Spring Brake Actuator Stopper for Torque Feedback
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Solution Overview
Problem
Spring brake actuators in commercial vehicles face issues where operators may unknowingly apply excessive torque, leading to potential damage when compressing the spring beyond its maximum state, especially with half-release bolts, due to steep torque increases and lack of clear feedback indicating the end stop position.
Innovation Solution
Incorporating a stopper and protrusion mechanism within the cylinder housing that provides haptic feedback by increasing torque when the end stop is reached, preventing further compression and featuring a shear pin to prevent excessive torque application, along with a marker for detecting force misuse.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a half-release bolt is used to compress the spring, then the piston movement per rotation is significantly increased (three times more), but the torque increases steeply and operators may apply excessive torque causing damage
Solution Approach 1:
The patent implements a feedback mechanism through a stopper that contacts the housing at a predetermined position during spring compression. This contact provides haptic feedback to the operator, signaling that the spring has reached its maximum compression state and no further torque should be applied. This solves the problem of operators not recognizing the end position due to the steep torque curve of half-release bolts.
Solution Approach 2:
The stopper mechanism performs preliminary anti-action by preventing excessive torque application before damage can occur. The stopper is positioned to engage with the housing exactly when the spring reaches maximum compression, creating a mechanical barrier that stops further compression and protects the system from damage.
2Ease of operation
If the operator rotates the release bolt further after the spring has reached maximum compression, then more torque is applied, but this leads to damage of the brake release bolt, running nut, and/or cylinder housing
Solution Approach 1:
The stopper provides clear haptic feedback through its contact with the housing, creating a noticeable change in torque resistance that alerts the operator to stop rotating the release bolt. This solves the recognition problem by providing tactile information that overcomes the difficulty of detecting the end position on steep-torque bolts.
Solution Approach 2:
The stopper acts as an intermediary element between the release bolt mechanism and the housing. It mediates the force transmission by providing a controlled contact point that prevents direct transmission of excessive torque to the vulnerable components (bolt, running nut, housing), thereby protecting the system while still allowing operator control.
3Device complexity
If no stop mechanism is provided, then the system is simpler, but operators cannot recognize when to stop rotating the release bolt
Solution Approach 1:
The stopper provides mechanical feedback through haptic contact with the housing, giving the operator clear information about the spring's compression state. This information transmission is achieved through a simple mechanical contact that does not require complex electronic or mechanical systems, thus providing end position indication with minimal added complexity.
Solution Approach 2:
The stopper mechanism is self-indicating through its haptic feedback, eliminating the need for additional indicators, gauges, or complex signaling systems. The operator receives direct tactile information from the stopper's contact with the housing, allowing the system to inform the operator of the end position through its own operational characteristics rather than requiring separate indication systems.
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 significantly reduces the risk of damage by providing clear haptic feedback and preventing excessive torque application, enhancing operational safety and reducing the likelihood of maloperation.
Implementation Method 1
a compression spring (9) located between the cylinder housing base (5) and the spring brake piston (11), said compression spring (9) being effective to push the spring brake piston (11) away from the base (5)
Implementation Method 2
a running nut (21) engaging the threaded portion (37), said running nut (21) being adapted to move the spring brake piston (11) against the force of the compression spring (9)
Implementation Method 3
a stopper (25) located on the release bolt (19) at a position between the running nut (21) and the static nut (31), said stopper (25) being adapted to abut against the protrusion (27) at a predetermined stroke position of the spring brake piston (11)
Data Source
Figure 1~2b
Figure 3a~3b
Figure 4a~4b
AI summary
The invention relates to a spring brake actuator (1), in particular parking or emergency spring brake actuator, for use in a commercial vehicle, said actuator comprising a cylinder housing (3) having a cylinder housing base, a spring brake piston (11) located in said cylinder housing for applying a braking force, a compression spring (9) located between the cylinder housing base and the spring brake piston, said compression spring being effective to push the spring brake piston away from the base, a brake release bolt (19), preferably a half-release bolt, having a threaded portion (37), a running nut (21) engaging the threaded portion (37), said running nut being adapted to move the spring brake piston against the force of the compression spring, wherein the spring brake piston comprises a flange portion (23) adapted for abutting against the running nut, and a static nut (31) fixedly attached to the bolt, said static nut being effective to move the running nut along the threaded portion. In particular, the actuator comprises a protrusion (27) inside the cylinder housing extending away from the cylinder housing base, and a stopper (25) located on the release bolt at a position between the running nut and the static nut, said stopper being adapted to abut against the protrusion (27) at a predetermined stroke position of the spring brake piston (11).