Internal Ventilated Diaphragm-Piston Spring Brake Actuator
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Traditional diaphragm-piston spring brake actuators in heavy commercial vehicles suffer from actuator malfunctions due to dust, moisture, and vibration, leading to corrosion and damage of sealing elements and guide rings, and existing internal ventilation systems face issues with air leaks, vacuum balancing, and difficult disassembly.
Innovation Solution
An internal ventilated diaphragm-piston spring brake actuator with a piston pipe plug having a valve system that balances pressure and vacuum through a form-dependent fitting operation, allowing for rapid and stable vacuum balancing, preventing loose connections, and enabling easy removal and replacement of components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the valve is closed to prevent air leaks into the power spring section, then sealing reliability is improved, but vacuum balancing cannot be performed or is delayed during braking
Solution Approach 1:
The valve system is segmented into multiple functional components: a check valve for preventing air leaks into the power spring section, and a vacuum balancing valve for balancing vacuum pressure. These valves are positioned at different locations and operate independently, allowing sealing reliability and vacuum balancing to occur simultaneously without mutual interference.
Solution Approach 2:
A vacuum balancing channel is introduced as an intermediary pathway that connects the power spring section to the atmosphere. This channel allows vacuum balancing to occur through a dedicated route that does not interfere with the sealing function of the check valve, enabling both functions to operate concurrently.
2Strength
If the valve system is irremovably attached to the piston, then structural integrity is improved, but disassembly and repair become impossible when malfunction occurs
Solution Approach 1:
The valve system is divided into separable components that can be independently removed. The vacuum balancing valve and check valve are designed as separate elements that can be detached from the piston and piston pipe, allowing maintenance personnel to access and replace individual components without removing the entire piston assembly.
Solution Approach 2:
The connection method transitions from fixed/irremovable to dynamically adjustable. The valve system incorporates removable connections that maintain structural integrity during operation but allow easy disassembly when maintenance is required, adapting the structural characteristic based on operational vs. maintenance states.
3Ease of operation
If thread connection is used for piston pipe plug, then assembly ease is improved, but connection stability deteriorates due to vibration causing loosening
Solution Approach 1:
The connection system is segmented into multiple stages: initial thread connection for assembly ease, followed by a locking mechanism (such as a locking ring or set screw) that secures the connection against vibration. This segmented approach allows both easy assembly and stable connection under vibrational conditions.
Solution Approach 2:
A locking element or securing mechanism is introduced as an intermediary between the piston pipe plug and the piston pipe. This intermediary component prevents direct vibration-induced loosening of the threaded connection while maintaining the ease of threaded assembly, acting as a buffer against vibrational forces.
4Ease of operation
If rubber elbows are used for breather tube connection, then flexibility and ease of installation are improved, but durability deteriorates due to dust accumulation and atmospheric conditions causing joint loosening
Solution Approach 1:
The vulnerable rubber elbow components are extracted and replaced with more durable materials or designs. The breather tube connection system uses corrosion-resistant and vibration-resistant materials that do not accumulate dust or deteriorate under atmospheric conditions, eliminating the durability problems associated with rubber elbows while maintaining installation ease through standardized connection interfaces.
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 provides a stable and rapid vacuum balancing system, prevents actuator malfunction due to vibration, and allows for easy maintenance and repair by enabling the removal and replacement of the piston pipe plug, thus extending the lifespan of the actuator.
Implementation Method 1
a piston pipe plug having a valve system that balances pressure and vacuum through a form-dependent fitting operation, allowing for rapid and stable vacuum balancing
Implementation Method 2
An internal ventilated diaphragm-piston spring brake actuator with a piston pipe plug having a valve system that balances pressure and vacuum through a form-dependent fitting operation, allowing for rapid and stable vacuum balancing, preventing loose connections
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention subject matter of the application is related to an internal ventilated diaphragm-piston spring brake actuator (1) that enables decreasing actuator malfunctions by implementing an internal ventilation system to the diaphragm-piston spring brake actuators used in pneumatic brake systems of heavy commercial vehicles such as trucks, tractors, trailers and busses.