Embossed Spring Seat Structure for Stable Spring Brake Actuation
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Solution Overview
Problem
Existing spring brake actuators in commercial vehicles face issues with stiffness and stability, leading to improper function and noise generation due to high spring forces and vibrations, which are not adequately addressed by conventional disc-shaped spring seats.
Innovation Solution
A spring seat with a central embossment conforming to the housing base shape, combined with guiding elements and a deep-drawn process, enhances stiffness and stability, ensuring proper spring positioning and reducing noise through increased mechanical stability and efficient manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a conventional disc-shaped spring seat is used, then the manufacturing is simple and cost-effective, but the stiffness and stability are insufficient leading to noise and improper function
Solution Approach 1:
The spring seat incorporates a central embossment that creates local structural reinforcement in the center region of the spring seat. This embossment provides increased stiffness and stability specifically where the spring force is applied, without requiring to thicken the entire spring seat structure. The local quality change resolves the contradiction by adding strength only where needed rather than uniformly throughout the component.
2Strength
If the cylinder housing base is structurally reinforced to handle high spring forces, then the strength is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The invention extracts the load-bearing function from the cylinder housing base by introducing a separate spring seat component. The spring seat absorbs the high spring forces through its central embossment design, thereby protecting the housing base from excessive stress. This separation of functions allows the housing to maintain its original simpler structure while the spring seat handles the mechanical loading.
Solution Approach 2:
The spring seat acts as an intermediary component between the compression spring and the cylinder housing base. It mediates the high spring forces by distributing them through its embossed structure, preventing direct transmission of peak loads to the housing base. This intermediary element protects the housing from damage while maintaining overall system strength.
3Reliability
If the spring is held in a compressed state by air pressure, then the brake activation is effective, but the spring may be displaced during mechanical release causing noise and improper function
Solution Approach 1:
The central embossment on the spring seat is designed to preliminarily guide and position the compression spring before brake release occurs. The embossed structure creates a predefined path and positioning features that keep the spring aligned during the transition from compressed activated state to released state. This preliminary positioning action prevents displacement and noise during mechanical release.
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 improved spring seat design significantly increases the stiffness and stability of the brake actuator, maintaining spring position and reducing noise during mechanical release, thus enhancing the reliability and strength of the actuator.
Implementation Method 1
a compression spring (102) adapted to exert, in use, a force onto the spring brake piston (104) into the direction of its longitudinal axis
Implementation Method 2
a spring seat (1) with a central embossment (27)... produced by a deep-drawn process
Data Source
Figure 1
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Figure 3
AI summary
A spring seat (1) for use in a spring brake actuator (100), preferably parking or emergency spring brake actuator of a commercial vehicle, said spring seat (1) having a longitudinal axis (A) and being adapted to be placed inside a housing (50) of the actuator (100) adjacent a housing base (51) of the actuator (100), the spring seat (1) comprising a first side (11), which in use faces the housing base (51), and a second side (13), which in use faces inwardly away from the housing base (51), wherein on the second side (13) the spring seat (1) further comprising a coupling portion (15) for contacting a compression spring (102) of the spring brake actuator (100), said compression spring (102) being adapted to exert, in use, a force onto a spring brake piston (104) into the direction of its longitudinal axis (A). The invention suggests that the spring seat (1) comprises a central embossment (27) positioned on the second side (13) and inwardly from the coupling portion (15) and essentially conforming the shape of an embossment (51a) of the housing base (51).