Mechanical Tensioning Tool for Emergency Brake Cable Accuracy
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Solution Overview
Problem
Conventional emergency brake cable tensioning systems require multiple workers and stations, leading to inefficiencies and inaccuracies in tension measurement, resulting in variations in brake performance due to indirect tension measurement methods and complex maintenance requirements.
Innovation Solution
A mechanical tensioning tool with a stationary load measurement structure and movable nut retention assembly, driven by a rotational driver, allows for direct and accurate measurement of brake cable tension with fewer moving parts, reducing resource usage and simplifying the assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional indirect tension measurement methods (strain gauges and transducers) are used, then tension can be measured during assembly, but measurement precision is limited and there is wide variation in ultimate tension
Solution Approach 1:
The patent replaces indirect electrical measurement systems (strain gauges and transducers) with a direct mechanical measurement system. A load cell is integrated into the tensioning tool's mechanical structure, providing direct mechanical measurement of cable tension. This substitution eliminates the inaccuracies of indirect electrical sensing and provides precise, reliable tension data throughout the assembly process.
Solution Approach 2:
The load cell acts as an intermediary element between the tensioning mechanism and the measurement system. It directly senses the mechanical load in the cable system and converts it into measurable signals, serving as a bridge that provides accurate tension information without the variability inherent in indirect measurement methods.
2Extent of automation
If automated hydraulic or pneumatic mechanisms are used for tensioning, then human element is reduced, but maintenance problems and system complexity increase
Solution Approach 1:
The patent extracts and removes hydraulic and pneumatic systems from the automated tensioning mechanism. By eliminating these complex fluid power systems, the design achieves automation through simpler mechanical means, reducing maintenance requirements and improving reliability while maintaining automated tensioning capability.
Solution Approach 2:
The patent employs simpler, more robust mechanical components in place of complex hydraulic/pneumatic systems. These simpler components are easier to manufacture, maintain, and replace if needed, following the principle of using less complex, more durable elements rather than sophisticated but fragile systems.
3Reliability
If multiple workers and assembly stations are used for cable tensioning, then adequate installation and tensioning can be achieved, but productivity decreases and labor costs increase
Solution Approach 1:
The patent combines multiple functions (tensioning, measurement, and verification) into a single integrated tool and process. This consolidation allows one worker at one station to perform tasks that previously required multiple workers and stations, thereby improving productivity while maintaining installation quality through the tool's built-in measurement and control capabilities.
Solution Approach 2:
The tensioning tool incorporates self-verification capabilities through integrated load cells and measurement systems. The tool automatically monitors and verifies tension levels during the process, eliminating the need for multiple workers to check and verify tension at different stations. The system serves itself by providing real-time feedback and control.
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 tool enables efficient and accurate tensioning of emergency brake systems, reducing labor costs and improving brake performance by allowing direct tension measurement and minimizing maintenance complexities.
Implementation Method 1
a load cell operably associated with the mechanical column structure to measure the tension load
Implementation Method 2
a nut and a threaded rod, the threaded rod extending through the equalizer, the nut initially positioned away from the equalizer. The input shaft is rotated to turn the nut along the threaded rod
Implementation Method 3
a thrust bearing positioned between the load cell and the output gear to allow rotation of the output gear while creating a compressive load on the load cell
Data Source
AI summary
A brake tensioning system and method are described herein for use on vehicles. The system includes a tool, and the method includes the use of the tool to effectuate tensioning of a brake system conveniently, accurately, and repeatably.