SAHR Brake Disc Stack Alignment Without a Coupler Shaft
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Solution Overview
Problem
Existing spring applied, hydraulically released (SAHR) brakes require manual alignment of springs, torque pins, and discs, and often necessitate the use of an additional coupler shaft, leading to increased assembly time and cost, while also facing issues with free-floating thicker discs causing drag and impingement on the disc stack.
Innovation Solution
A spring applied, hydraulically released brake design that includes full alignment of springs, torque pins, and discs, eliminating the need for manual alignment and a coupler shaft, with a thicker stationary disc secured by a slotted spring pin to prevent free-floating and impingement, utilizing an internal ring and torque pins with annular support to maintain disc stack alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual alignment of springs, torque pins, and discs is used in conventional brakes, then assembly flexibility is maintained, but assembly time and labor cost increase
Solution Approach 1:
The disc stack is pre-assembled with springs, torque pins, and discs all aligned together as a single unit before installation. This preliminary alignment eliminates the need for manual alignment during final assembly, significantly reducing assembly time and labor cost while maintaining the necessary alignment precision through the integrated design
2Manufacturing precision
If a coupler shaft is used to align discs in conventional open-ended brakes, then disc alignment is achieved, but device complexity and cost increase
Solution Approach 1:
The coupler shaft component is completely removed from the brake design. Instead of using a separate coupler shaft to align the discs, the disc stack is designed as a self-contained pre-assembled unit where all alignment functions are integrated into the stack structure itself, eliminating the need for additional alignment components
Solution Approach 2:
The alignment function previously performed by a separate coupler shaft is merged into the disc stack assembly. The torque pins and internal ring structure of the pre-assembled disc stack provide the necessary alignment features, combining multiple functions into a single integrated component
3Reliability
If a thicker stationary disc is used to prevent free-wheeling drag, then braking performance is improved, but free-floating causes drag and impingement on disc stack
Solution Approach 1:
The thicker stationary disc is integrated as part of the pre-assembled disc stack unit, where it is permanently positioned and secured relative to other discs and components. This integration eliminates free-floating movement while maintaining the improved braking performance provided by the thicker disc design
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 faster and cost-effective assembly of the brake system, prevents free-floating of the thicker disc, and maintains disc stack alignment, ensuring efficient braking and reduced drag during free-wheeling operations.
Implementation Method 1
the pin spring urges the thicker stationary disc into contact with the internal ring of the housing to thereby prevent the thicker stationary disc from free floating
Implementation Method 2
a spring assembly adapted to urge the piston into contact with the thicker stationary disc of the disc stack to establish a default position of the brake
Implementation Method 3
spring applied, hydraulically released brake
Data Source
AI summary
A spring applied, hydraulically released brake includes a housing having an open end adapted to align with a vehicle surface and an internal ring extending from an inner perimeter of the housing; a piston; a disc stack including a thicker stationary disc including a tab with a hole therethrough, the hole receiving a slotted spring pin, the slotted spring pin slidably receiving a pin spring over a portion thereof; and a spring assembly adapted to urge the piston into contact with the thicker stationary disc to establish a default position of the brake; where, in a released position of the brake, the piston is not in contact with the thicker stationary disc, and the pin spring urges the thicker stationary disc into contact with the internal ring of the housing to thereby prevent the thicker stationary disc from free floating.