily exchanged, and the sliding blocks ensure secure sealing without the need for additional vulcanizing or rigid connections, thereby lowering overall costs and maintenance complexity.
Implementation Method 1
the sealing ring is vulcanized onto the piston
Data Source
AI summary
The invention relates to a pneumatic brake cylinder including a piston for transferring the pneumatic pressure to a brake, a pressure chamber defined by the piston and part of the inner wall of the brake cylinder, and a sealing ring sealing a gap between the piston and the inner wall of the brake cylinder. According to the invention, the sealing ring is vulcanised onto the piston.