Brake Spring Lubrication Using an Annular Wicking Absorber
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Solution Overview
Problem
Existing brake assemblies in vehicles face challenges in efficiently supplying lubricant to critical components, leading to increased friction, wear, and reduced longevity due to inadequate lubrication, particularly in spring-applied and hydraulically-released brake systems.
Innovation Solution
A brake assembly design incorporating an annular lubricant absorber positioned between conical spring washers, which supplies lubricant to the upper portion of the spring through wicking, utilizing the spring's compression and expansion to facilitate lubricant movement above the lubricant level, thereby ensuring consistent lubrication without complex pumps or passages.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a simple brake assembly design is used, then device complexity is reduced, but lubrication effectiveness deteriorates due to insufficient lubricant supply to upper spring portions
Solution Approach 1:
The spring mechanism itself serves as the lubricant delivery system. During compression, the spring pushes lubricant from the lower reservoir through the lubricant absorber to the upper spring portions, eliminating the need for external pumps or complex delivery mechanisms while ensuring reliable lubrication.
Solution Approach 2:
The system utilizes changes in spring compression state to drive lubricant delivery. As the spring compresses under piston pressure, the changing volume and pressure parameters force lubricant from the lower reservoir through the absorber to areas needing lubrication, converting mechanical compression into a lubrication delivery mechanism.
2Force
If spring compression is increased to improve braking force, then friction-induced heat and wear increase due to insufficient lubrication
Solution Approach 1:
The lubricant absorber is pre-positioned between the spring washers, ready to deliver lubricant as soon as compression begins. This preliminary positioning ensures that lubrication is applied before excessive heat and wear can occur during the braking process, preventing rather than just responding to the harmful effects.
Solution Approach 2:
The lubricant absorber acts as an intermediary between the lubricant reservoir and the spring components. It receives lubricant from the lower portion during compression and distributes it to the upper spring portions and friction surfaces, mediating the lubrication process to reduce heat and wear while allowing high braking forces.
3Quantity of substance
If lubricant level is increased to ensure adequate lubrication, then housing volume requirements increase
Solution Approach 1:
The lubrication system is segmented into two functional zones: a lower reservoir area that stores lubricant and an upper delivery area that distributes it during compression. This segmentation allows the housing to contain sufficient lubricant quantity in a compact lower section while delivering it efficiently to upper components, avoiding the need for increased overall housing volume.
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 reduces friction-induced heat and wear, enhancing the longevity of brake components by ensuring adequate lubrication, thus eliminating the need for large, expensive pumps or complex lubrication systems.
Implementation Method 1
an annular lubricant absorber disposed at the spring and configured to supply lubricant to the upper portion of the spring
Implementation Method 2
The lubricant absorber may be deformed by the spring upon the spring acting against the piston to supply lubricant to the upper portion of the spring
Data Source
AI summary
A brake assembly includes a housing configured to contain lubricant at a lubricant level, a shaft disposed in the housing, an annular brake pack disposed in the housing and around the shaft, an annular piston disposed in the housing and around the shaft and configured to move axially relative to the annular brake pack, a spring disposed in the housing and around the shaft, abutting the piston, configured to act against the piston, and including a lower portion of the spring configured to be disposed below the lubricant level and an upper portion of the spring configured to be disposed above the lubricant level, and an annular lubricant absorber disposed at the spring and configured to supply lubricant to the upper portion of the spring.