Drum Brake Cylinder Mounting Layout for Lower Connection Stress
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Solution Overview
Problem
Existing brake systems for commercial vehicles, particularly those with spreading wedge drum brakes, face issues with the connection point of the brake cylinder to the carrier unit, leading to wear and tear, and are more expensive due to limited mass production compared to disc brake systems.
Innovation Solution
A brake system design that includes a carrier unit and a brake cylinder, where a connection element with a first connection section for the brake cylinder and a second connection section on the carrier unit allows for the use of a standard brake cylinder, optimizing the connection point and enabling cost-effective production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If brake cylinders specifically designed for expanding wedge drum brakes are used, then the braking system functions correctly, but the weight and lever arm result in considerable moments of stress and fatigue on the connection point
Solution Approach 1:
The connecting element is divided into two distinct connecting sections: a first connecting section for securing the brake cylinder and a second connecting section for securing to the carrier unit. These sections are arranged parallel to the wheel axis at different positions, allowing the brake cylinder's center of gravity to be positioned closer to the first connecting section, thereby reducing the lever arm and moments of stress on the connection point while maintaining proper braking function.
2Reliability
If brake cylinders specifically designed for expanding wedge drum brakes are used, then the braking system functions correctly, but they are significantly more expensive than brake cylinders for disc brake systems
Solution Approach 1:
The connecting element with its two connecting sections arranged parallel to the wheel axis serves as a universal mounting solution that enables the use of standard brake cylinders (designed for disc brake systems) in expanding wedge drum brake applications. This universal approach allows standard brake cylinders to be used instead of specialized expensive ones, reducing production costs while maintaining braking functionality.
3Device complexity
If the brake cylinder is attached directly to the carrier unit, then the structure is simple, but the distance between the center of gravity of the brake cylinder and the connection point is large, resulting in considerable moments of stress
Solution Approach 1:
Instead of a direct single-point attachment, the connection structure is segmented into a connecting element with two connecting sections positioned at different locations. The first connecting section is arranged closer to the brake cylinder's center of gravity, while the second connects to the carrier unit. This segmentation allows optimization of the center of gravity position to minimize lever arm and stress moments while maintaining structural integrity.
4Ease of manufacture
If standard brake cylinders are used, then production costs decrease, but the connection point optimization is required to reduce wear and tear
Solution Approach 1:
The connecting element is segmented into two connecting sections positioned parallel to the wheel axis at different locations. This segmentation enables the brake cylinder to be mounted with its center of gravity closer to the first connecting section, reducing the lever arm and moments of stress on the connection point. This design optimization reduces wear and tear on the connection point, enhancing durability while allowing the use of cost-effective standard brake cylinders.
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 optimized connection design reduces wear and tear on the brake system components, allows for the use of standard brake cylinders, and decreases production costs by enabling mass production similar to disc brake systems.
Implementation Method 1
The brake cylinder is preferably a pneumatically operated brake cylinder which converts a compressive force of a compressed air system into a transverse movement or a longitudinal force
Data Source
Figure 1~2
AI summary
The present invention relates to a braking system of a drum brake, comprising a carrier unit (8) and a brake cylinder (2), wherein a connecting element (3) is provided, which has a first connection section (31) for fixing the brake cylinder (2) and is fixed in a second connection section (32) to the carrier unit (8). According to the invention, the first connection section (31) is arranged offset to the second connection section (32) while being parallel relative to the wheel axis, and the first connection section (31) can be fixed directly to the brake cylinder (2) in order to keep the distance between the center of gravity of the brake cylinder (2) and the first connection section (31) low.