Brake Unit Mounting on Transfer Case Housing
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Solution Overview
Problem
Existing vehicle brake systems, particularly in large vehicles, face maintenance and reliability issues in physically demanding environments due to exposure to aggressive conditions such as rocks, dust, and undulating terrain, and lack a robust solution for mounting in place of a transfer case or front tail housing.
Innovation Solution
A vehicle brake unit with a housing configured for mounting directly to a drive train subassembly, featuring a power shaft that connects the drive train output shaft with a further drive shaft, and includes a retaining mechanism and seal to prevent lubricant cross-contamination, allowing for independent lubrication and mounting in place of a transfer case or tail housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If brake systems are mounted at or near the wheels or axle ends, then braking function is achieved, but the brake mechanisms are exposed to aggressive conditions (rocks, dust, loose matter, undulating terrain) leading to maintenance and reliability problems
Solution Approach 1:
The brake mechanism is extracted from its conventional location at or near the wheels/axle ends and relocated to the transfer case housing. The brake mechanism is now housed within the transfer case, removing it from direct exposure to rocks, dust, and terrain-related hazards while maintaining its braking function on the drive shaft.
Solution Approach 2:
The transfer case housing serves as an intermediary protective enclosure for the brake mechanism. By mounting the brake within the transfer case housing and using the power shaft to transmit braking force, the system protects the brake from aggressive external conditions while still achieving the braking function.
2Adaptability or versatility
If a brake unit is mounted in place of a transfer case or tail housing, then integration with drive train is achieved, but lubricant cross-contamination between brake and drive train may occur
Solution Approach 1:
The housing is segmented into separate sealed compartments: one for the brake mechanism and another for the drive train components. This segmentation allows the brake unit to be integrated into the transfer case while preventing lubricant cross-contamination through physical separation and independent sealing of each compartment.
Solution Approach 2:
Seals act as intermediary elements between the brake compartment and drive train compartment. These seals prevent direct contact between brake lubricant and drive train lubricant, allowing the integrated mounting arrangement while eliminating the harmful effect of lubricant cross-contamination.
3Productivity
If conventional brake systems are used in demanding environments, then braking function is provided, but significant maintenance and reliability problems occur due to exposure to rocks, dust and loose matter
Solution Approach 1:
The brake mechanism is extracted from the harsh under-vehicle environment and relocated to the protected transfer case housing. This extraction reduces exposure to rocks, dust, and loose matter, thereby reducing maintenance requirements while maintaining braking functionality.
Solution Approach 2:
The transfer case housing provides beforehand protection (cushioning) for the brake mechanism against aggressive environmental conditions. By anticipating the harmful effects of rocks, dust, and terrain, the design places the brake within the protected housing, reducing maintenance needs before problems occur.
Data Source
Figure 1
Figure 2~2A
Figure 3
AI summary
A vehicle brake unit is provided for use with a drive train having a drive train subassembly. The brake unit comprises a brake unit housing for enclosing a braking mechanism, the braking mechanism arranged to act on a power shaft configured for operatively connecting the output drive shaft of the drive train subassembly with a further drive shaft, in order to transfer power therebetween. The brake unit housing is arranged for mounting directly to a housing of the drive train subassembly. In one embodiment of the invention, the brake unit housing replaces the rear tail housing of a four-wheel drive transfer case.