Internal Ventilated Diaphragm Piston Brake Actuator
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Solution Overview
Problem
Traditional diaphragm-piston spring brake actuators in heavy vehicles are prone to contamination and corrosion due to dust, dirt, moisture, and atmospheric exposure through breather tubes, leading to premature failure of sealing elements and emergency springs.
Innovation Solution
An internal ventilation system isolates the back part of the piston from the external environment, using a balanced valve system with an aluminum piston and plug, and a larger sectional sealing ring to maintain air pressure and prevent contamination, replacing traditional breather tubes and rubber connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If an external breather tube with rubber connections is used to ventilate the back part of the piston, then air can be transferred during piston motion, but dust, dirt, and moisture enter the actuator causing corrosion and damage to sealing elements
Solution Approach 1:
The harmful external breathing function is extracted and removed from the system. The patent eliminates the breather tube and rubber elbow connections that exposed the actuator to contaminants, replacing them with an internal ventilation system that uses only the existing air inlet and outlet ports to achieve ventilation using dry air from the vehicle's air system.
Solution Approach 2:
The patent creates a protected internal environment by using dry air from the vehicle's air system to ventilate the back part of the piston. This replaces the harmful external atmosphere with a controlled, contaminant-free air supply that prevents corrosion of the emergency spring and damage to sealing elements.
2Ease of manufacture
If rubber elbows are used to connect the breather tube to the housing, then the breather tube can be attached, but the rubber connections deteriorate over time due to atmospheric conditions and vibration causing loosening or damage
Solution Approach 1:
The removable rubber elbow connections are extracted and eliminated from the system. The patent integrates the breather tube function directly into the housing with fixed mounting, removing the vulnerable rubber connection components that deteriorated due to atmospheric exposure and vibration.
Solution Approach 2:
The breather tube connection function is merged with the housing structure itself. The breather tube is fixedly mounted to the housing, eliminating separate connection components and creating a more reliable, vibration-resistant assembly.
3Ease of operation
If the back part of the piston is exposed to the atmosphere through the breather tube, then air can be absorbed during piston motion, but water and mud enter causing corrosion of the sliding ring and sealing member leading to seal failure
Solution Approach 1:
The patent protects the back part of the piston by ventilating it with dry air from the vehicle's air system instead of exposing it to the external atmosphere. This creates a controlled environment that prevents water and mud from entering through the air passages, thereby protecting the sliding ring and sealing member from corrosion and maintaining sealing performance.
4Ease of operation
If the emergency spring is exposed to atmospheric moisture through the breather tube, then the spring can function, but moisture causes corrosion of the emergency spring requiring urgent repair or replacement
Solution Approach 1:
The patent protects the emergency spring by using dry air from the vehicle's air system to ventilate the back part of the piston, creating a moisture-free environment. This prevents corrosion of the emergency spring, extending its service life and eliminating the need for urgent repairs or replacements.
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 internal ventilation system effectively prevents contamination and corrosion, enhancing the reliability and safety of the actuator by maintaining a dry environment and ensuring consistent sealing, thus reducing the need for frequent repairs or replacements.
Implementation Method 1
By insufflating the air into the park chamber (3), the said park chamber (3) is filled with the pressurized air received from the air tanks of the vehicle. In this case, steel ball (9) of the piston valve (6) compresses the spring (7) by the effect of the pressure and fits on the O-Ring (8).
Implementation Method 2
the piston (1) moves in (b) direction by the force created by the emergency spring (25)
Data Source
Figure 1
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AI summary
This invention is related to the decrease of the breakdowns that occur in the actuators by means of the application of internal ventilation system to the diaphragm piston spring brake actuators which are used in vehicles such as truck, van, bus and trailer. The internally ventilated diaphragm - piston spring brake actuator that is developed by this invention is comprised by an aluminum piston (1), an aluminum pipe (2), a park chamber (3), a service chamber (5), a piston valve (6), a piston valve spring (7), inlet air openings (11), air transition space (12), plug (13), air inlet holes (14), pneumatic sealing (15), outlet channel (16) and characterized in that it has a valve (26) having sealing lips (27), sealing surface of piston valve (28) and square or rectangular sectioned sealing member (29).