Brake Slack Adjuster Clutch Layout for Stronger Wear Compensation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional automatic slack adjusters for vehicle brakes face challenges with complex designs, stress on components, and difficulties in manufacturing and repair due to the small size of one-way clutch components, which affects their strength and reliability.
Innovation Solution
The automatic slack adjuster locates the one-way clutch along the axis of the driving worm screw, allowing for larger component sizes that simplify design, manufacturing, and repair, while reducing stress on the control worm wheel, and incorporates a wear adjustment mechanism with a spring and gear system for robust performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the one-way clutch is located along the axis of the control worm screw, then the clutch components can be made larger and stronger, but the design becomes more complex and places undue stress on the control worm wheel
Solution Approach 1:
The patent relocates the one-way clutch from the control worm screw axis to the driving worm screw axis, utilizing a different spatial dimension and arrangement. This dimensional change allows the clutch components to be larger and stronger while distributing stresses more effectively through the gear train, avoiding the complexity and stress concentration issues of the conventional arrangement.
2Volume of stationary object
If the control worm screw is made small to fit within the housing, then the overall device size is reduced, but the clutch components become too small for easy design, manufacturing, and repair
Solution Approach 1:
By moving the clutch to the driving worm screw axis, the patent creates a different spatial arrangement where clutch components can be made larger without increasing the overall housing volume. This dimensional reconfiguration allows for larger, more manufacturable clutch components while maintaining compact device dimensions through optimized space utilization.
3Ease of repair
If the one-way clutch components are made larger, then design, manufacturing, and repair become easier, but the device occupies more space and may increase stress on other components
Solution Approach 1:
The patent achieves larger clutch components by relocating them to the driving worm screw axis, utilizing a different spatial dimension. This reconfiguration allows larger components that are easier to service while maintaining compact overall device volume through optimized arrangement of the gear train and clutch elements.
Solution Approach 2:
The patent divides the slack adjuster into distinct functional segments: the driving worm screw assembly with clutch, the control worm screw assembly, and the gear train. This segmentation allows the clutch components to be larger and more accessible for repair while the overall device remains compact through efficient modular arrangement.
4Reliability
If conventional slack adjuster designs are used, then the basic function is achieved, but the design is overly complex and places undue stress on the control worm wheel
Solution Approach 1:
The patent simplifies the overall design by relocating the one-way clutch to the driving worm screw axis, which redistributes mechanical stresses more favorably. This dimensional change reduces undue stress on the control worm wheel while maintaining reliable brake actuation, resulting in a less complex but equally reliable design.
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 enhances the strength and reliability of the slack adjuster, simplifies assembly, and maintains consistent performance by allowing for larger clutch components and reduced stress on the control worm wheel, improving the overall efficiency of brake actuation and wear compensation.
Implementation Method 1
a spring configured to apply a biasing force to the first shaft portion of the driving worm screw
Implementation Method 2
a wrap spring engaging surfaces of the control worm wheel and the clutch ring
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
A clearance sensing vehicle brake slack adjuster includes a housing (12) coupled to a brake actuator and supporting a driving worm wheel (14) engaging the brake cam shaft and a driving worm screw (16) having a threaded portion meshed with the driving worm wheel (14) and transferring a brake actuating force, imparted by the brake actuator to the housing (12), to the driving worm wheel (14) and cam shaft. A wear adjustment mechanism (18) for the adjuster includes a control worm wheel (78) and a clutch ring (80) disposed about the driving worm screw (16) and a wrap spring (82) engaging surfaces of the control worm wheel (78) and the clutch ring (80). The control worm wheel (78) is in mesh with a control worm screw (72). The clutch ring (80) is disposed on a side of the control worm wheel (78) opposite the threaded portion of the driving worm screw (16) and includes teeth engaging corresponding teeth on the driving worm screw.