Universal Brake Pad Carrier for Air and Hydraulic Actuator Conversion
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Solution Overview
Problem
Heavy vehicles traditionally require either air-operated or dual air and hydraulic service brake assemblies, which are costly and inefficient, especially with the advent of regenerative braking systems reducing the need for heat dissipation in braking systems.
Innovation Solution
A method to manufacture service brake assemblies using common components for both air-operated and hydraulically operated brake systems, allowing for the attachment of either type of actuator to a shared brake pad carrier and bridge, enabling easy conversion between systems and reducing manufacturing costs through economies of scale.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If both air operated and hydraulic operated actuators are provided on the brake pad carrier, then the brake assembly can serve both traditional air braking systems and modern hydraulic braking systems, but the device complexity and manufacturing cost increase significantly
Solution Approach 1:
The brake pad carrier is designed with a universal mounting interface that can accommodate both air-operated actuators and hydraulically operated actuators. The carrier includes a single actuator mounting location with standardized attachment features, allowing the same physical structure to serve dual purposes with different actuator types rather than requiring separate mounting locations for each actuator type
2Reliability
If separate brake pad carriers are manufactured for air operated and hydraulic operated actuators, then each carrier can be optimized for its specific actuator type, but the manufacturing cost and inventory complexity increase
Solution Approach 1:
A single brake pad carrier design serves both air-operated and hydraulically operated actuators through a universal mounting interface. This eliminates the need to manufacture and inventory multiple carrier variants, reducing production complexity and stockkeeping requirements while maintaining compatibility with both actuator types
3Temperature
If heavy vehicles use traditional air operated service brake assemblies, then the braking system can effectively dissipate heat for heavy loads, but the manufacturing cost and complexity increase compared to hydraulic systems
Solution Approach 1:
The brake system is designed to dynamically adapt between air-operated and hydraulically operated modes based on vehicle configuration. The universal carrier allows the system to switch between actuator types, enabling vehicles with regenerative braking to use simpler hydraulic systems while heavy-duty vehicles without regenerative braking can utilize air-operated systems for superior heat dissipation
Data Source
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AI summary
A method of making a brake assembly including the steps of:- a) providing a brake pad carrier, b) providing an air operated brake actuator suitable for attaching to the brake pad carrier, c) providing a hydraulically operated brake actuator suitable for attaching to the brake pad carrier, d) attaching one of the air operated brake actuator and hydraulically operated brake actuator to the brake pad carrier to provide a brake assembly.