Drum Brake Cover Plate Segmentation With Tension Spring
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Solution Overview
Problem
The manufacturing and assembly costs of drum brake cover plates are high due to numerous screw connections, which require threaded holes and complex assembly processes.
Innovation Solution
A drum brake design featuring a cover plate with two halves that engage in a groove of the brake camshaft bearing housing, secured by a tension spring, reducing the need for fastening screws and simplifying assembly by bracing the cover plate halves against each other.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple screw connections are used to fix the cover plate to the brake carrier, then the cover plate is securely fixed, but the manufacturing and assembly costs increase significantly
Solution Approach 1:
The cover plate is divided into two separate halves that are joined together using a tension spring. This segmentation allows the cover plate to be fixed to the brake carrier as a single unit, reducing the number of screw connections needed while maintaining secure fixation. The tension spring provides continuous clamping force to keep the two halves firmly joined.
Solution Approach 2:
A tension spring is introduced as an intermediary element between the two cover plate halves. The spring acts as a mediator that provides elastic clamping force, allowing the cover plate halves to be firmly connected without requiring multiple rigid screw fastenings. This reduces assembly complexity and cost while maintaining reliable fixation.
2Reliability
If threaded holes are made in the brake carrier for fastening screws, then the cover plate can be securely attached, but the manufacturing complexity and costs increase
Solution Approach 1:
The cover plate is segmented into two halves that are joined by a tension spring, forming a single assembly unit. This segmentation strategy allows the cover plate to be mounted using fewer attachment points to the brake carrier, eliminating the need for multiple threaded holes and reducing manufacturing complexity.
3Reliability
If multiple fastening screws are used to secure the cover plate, then the cover plate is firmly fixed, but the assembly process becomes more complex and time-consuming
Solution Approach 1:
The cover plate is divided into two halves joined by a tension spring, creating a pre-assembled unit that requires fewer fastening operations to the brake carrier. This segmentation reduces the number of screws needed and simplifies the overall assembly process while maintaining firm fixation.
Solution Approach 2:
The tension spring serves as an intermediary that automatically maintains clamping force between the cover plate halves. This elastic element simplifies assembly by eliminating the need for multiple rigid fasteners, as the spring self-adjusts to maintain firm connection during and after assembly.
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
Significantly lowers manufacturing and assembly costs while maintaining a secure seal against external contaminants, with the tension spring providing a secure and efficient clamping mechanism.
Implementation Method 1
the two cover plate halves being pulled against one another and thus fixed by means of separate clamps or clamps formed onto the cover halves
Data Source
Figure 1
Figure 2~3
AI summary
The brake has a brake drum (2) that is closed using cover plates (6, 7) and divides the cover plates by a partial level (17). Cover plate halves are fastened at axially fixed parts of a vehicle. A tension spring is provided for mutual deformation of the cover plate halves against a bearing housing (4) and is formed as a cylindrical helical spring. Each cover plate half is engaged in a groove of the bearing housing.