Wet Disc Brake System Load Transfer to Axle Housing
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Solution Overview
Problem
Heavy vehicles, such as garbage trucks, incur high maintenance costs due to frequent braking events, requiring frequent overhauls of braking systems, especially the rear brake system every six months and front brake system every twelve months, resulting in significant annual expenses.
Innovation Solution
A wet disc brake system is developed, featuring a housing assembly with a liquid-tight seal, callipers configured for both service and park brakes, and a method for retrofitting air-operated drum brake systems with preassembled brake components, including mechanical fasteners to transfer braking loads to the axle housing, and hydraulic actuation for service brakes with a spring-applied air release for park brakes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional air-operated drum brake systems are used in heavy vehicles, then the braking system can provide sufficient stopping power, but the maintenance cost increases significantly and the service interval decreases to every 6-12 months
Solution Approach 1:
The patent replaces the conventional air-operated drum brake system with a wet disc brake system that uses hydraulic actuation. The hydraulic cylinder with piston mechanism provides brake actuation, eliminating the need for air compressors and dry brake components. This hydraulic system operates within a sealed housing filled with lubricant, creating a wet brake environment that significantly reduces wear and maintenance requirements compared to conventional air brakes.
Solution Approach 2:
The patent fundamentally changes the operating parameters of the brake system by transitioning from dry air-operated drums to wet hydraulic disc brakes. The introduction of lubricant as the operating medium changes the friction characteristics and thermal management of the brake system. The hydraulic pressure system operates at different pressure levels compared to pneumatic systems, enabling more precise and controlled braking with reduced component wear.
2Reliability
If frequent brake overhauls are performed to maintain braking performance, then brake reliability is maintained, but vehicle uptime decreases and operational expenses increase
Solution Approach 1:
The wet brake system is designed to be self-lubricating through the sealed housing filled with lubricant. The lubricant continuously bathes the brake discs and pads, providing ongoing protection against wear and heat buildup without requiring external intervention. This self-sustaining lubrication system dramatically extends the service interval between overhauls, allowing vehicles to operate for years without brake system replacement, thereby maximizing vehicle uptime and productivity.
3Device complexity
If conventional brake systems are used, then the design is simple and well-established, but the maintenance frequency increases to every 6-12 months
Solution Approach 1:
The brake system is segmented into distinct modular components: a sealed housing assembly containing the lubricant and brake mechanism, removable callipers with brake pads, and replaceable brake discs. This segmentation allows for easy maintenance where only worn brake pads or discs need to be replaced while the sealed housing and hydraulic actuation system remain in service. The modular design simplifies the maintenance process despite the advanced wet brake technology.
Solution Approach 2:
The patent employs a design where the expensive sealed housing and hydraulic actuation system are long-lasting components that remain in service for years, while the brake pads and discs are treated as consumable items that are periodically replaced. This approach concentrates the investment in durable, maintenance-free components while using inexpensive replaceable parts, effectively extending the overall service interval of the brake system.
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 wet disc brake system reduces maintenance costs and extends the interval between overhauls, providing effective service and park braking capabilities while minimizing the load on the brake housing, thus lowering operational expenses and improving vehicle uptime.
Implementation Method 1
a respective seal located between each cylinder and forming a seal between that cylinder and a corresponding opening in which that cylinder is seated
Implementation Method 2
wet disc brake system that is suitable for heavy vehicles which undergo a large number of braking events
Data Source
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AI summary
Wet disc brake system (10) comprises a housing assembly (12) and brake callipers (14). Housing assembly (12) is provided with openings (24) for seating cylinders (22) of respective brake callipers (14). The callipers (14) are coupled to a structural component of a vehicle to which the system (10) is fitted and in particular a flange (28) of an axle housing (16). This enables reactive forces created during a braking operation to be transmitted via the callipers to the flange (28) and axle housing (16) rather than being carried by housing assembly (12). As housing assembly (12) does not bear any substantive load, it may be made of a relatively light weight construction or material. The application is also directed to a disc brake system comprising a service and park brake calliper provided with at least two cylinders wherein at least one cylinder houses a hydraulically operated service piston and at least one cylinder houses a park piston that is applied by a spring and released by air pressure.