Unit Brake Assembly With Integrated Pipe Connection for Bogie Mounting
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Solution Overview
Problem
The existing unit brake device requires a cumbersome series of steps to mount onto a bogie due to the need to temporarily remove the device for welding the pipe, caused by the small gap between the bogie beam and the unit brake device.
Innovation Solution
A unit brake device design that includes a brake cylinder, a pressing unit, a body covering the pressing unit, a bogie-side attachment structure, and a brake-side pipe. The brake-side pipe is fixedly attached to the body and connects the air inlet of the brake cylinder to the bogie-side connection port, allowing for simplified mounting by attaching the body to the bogie-side attachment structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the unit brake device is mounted onto the bogie with the brake cylinder and pipe connection, then the braking function is achieved, but the mounting process becomes cumbersome requiring temporary removal for welding
Solution Approach 1:
The brake device is divided into modular components: the brake cylinder assembly with integrated pipe connection structure, and the bogie mounting structure with connection ports. This segmentation allows the pipe connection to be pre-integrated into the brake cylinder assembly, eliminating the need for separate welding operations during mounting.
Solution Approach 2:
The pipe connection structure is pre-integrated into the brake cylinder assembly during manufacturing, and the bogie mounting structure has pre-positioned connection ports. This preliminary preparation of connection interfaces eliminates the need for temporary removal and welding operations during the actual mounting process.
2Strength
If the pipe is welded onto the bogie while the unit brake device is attached, then the connection is established, but the small gap between the bogie beam and brake device prevents welding
Solution Approach 1:
The connection structure is segmented into the brake cylinder assembly with integrated pipe connection and the bogie mounting structure with connection ports. This segmentation allows the pipe to be connected to the brake cylinder assembly in a controlled manufacturing environment rather than requiring welding in the constrained space on the bogie.
Solution Approach 2:
The brake cylinder assembly serves as an intermediary structure that integrates the pipe connection. Instead of directly welding the pipe to the bogie in the constrained space, the pipe is connected to the brake cylinder assembly which then connects to the bogie, providing the necessary space and access for connection operations.
3Strength
If the unit brake device is temporarily removed for pipe welding, then the pipe connection can be made, but the mounting time and complexity increase
Solution Approach 1:
The pipe connection structure is pre-integrated into the brake cylinder assembly during manufacturing, and the bogie mounting structure has pre-positioned connection ports. This preliminary preparation of connection interfaces eliminates the need for temporary removal and welding operations during the actual mounting process, reducing mounting time.
Solution Approach 2:
The brake device is divided into modular components with pre-integrated connection structures. This segmentation allows the pipe connection to be established as part of the modular assembly rather than requiring separate temporary removal and welding steps, reducing overall mounting time.
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
Provided is a unit brake device (1, 101, 111) that can be mounted in a simplified manner as the need of temporarily mounting the unit brake device (1, 101, 111) is eliminated. A unit brake device (1) includes: a brake cylinder (20) configured to be driven by compressed air fed through a bogie-side pipe (16) fixedly attached onto a bogie; a pressing unit configured to be driven by the brake cylinder (20) and to press a brake shoe 2 against a tread of a wheel of the bogie; a body (31) covering the pressing unit; a bogie-side attachment structure (10) to which the body (31) is to be attached with the bogie-side attachment structure (10) being fixedly attached onto the bogie, the bogie-side attachment structure (10) having a bogie-side connection port (13) to which the bogie-side pipe (16) is connected; and a brake-side pipe (26) configured to establish connection between an air inlet (20A) of the brake cylinder (20) and the bogie-side connection port (13). The brake-side pipe (26) is fixedly attached onto the body (31) such that the brake-side pipe (26) establishes the connection between the air inlet (20A) and the bogie-side connection port (13) upon attaching the body (31) onto the bogie-side attachment structure (10).