Brake Release Mechanism Indicator Pin Permanent Bond

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing brake release mechanisms for spring brake actuators require significant installation space, are costly due to numerous customized parts, and have less durable snap-fit connections between pin actuators and indicator pins, making them difficult to assemble and maintain.

Innovation Solution

A brake release mechanism with a permanent bond or deformation connection between the indicator cap and pin, using material joining or positive fits like ultrasonic welding, reduces parts, assembly complexity, and increases durability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If snap-fit connections are used between pin actuators and indicator pins, then assembly is easier and parts can be replaced, but connection durability decreases in harsh environments

Engineering Contradiction:

Improveassembly easeVSAvoidconnection durability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent changes the connection parameter from reversible snap-fit to permanent deformation connection. The indicator cap includes a deformation portion that permanently deforms to create a durable connection with the indicator pin, eliminating the reliability issue of snap-fit connections while maintaining assembly feasibility through controlled deformation during assembly

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs composite connection approach combining deformation portion in indicator cap with corresponding engagement features on indicator pin. This creates a hybrid connection that achieves both durability through permanent deformation and functional requirements for indication and movement

Inventive Principle:

Principle #40Composite materials

2Adaptability or versatility

If many customized parts are used in brake release mechanisms, then functional requirements are met, but manufacturing cost increases and assembly complexity increases

Engineering Contradiction:

Improvefunctional requirementsVSAvoidassembly complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent merges the indicator cap and indicator pin into a more integrated assembly. The deformation portion of the indicator cap directly engages with the indicator pin, reducing the need for separate fastening components and simplifying the overall structure while maintaining functional requirements for brake release indication

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The indicator cap serves multiple functions: it protects the indicator pin, provides the deformation connection for durability, enables indication functionality, and integrates with the pin actuator mechanism. This multi-functionality reduces the need for separate customized parts

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Adaptability or versatility

If traditional brake release mechanisms are designed with complete functionality, then all operational requirements are met, but installation space requirement increases

Engineering Contradiction:

Improveoperational requirementsVSAvoidinstallation space

Core Design Contradiction:

Adaptability or versatilityVSArea of stationary object

Solution Approach 1:

The patent implements a nested arrangement where the indicator pin is received within the indicator cap, and the deformation portion of the cap engages with the pin. This nesting reduces the overall spatial footprint of the indicator device while maintaining all operational functions for brake release indication

Inventive Principle:

Principle #7Nested doll (Nesting)

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 reduces installation space, simplifies assembly, and enhances durability, leading to lower maintenance costs and improved reliability of the brake release mechanism.

Implementation Method 1

the indicator cap and the indicator pin are non-releasably connected to one another in their assembled state by a permanent bond and/or by a permanent deformation portion

Methodology Applied

Scientific EffectMaterial joining: Welding

Implementation Method 2

using material joining, positive fits like ultrasonic welding

Methodology Applied

Scientific EffectUltrasonic welding: Ultrasonic Vibration

Data Source

PatentEP3964411B1Brake release mechanism for a spring brake actuator and spring brake actuator comprising such brake release mechanism

Publication Date: 2023.07.12 ZF CV SYST EURO BV

Figure 1
Figure 2
Figure 3

AI summary

Brake release mechanism (24, 124) for a spring brake actuator (2), said release mechanism comprising a brake release bolt (30, 130) having an indicator device (32, 132) comprising an indicator pin (26, 126) having a longitudinal axis (28, 128) and being at least partially accommodated in a receiving space (40, 140) of the release bolt, and a pin actuator (16, 116) for moving the indicator pin relative to the receiving space along its longitudinal axis and wherein the pin actuator comprises an indicator cap (36, 136) being configured to abut against a running nut (12, 112) for moving the pin actuator along its longitudinal axis. The indicator cap and the indicator pin are non-releasably connected to one another in their assembled state by a permanent bond (38) and/or by a permanent deformation portion (142) arranged at the indicator pin, for providing a durable connection between the indicator cap and the indicator pin.