Guide Pin Assembly With Shear Adaptor for Precise Brake Torque
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Solution Overview
Problem
Existing guide pin assemblies for heavy-duty vehicle disc brakes require large equipment for assembly and maintenance, leading to potential errors and increased downtime due to off-axis torque and the need for specialized tools, which complicates the process and increases costs.
Innovation Solution
A guide pin assembly with a shear-to-torque interface and a piloting adaptor that allows the use of commonly-available, low-profile tools, ensuring consistent torques and reducing complexity by using a shear adaptor that fractures at a predetermined optimal torque, eliminating the need for specialized equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If large specialized equipment is used for assembly and maintenance, then assembly precision and torque consistency are improved, but device complexity and operational difficulty increase
Solution Approach 1:
The guide pin assembly acts as an intermediary component that translates and controls the application of torque during assembly. By incorporating the shear-to-torque interface directly into the guide pin, the system mediates between the simple act of bolt tightening and the complex requirement for precise torque application, eliminating the need for specialized equipment while maintaining assembly precision.
Solution Approach 2:
The guide pin assembly performs self-service by automatically controlling torque application through its shear-to-torque interface. The shear pin fractures at a predetermined torque value, automatically stopping the tightening process and eliminating the need for external torque monitoring equipment or specialized assembly tools.
2Manufacturing precision
If shear-to-torque interface is implemented, then torque consistency is improved, but the need for specialized tools increases
Solution Approach 1:
The shear pin is designed as a disposable component that fractures at a predetermined torque value. This low-cost sacrificial element ensures consistent torque application while eliminating the need for expensive specialized tools. After use, the shear pin is discarded and replaced, simplifying the operation for maintenance personnel.
Solution Approach 2:
The torque control function is extracted from complex specialized equipment and embedded directly into the simple shear pin structure. This extraction allows torque consistency to be achieved through a basic mechanical feature rather than requiring sophisticated external devices.
3Ease of operation
If commonly-available tools are used, then ease of operation is improved, but torque precision and consistency deteriorate
Solution Approach 1:
The shear-to-torque interface serves as an intermediary that bridges the gap between simple commonly-available tools and the precision requirements for torque application. The shear pin mechanically enforces the correct torque level, compensating for the lack of precision in standard tools.
Solution Approach 2:
The assembly system performs self-service torque control through the shear pin's fracture mechanism. The shear pin automatically monitors and limits torque application, eliminating the need for operator skill or specialized equipment while maintaining precise torque consistency.
4Manufacturing precision
If specialized tools are required, then torque control precision is improved, but maintenance time and costs increase
Solution Approach 1:
The shear pin is a disposable component that replaces complex torque monitoring systems. By using this simple sacrificial element, maintenance personnel can perform torque-controlled assembly with standard tools, significantly reducing maintenance time while maintaining precision through the shear pin's predetermined fracture point.
Solution Approach 2:
The torque control function is extracted from time-consuming specialized equipment and embedded into the quick-fracturing shear pin. This allows torque precision to be achieved through a simple mechanical event rather than requiring prolonged use of complex equipment.
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
Facilitates assembly and maintenance with commonly-available tools, ensuring consistent torques and reducing errors, thereby improving operational efficiency and reducing downtime and costs.
Implementation Method 1
a shear-to-torque feature and a piloting or supporting adaptor for use with a heavy-duty vehicle disc brake system, the guide pin assembly allowing for the use of commonly-available, low-profile tools and facilitating consistent torques
Data Source
AI summary
A guide pin assembly for use with heavy-duty vehicle disc brake systems, the guide pin assembly comprising a hollow guide pin, a fastener, a separate torque-separable shear adaptor. The guide pin mounts a component of the disc brake system. The fastener is at least partially disposed through the guide pin and engages another component of the disc brake system to attach the guide pin to the other component. The shear adaptor is at least partially disposed within the guide pin and is removably attached to the fastener.