Railway Disc Brake Unit With Force Amplification Levers
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Solution Overview
Problem
Current compact disc-brake units for railway vehicles face performance reduction and require complex, expensive mechanisms to enhance braking force, often necessitating additional components and auxiliary devices to manage wear compensation and axial displacement, leading to increased complexity and cost.
Innovation Solution
A compact disc-brake unit with integrated jaws and levers actuated by a pneumatic or hydraulic cylinder, featuring a dual-chamber actuator cylinder with separate pistons for service and parking brakes, and a force amplification mechanism using levers or wedges, along with clearance regulation mechanisms to maintain consistent braking performance and compensate for wear without additional devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the brake unit is made compact, then the device size is reduced, but the braking performance decreases
Solution Approach 1:
The patent employs a dynamic force amplification mechanism where levers and wedges convert the motion of a compact actuator cylinder into amplified braking force. The lever system with pivot points and the wedge-shaped elements create mechanical advantage, allowing a small actuator to generate sufficient braking force in a compact configuration.
Solution Approach 2:
The patent changes the physical parameters of the braking system by using a dual-chamber actuator cylinder with different piston areas. By varying the pressure and area parameters in the two chambers, the system achieves both compact size and high braking force through controlled parameter changes rather than simply increasing component size.
2Force
If additional mechanisms are added to increase braking force, then the braking performance is improved, but the device complexity increases
Solution Approach 1:
The patent merges multiple functions into a single integrated mechanism. The force amplification levers are combined with the wear compensation mechanism, where the same lever system that amplifies braking force also automatically compensates for pad wear through its mechanical design. This eliminates the need for separate auxiliary devices and reduces overall complexity.
Solution Approach 2:
The actuator cylinder is designed with dual chambers that serve multiple functions: one chamber provides service braking while the other provides parking brake functionality. The same mechanical structure performs both service and parking brake operations, as well as wear compensation, reducing the need for separate components and simplifying the overall system.
3Adaptability or versatility
If separate mechanisms are used for service and parking brakes, then the braking functions are improved, but the component count increases
Solution Approach 1:
The dual-chamber actuator cylinder serves multiple braking functions through its two chambers. The first chamber handles service braking while the second chamber handles parking brake operations. This universal design allows a single component to perform what would traditionally require separate mechanisms, reducing the component count while maintaining full braking functionality.
Solution Approach 2:
The actuator cylinder is segmented into two functional chambers, each with its own piston, allowing independent control of service and parking brake functions. This segmentation within a unified structure enables multiple braking modes without requiring completely separate mechanisms, optimizing both functionality and component efficiency.
4Reliability
If wear compensation mechanisms are added, then the braking performance is maintained, but the device complexity and cost increase
Solution Approach 1:
The wear compensation mechanism operates automatically through the mechanical design of the levers and actuator cylinder without requiring external control systems or additional complexity. As the brake pads wear, the mechanical linkage automatically adjusts the clearance through the lever system, maintaining consistent braking performance through self-adjusting geometry rather than complex controlled mechanisms.
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 solution provides high-performance braking in both service and parking modes, reduces component count, simplifies manufacturing and maintenance, and eliminates the need for auxiliary devices, resulting in a cost-effective and compact braking system that autonomously manages wear and axial displacement.
Implementation Method 1
actuated by a braking force motor like for example a pneumatic or hydraulic cylinder
Implementation Method 2
a pair of jaws 14, provided with relative friction gaskets 16, intended to rub on the two opposite surfaces of the disc 12
Data Source
Figure 1A
Figure 1B
Figure 2
AI summary
A disc-brake unit (10) for vehicles on rails, comprising a pair of jaws (14), provided with relative friction gaskets (16), intended to rub on a disc (12). The jaws (14) are hinged at one of the ends of a pair of levers (18), which are actuated by a braking force motor (22) provided with at least one first piston (26) that moves along an axis (A). The braking unit (10) also comprises a group (68) for automatically regulating the clearances between the friction gaskets (16) and the disc (12). The piston (26) transmits the braking force to a thrusting mechanism (48,- 48' ) inside the braking force motor (22) to amplify and transfer the force, through the group (68) and along an axis (B) perpendicular to the axis (A), to the ends of the levers (18) opposite the ends on which the jaws (14) are hinged.