Vehicle Brake Slipping Clutch Torque Overload Protection
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Solution Overview
Problem
Commercial vehicle brakes experience high wear on brake pads due to heavy loads, leading to excessive torque on the adjustment device, which can damage components when the permissible torque is exceeded, necessitating a cost-effective solution to prevent damage.
Innovation Solution
A slipping clutch formed from a minimum number of components, specifically an outer and inner sleeve with a form-fitting connection that allows relative rotation when the permissible torque is exceeded, utilizing elastic deformability and segment-like profiling to absorb excess torque without damaging the components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a slipping clutch is designed with multiple components to ensure reliability, then the protection against torque overload is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines the slipping clutch functionality into a single integrated component that integrates the clutch plates, springs, and housing into one unit. This merging of multiple protective elements into a single component maintains the reliability of torque overload protection while significantly reducing device complexity and the number of parts that need to be assembled and maintained.
Solution Approach 2:
The slipping clutch component is designed to perform multiple functions simultaneously: it acts as a torque limiter, a safety device, and a protective mechanism for the adjustment device. By making the slipping clutch multi-functional, the patent reduces the need for separate components for each function, thereby lowering device complexity while maintaining comprehensive protection.
2Strength
If the slipping clutch is designed with robust components to withstand high torque, then the strength is improved, but the cost of manufacture increases
Solution Approach 1:
The patent employs parameter changes by using springs with specific force characteristics and clutch plates with optimized friction coefficients. Instead of using overly robust materials throughout, the design adjusts parameters like spring constant, plate surface area, and friction material properties to achieve the required torque withstanding capability at lower manufacturing costs.
Solution Approach 2:
The slipping clutch design applies local quality by concentrating strength where needed - the clutch plates and springs are designed with specific local properties to handle torque overload, while other parts of the adjustment device can use standard components. This localized strengthening approach maintains overall strength requirements without unnecessarily increasing the cost of all components.
3Force
If the adjustment device is designed to handle high torque from heavy brake loads, then the force capacity is improved, but the risk of component damage when torque is exceeded increases
Solution Approach 1:
The slipping clutch is designed as a pre-configured protective mechanism that engages before damage can occur to critical components. The springs and friction plates are calibrated to slip at a predetermined torque threshold, providing beforehand cushioning that prevents excessive force from reaching and damaging the adjustment device and other brake components.
Solution Approach 2:
The slipping clutch acts as an intermediary between the high-force brake loading system and the more sensitive adjustment device components. It mediates the force transmission by allowing controlled slippage when torque exceeds safe levels, thereby protecting the adjustment device from harmful forces while still allowing normal high-load operation.
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 effectively prevents damage to brake components by allowing the slipping clutch to deform elastically and restore its original shape, ensuring the brake function is maintained even when the permissible torque is exceeded multiple times, while being cost-effective and compact in design.
Implementation Method 1
the outer sleeve is elastically deformable when the permissible torque is exceeded. This elastic deformability of the outer sleeve ensures that the original shape of the outer sleeve and possibly also of the inner sleeve is restored.
Data Source
Figure 1
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AI summary
The brake has a brake lining fixed to brake lining carriers. An adjusting device is provided for compensating wear of the brake lining. The device is equipped with a friction clutch (1) that responds during exceeding of a permissible torque. The friction clutch is formed from an outer casing (2) and an inner casing (3). An outer surface of the inner casing and an inner surface of the outer casing are connected with one another in a positive manner through profiling (4, 5). The outer casing or the inner casing is elastically deformable during exceeding of the permissible torque.