Trailer Overrun Brake Gas Spring Locking Mechanism
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing trailer overrun brake systems activate during reversing, leading to safety issues such as locked wheels and inability to park uphill, and current solutions either require manual intervention or have safety risks due to mechanical failures like lubrication issues or hydraulic leaks.
Innovation Solution
A system featuring a lockable gas spring with a solenoid-controlled valve that disconnects the brakes during reversing by closing the gas flow when the vehicle is in reverse gear, ensuring full brake functionality returns when the gear is changed, and is designed to work with both mechanical and hydraulic overrun brakes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mechanical overrun brakes with gas spring are used, then braking force is transmitted gradually during forward driving, but brakes are also activated during reversing causing locked wheels
Solution Approach 1:
The patent extracts the harmful braking effect during reversing by introducing a locking mechanism that isolates the slide from the brake system when reversing occurs. The locking device physically disconnects the force transmission path, removing the harmful effect without affecting the normal braking function during forward driving.
Solution Approach 2:
The system dynamically changes the state of the slide based on driving direction. During forward driving, the slide is free to move and transmit braking force. During reversing, the locking mechanism engages to prevent slide movement, thus dynamically adapting the brake system's behavior to the operating condition.
2Object-affected harmful factors
If manual locking devices are used to prevent brake activation during reversing, then braking effect is prevented, but safety risk increases due to insufficient lubrication and maintenance
Solution Approach 1:
The patent replaces the purely mechanical locking system with an electromechanical system. A solenoid actuator controls the locking mechanism, allowing for more reliable and controllable operation. The electrical control system can detect reversing conditions and automatically engage/disengage the lock without requiring manual intervention, reducing maintenance issues related to mechanical wear and lubrication.
3Object-affected harmful factors
If hydraulic cylinder with solenoid controlled valve is used, then braking effect is prevented during reversing, but braking reliability is reduced if hydraulic system leaks
Solution Approach 1:
The patent extracts the hydraulic system from the critical force transmission path by using a mechanical locking device. The hydraulic brake system remains intact and reliable for normal operation, while the mechanical lock provides a fail-safe method to prevent braking during reversing without relying on hydraulic pressure or seals.
Solution Approach 2:
The locking mechanism acts as a protective measure that engages before any potential hydraulic failure could affect reversing operations. By providing a mechanical backup system, the patent ensures that even if the hydraulic system fails, the braking function remains reliable during forward driving and is properly disabled during reversing.
4Ease of operation
If hand brake is used with traditional overrun brakes, then parking is possible during forward driving, but uphill parking is impossible without backstops
Solution Approach 1:
The patent removes the harmful braking effect during reversing, which allows the hand brake to function effectively in both forward and reverse directions. By preventing unintended brake activation during reversing, the hand brake can now reliably hold the trailer on uphill slopes without the risk of the overrun brakes interfering or requiring additional backstop devices.
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 system prevents brake activation during reversing, ensuring safe uphill parking and eliminating risks associated with mechanical or hydraulic failures, as it automatically disengages the brake mechanism when reversing and re-engages when driving forward, maintaining 100% braking effectiveness.
Implementation Method 1
A solenoid controlled valve (17) is built into the piston (5) of the gas spring (3)... when current flows through the solenoid the valve becomes closed
Implementation Method 2
a gas spring (3) acting as a shock absorber on the slide... This gas spring is also pushing the slide out again after each braking sequence
Data Source
AI summary
A overrun brake system includes a gas spring with a gas-tight cylinder and a piston with holes allowing gas to slip through so that the pressure is the same on both sides. Since the free end of the piston has a larger area than the side where the piston rod is located, the gas spring will act as a compression spring. To prevent the overrun brakes from being activated during reversing, the gas spring has a solenoid controlled valve receiving current from the reverse light circuit and closing the flow of gas through the piston when the towing unit's gear is set into reverse. When the gear is set into forward position the solenoid loses its current and a mechanical return spring opens the valve, so that the overrun brakes may act normally again.