Pushrod Measurement Tool for Air Brake Cutback Verification
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Solution Overview
Problem
The existing methods for setting up air brake systems in heavy equipment, particularly the determination of pushrod length, are prone to errors, leading to potential vehicle performance issues, safety risks, and costly repairs due to the complexity and confusion in configuring brake assemblies.
Innovation Solution
A pushrod measurement and verification system that includes a measurement member with a cradle portion and verification member, allowing technicians to accurately determine and confirm the correct cutback length of pushrods and proper installation of brake assemblies, using a system that can be mounted to the S-cam spline and indicating the exact location for cutting the pushrod, and verifying the alignment of clevis and slack adjusters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If technicians use charts and template inserts to determine pushrod length, then they have reference guidance available, but the process remains confusing and prone to error
Solution Approach 1:
The patent introduces a physical measurement tool as an intermediary device that bridges the gap between abstract reference charts and actual pushrod installation. This tool provides tactile, visual feedback directly at the installation site, eliminating the need for technicians to interpret two-dimensional charts while working in difficult-to-reach locations underneath trucks.
Solution Approach 2:
The invention transitions from two-dimensional reference charts to a three-dimensional physical measurement tool that can be directly engaged with the brake assembly components. This spatial transformation allows technicians to obtain measurements through direct physical interaction rather than visual interpretation of flat diagrams.
2Productivity
If technicians eyeball pushrod length estimation, then the process is quick and simple, but critical errors occur leading to brake failure or lockup
Solution Approach 1:
The measurement tool enables technicians to determine the correct pushrod length before actual installation occurs. By establishing the precise cut length in advance through the measurement tool's physical indicators, technicians avoid the need for trial-and-error adjustments that compromise both speed and reliability.
Solution Approach 2:
The invention replaces the human visual estimation system with a mechanical measurement system that provides objective, repeatable measurements. The tool's physical structure and measurement markings eliminate subjective judgment, ensuring consistent results that maintain both installation speed and system reliability.
3Ease of operation
If pushrod length is not precisely controlled, then installation is more forgiving, but brake geometry falls out of predetermined range causing component failure
Solution Approach 1:
The measurement tool provides localized precision measurement at the specific installation point, allowing the rest of the installation process to maintain normal tolerances. The tool focuses measurement accuracy where it is most critical - at the pushrod cut length - while not requiring excessive precision elsewhere in the assembly process.
Data Source
AI summary
A pushrod measurement and verification system for determining a cutback length at which to sever a pushrod extending from a brake chamber so that a slack adjuster is properly mounted in an air brake system. The system includes a measurement member having a body member that includes opposed lower and upper ends, the body member having a thin and planar configuration. The body member defines a plurality of holes adjacent the lower end corresponding to sizes of the slack adjuster to be installed. The measurement member includes a cradle portion mounted to the upper end of the body member, the cradle portion having a bottom wall and a pair of side walls extending upwardly from the bottom wall and defining an open top, the cradle portion configured to cradle a pushrod. A front surface of the cradle portion includes measurement indicia for determining a cutback length of the pushrod.