Pull-Type Double Diaphragm Spring Brake Actuator
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Solution Overview
Problem
Existing spring brake actuators for vehicles require a robust structure to withstand vibrations and forces, leading to increased material usage, cost, and space requirements due to their push-type design, which suspends a large mass far from the brake caliper mounting flange.
Innovation Solution
A pull-type double diaphragm spring brake actuator is designed with the center of mass closer to the mounting flange, using a power spring adjacent to the flange, allowing for lighter components and reduced structural demands, enabling a more compact and cost-effective design that can be integrated with existing brake systems without significant modifications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a push-type spring brake actuator design is used, then the brake can be applied with sufficient force, but the center of mass is positioned far from the mounting flange requiring robust structure with increased material usage and cost
Solution Approach 1:
The patent inverts the conventional push-type actuator design by using a pull-type mechanism. The power spring is positioned adjacent to the mounting flange and pulls on the parking brake piston through a connecting rod, rather than pushing from the opposite end. This inversion relocates the center of mass closer to the mounting flange, reducing the moment arm and allowing for lighter structural components while maintaining sufficient brake application force.
2Force
If the center of mass is positioned far from the mounting flange, then the brake application force is sufficient, but the structural demands increase leading to more material usage and space requirements
Solution Approach 1:
By inverting the actuator design to pull-type configuration, the center of mass is relocated closer to the mounting flange. This reduces the moment arm distance, thereby reducing the structural area and material needed to withstand vibrations and forces, while still achieving sufficient brake application force through the power spring mechanism.
3Reliability
If a robust structure is used to withstand vibrations and forces, then the actuator reliability is improved, but the manufacturing cost and material usage increase
Solution Approach 1:
The inverted pull-type design positions the power spring and center of mass closer to the mounting flange, which reduces the moment arm and the forces transmitted to the structural components. This allows for lighter, less costly materials and simpler manufacturing while maintaining adequate reliability to withstand vibrations and operational forces.
4Device complexity
If the power spring is positioned away from the mounting flange, then the brake application mechanism is simpler, but the center of mass positioning creates larger moments requiring robust structure
Solution Approach 1:
Instead of positioning the power spring away from the mounting flange, the invention inverts the design to place the power spring adjacent to the mounting flange. This inversion reduces the moment arm and structural weight requirements, while the complexity of the brake application mechanism is managed through the connecting rod that transmits the pull force from the spring to the parking brake piston.
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 pull-type actuator achieves a greater than 10% reduction in weight, 25% improvement in center of mass positioning, and a substantial reduction in parts and manufacturing costs, while maintaining effective brake functionality.
Implementation Method 1
a power spring positioned adjacent to the mounting flange and configured to move the parking brake piston in the brake application direction when the parking brake is applied
Implementation Method 2
A service brake diaphragm is provided in the service brake chamber and is arranged to move the service brake piston in a brake application direction when the service brake is applied
Implementation Method 3
A parking brake release diaphragm is provided in the parking brake chamber and is arranged to move the parking brake piston in the brake release direction when the parking brake is released
Data Source
AI summary
A spring-type brake actuator for a vehicle brake such as a pneumatically-actuated brake is provided, in which the actuator's operating rod is pulled toward the actuator to apply the brake. The actuator's parking brake release piston is located closer to the brake than the service brake piston, and the parking brake power spring is positioned between the mounting end of the actuator and the parking brake piston such that when parking brake release pressure is removed from the parking brake release chamber the parking brake piston biases the operating rod in the brake application direction, drawing the operating rod further into the actuator. The operating rod may penetrate the parking brake piston and an intermediate flange between the parking brake piston and the service brake piston, and be connected to the service brake piston such that the service brake piston may control brake application when the parking brake piston is in its parking brake release position adjacent to the end of the actuator that is mounted to the brake.