Abstract: An improved bracket assembly for receiving a brake assembly and a brake actuator is provided. The bracket assembly includes a tube configured to receive a camshaft of the brake assembly. A brake spider mounting flange is disposed proximate a first end of the tube, defines an aperture configured to allow the tube to extend therethrough, and is configured to receive a brake spider of the brake assembly. An actuator mounting arm is disposed proximate a second end of the tube, is configured for coupling to the brake actuator, and has inboard and outboard members. Each of the inboard and outboard members has a body having a first end affixed to the tube and an actuator mounting flange extending from a second end of the body. The actuator mounting flanges define aligned bores configured to receive a fastener extending from the brake actuator.

Abstract: A system and method are provided for mounting, removing and retaining brake pads in disc brakes, such as air-operated disc brakes utilized on commercial vehicles, in a manner which does not require the use of separate brake pad retaining devices while providing positive retention of the brake pad. A preferred embodiment includes a brake caliper mount having brake pad abutment surfaces having radially-oriented and lateral grooves which permit a brake pad with corresponding projections on is lateral sides to be inserted through an opening of the brake caliper into the radially-oriented grooves until the backing plate projections are aligned with the lateral groove, and advancing the brake actuator behind the brake pad to place the brake pad in an operating position in which the actuator prevents the brake pad from realigning with the radially-oriented grooves until the actuator is retracted to permit brake pad extraction.

Abstract: A plug for sealing an aperture in a brake actuator housing is provided that provides improvements in installation and retention of the plug and protection for sealing surfaces. The plug includes a retention member including a body defining an aperture configured for alignment with the actuator housing aperture along an axis extending through the apertures. The retention member further includes a plurality of alignment tabs extending radially from the body. The tabs are configured to be received within a plurality of notches formed in a retaining ring affixed to the housing when the retention member is disposed in an unlocked position and configured to be disposed on a first side of the retaining ring when the retention member is rotated about the axis to a locked position. The plug further includes a seal configured to be received within the aperture in the body. The seal closes the second aperture.

Abstract: A brake shoe for a drum brake is provided that improves the direction of the brake actuating forces to reduce stress, improve efficiency and permit thicker brake linings. The brake shoe has a web having first and second ends with the first end configured for pivotally coupling to an associated brake spider. A brake table is supported on the web. The second end of the web is configured to engage an associated cam follower that causes the brake shoe to move between positions of engagement and disengagement with an associated braking surface at either of first and second radially offset positions on the second end of the web such that the cam followers can engage two brake shoes in the brake at offset positions and improve the direction of the force vectors.

Abstract: A mounting arrangement for a disc brake is provided, in which a torque plate affixed to a vehicle axle and a brake caliper mounting frame affixed to the torque plate have corresponding opposing projections and recesses provided to laterally and circumferentially limit relative motion between the torque plate and the mounting frame. A wedge element with at least one angled face is located between correspondingly-angled faces of the mounting frame and/or the torque plate to generate lateral and/or circumferential loading in response to tightening of vertically-oriented fasteners. The use of the angled components substantially reduces the amount of loading required to be applied by the vertical fasteners to resist relative motion between the torque plate and the mounting frame.

Abstract: A system and method are provided for mounting, removing and retaining brake pads in disc brakes, such as air-operated disc brakes utilized on commercial vehicles. A preferred embodiment includes a brake pad carrier having features to fixedly receive spring retaining elements, such as bushings, which in turn retain spring elements, such as spring clips, having features that cooperate with corresponding brake pad surfaces to resist radially-outward motion of the brake pad.

Abstract: A drum brake is provided that improves the direction of the actuating forces to reduce stress, improve efficiency and permit thicker brake linings. First and second brake shoes each have a first end pivotally coupled to a brake spider. First and second cam followers are disposed at corresponding second ends of the brake shoes. A cam engages the cam followers with movement of the cam causing the brake shoes to move between positions of engagement and disengagement with a braking surface. The cam followers are offset such that a center of the first cam follower is disposed at a first distance from a center axis of the brake and a center of the second cam follower is disposed at a second distance from the center axis with the first distance different from the second distance so as to improve the direction of the cam force vector.

Abstract: A bushing adapted to secure an O-ring seal in position relative to an area of a passage permitting reciprocation of a push rod forms a generally circular bushing body with opposed end faces. The end faces are separated by a gap so as to provide the bushing with an approximately C-shaped structure. The bushing includes a plurality of locking elements resistant to axial loads imposed on the bushing by the push rod disposed at least substantially within a corresponding plurality of recesses distributed around a circumferential exterior of the bushing. Solid ribs are interspersed with the locking fingers to resist radial loads imposed on the bushing by the push rod during operation. The O-ring seal is secured in position within the passage area of the passage by an end surface of the bushing.

Abstract: Various embodiments of an apparatus and method for impact forming a cotter pin in a brake assembly are disclosed. In one example, an impact forming tool comprises a handle for receiving an operating force, a stationary portion and a hammer portion. The stationary portion is connected to the handle at a proximate end. An orientation pin is positioned on a distal end and two anvil pins are positioned on the stationary portion between the proximate end and the orientation pin. The hammer portion communicates with the operating force and moves linearly across the face of the stationary portion from a first position to a second position. The hammer portion has a symmetrical arcuate end, wherein a vertex of the symmetrical arcuate end is between the two anvil pins when the hammer is in the second position.

Abstract: A drum brake is provided that improves the direction of the actuating forces to reduce stress, improve efficiency and permit thicker brake linings. First and second brake shoes each have a first end pivotally coupled to the same or different anchor pins on a brake spider. First and second cam followers are disposed at corresponding second ends of the brake shoes. A cam engages the cam followers with movement of the cam causing the brake shoes to move between positions of engagement and disengagement with a braking surface. The cam followers are offset such that distances between the centers of the first cam followers and the anchor pin or pins supporting the brake shoes differ so as to improve the direction of the cam force vector.

Abstract: An automatic slack adjuster for a vehicle brake includes a one-way clutch having first and second parts rotatable about an axis. The first part is rotatable in both a drive direction and a slip direction opposite to the drive direction, while the second part is driven about the axis by the first part when the first part rotates in the drive direction, but not driven when the first part rotates in the slip direction. Movable elements are carried within receptacles distributed circumferentially about and projecting into one of the parts, and are displaceable so as to move within the receptacles in radial directions relative to the axis. The movable elements engage corresponding surfaces of teeth that are immovably fixed on or form part of a circumferential surface of the other of the parts.

Abstract: A brake pad retaining device is provided for holding a brake pad within a brake caliper of an air disc brake system. The device may be formed as a spring which provides at least four retention forces at longitudinal ends of the brake pad in order to suppress brake pad kick motion and vibration, while applying a biasing force that pre-loads a caliper to its mounting pins. The device may include a mounting section that is coupled to a brake carrier, a first projection and a second projection. The first projection extends from one region of the mounting section to a region near a longitudinal end of the brake pad to thereby exert a radially inward force against the brake pad. The second projection extends from another region of the mounting section to an inner surface of the brake caliper to thereby exert a biasing force against the brake caliper.

Abstract: A disc brake for a vehicle axle includes a brake rotor, a brake caliper that straddles the brake rotor, a wheel hub, and a plurality of brake rotor mounting elements that couple the brake rotor to the wheel hub. The brake rotor includes a friction ring portion and a rotor mounting portion radially inward of the friction ring portion. The rotor mounting portion is formed on a radially inner circumference of the brake rotor, and includes a plurality of splines extending radially inward toward an axis of rotation of the brake rotor and a radially inward extending axial motion limiting feature disposed between each adjacent pair of the plurality of splines.

Abstract: An improved bracket assembly for receiving a brake assembly and a brake actuator is provided. The bracket assembly includes a tube configured to receive a camshaft of the brake assembly and an actuator mounting bracket disposed proximate a first end of the tube. The actuator mounting bracket is configured for coupling to the actuator and defines an aperture configured to receive the tube. The bracket assembly further includes a brake spider mounting bracket disposed proximate a second end of the tube. The spider mounting bracket includes a body defining inboard and outboard sides, is configured to receive a brake spider on the outboard side and defines an aperture configured to allow the tube to extend therethrough. The spider mounting bracket further includes a neck extending from the inboard side of the body that is configured to receive the tube and positions the weld away from the body to reduce stress.

Abstract: A system and method are provided for mounting, removing and retaining brake pads in disc brakes, such as air-operated disc brakes utilized on commercial vehicles, in a manner which does not require the use of separate brake pad retaining devices while providing positive retention of the brake pad. A preferred embodiment includes a brake caliper mount having brake pad abutment surfaces having radially-oriented and lateral grooves which permit a brake pad with corresponding projections on is lateral sides to be inserted through an opening of the brake caliper into the radially-oriented grooves until the backing plate projections are aligned with the lateral groove, and advancing the brake actuator behind the brake pad to place the brake pad in an operating position in which the actuator prevents the brake pad from realigning with the radially-oriented grooves until the actuator is retracted to permit brake pad extraction.

Abstract: A brake system and a valve device for a brake system are provided which provide at least partial front brake actuation in the event of a failure in the front brake pneumatic supply circuit. The valve device may be configured as a biased orifice double check valve which permits compressed air flow from the front brake pneumatic supply circuit to a front brake actuator during normal brake operation, but in the event of lack of sufficient front brake pneumatic pressure permits compressed air to be supplied to the front brake actuator from a rear brake pneumatic supply circuit, as well as permitting compressed air in the front brake actuator to be ventilated back through the rear brake pneumatic supply circuit when the brake is released.

Abstract: A brake spider for a drum brake is provided. The brake spider includes a mounting portion configured for mounting the spider to a vehicle frame and an anchor pin support portion extending from the mounting portion. The mounting portion defines an aperture centered about a first axis and configured to receive a vehicle axle extending therethrough along the first axis. The anchor pin support portion includes a pin receiving section defining a bore centered about a second axis and configured to receive an anchor pin extending therethrough along the second axis. The pin support portion further includes bracket support sections extending axially from opposite sides of the pin receiving section. The bracket support sections face one another and diverge from one another approaching the mounting portion of the spider.

Abstract: A fluid pressure operable actuator includes a housing, with an end wall, and a pushrod projecting through an opening in the end wall for reciprocation upon service pressure application or release. A shield, configured as an annulus, is disposed on the pushrod to restrict contamination of an interior chamber of the actuator housing through a gap existing between an edge of the opening and a pushrod outer surface. To facilitate connecting the shield and the pushrod together, the annulus has a slit with an enlarged void at a radially outer end of the slit. This enlarged void engages an outer pushrod surface as the shield and the pushrod are joined.

Abstract: A disc brake for a motor vehicle is provided. The disc brake includes a brake disc, a brake caliper configured to straddle the brake disc, a tappet carried by the brake caliper and arranged to push a brake pad against the brake disc, and a bellows provided between the brake caliper and the tappet to seal a gap between the brake caliper and the tappet. A layer of flexible thermal insulation material may be provided between the bellows and the tappet. The layer of flexible thermal insulation material is configured to protect an outer surface of the bellows facing the brake pad from exposure to heat. Alternatively, the bellows may include a layer of flexible thermal insulation material on which an elastomer layer is formed. The layer of flexible thermal insulation material is configured to face the brake pad.