Air Pressure Brake Spring Support Assembly With Insertion Marking

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Solution Overview

Problem

The existing air pressure brake systems with brake calipers and spring supports face challenges during assembly due to deeper recesses that can lead to incorrect installation, resulting in increased manufacturing costs and the need for additional correction steps.

Innovation Solution

Incorporating markings such as notches, stickers, or holes on the spring support or brake caliper to indicate the correct depth of insertion, ensuring proper assembly and preventing collisions with the brake caliper border, thus simplifying the assembly process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If the recess is made deeper to compensate for tolerances, then the tolerance compensation is improved, but the risk of incorrect installation increases leading to additional assembly steps

Engineering Contradiction:

Improvetolerance compensationVSAvoidassembly process

Core Design Contradiction:

Manufacturing precisionVSEase of operation

Solution Approach 1:

The patent applies the preliminary action principle by pre-marking the spring support with reference marks before assembly. These marks indicate the correct insertion depth and positioning, allowing the assembler to correctly position the spring support in a single step without needing to perform additional correction steps after incorrect installation. The marking is created during manufacturing, so the guidance information is prepared in advance to prevent assembly errors.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent uses reference marks as an intermediary element between the spring support and the assembler. These marks serve as a communication medium that conveys the correct positioning information without requiring complex measurement or judgment by the assembler. The reference marks act as a mediator that translates the design intent (correct insertion depth) into actionable visual guidance for the assembly process.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Device complexity

If no marking is provided on the spring support, then the device complexity is reduced, but incorrect installation occurs requiring additional assembly steps

Engineering Contradiction:

Improvestructure simplicityVSAvoidassembly time

Core Design Contradiction:

Device complexityVSLoss of time

Solution Approach 1:

The reference marks are prepared in advance during the manufacturing of the spring support, before the assembly process begins. This preliminary action ensures that all necessary guidance information is already in place, eliminating the need for time-consuming measurement, calculation, or adjustment steps during assembly. The assembler can directly use the pre-prepared marks to achieve correct positioning on the first attempt.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The spring support with reference marks is self-servicing in terms of assembly guidance. Instead of requiring external tools, complex fixtures, or skilled judgment from the assembler, the spring support itself provides the necessary information through its markings. The component essentially guides its own correct installation, reducing the skill level and time required for assembly operations.

Inventive Principle:

Principle #25Self-service

3Productivity

If the spring support is pushed too deep into the recess, then the assembly process continues without markings, but the spring support collides with the brake caliper border and cannot be screwed

Engineering Contradiction:

Improveassembly speedVSAvoidassembly correctness

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The reference marks are created during the manufacturing process, before assembly takes place. This preliminary preparation of guidance information allows the assembly operation to proceed quickly without sacrificing correctness. The marks are pre-positioned at the exact locations that correspond to the correct insertion depth, so the assembler can rely on them to prevent over-insertion that would cause collision with the brake caliper border.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The reference marks serve as a preventive measure that cushions against the harmful effect of over-insertion. By providing visual guidance before the assembly action is completed, the marks prevent the spring support from being pushed too deep and colliding with the brake caliper border. This is a form of beforehand cushioning where potential assembly errors are prevented in advance rather than corrected after they occur.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Data Source

PatentEP3992486B1Air pressure brake with a spring support and commercial vehicle with an air pressure brake

Publication Date: 2023.10.04 ZF CV SYST EURO BV

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AI summary

An air pressure brake (100) comprising a brake caliper (41), at least one leaf spring (44, 45) and a spring support (30a), wherein the spring support is inserted into a recess (42) of the brake caliper before being bolted to it during assembly. The spring support (30a) has a marking (38a) for adjusting the spring support (30a) or the brake caliper has a notch for adjusting a spring support.