Abstract: A support arrangement, operable to clamp a cam tube for a drum brake assembly in position relative to an adjacent vehicle component, includes a first jaw having a first pair of arms, each of which has an one opening in an inclined end section, a second jaw having a second pair of arms, each of which has an opening in an inclined end section, and a base associated with the vehicle component and having a third pair of arms. Each of the third pair of arms also has an opening in its end section. Bolts or other such fastener elements are receivable within aligned sets of openings in the first, second, and third pairs of arms, permitting displacement of the first and second jaws relative to the base upon adjustment of the fasteners so that the jaws grip the tube and clamp the tube in its proper position. A clamping process is also described.

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.

Abstract: A system and method for evaluating characteristics of an S-cam are provided. The inventive method includes the step of obtaining angle values and displacement values indicative of an angle of rotation of the S-cam and displacement of a cam follower caused by rotation of a lobe of the S-cam. The method further includes the step of determining a profile for the lobe of the S-cam responsive to the angle values and the displacement values. The method further includes the steps of computing a deviation of the profile from a desired profile for the lobe of the S-cam and determining a rate of change in the deviation of the profile. In addition, the system and method may evaluate characteristics such as the concentricity of the S-cam and power transfer characteristics of the S-cam.

Abstract: An improved approach to brake pad retention within a brake caliper is provided by a brake pad and brake caliper system in which brake pad retention features are provided on one of the brake pad or the caliper, with corresponding holes for receiving the retention features being provided on the corresponding pad or caliper part. The retention feature may be pin affixed to or integrally formed with the brake pad backing plate, about which a self-retaining spring bushing is located. The spring bushing and the corresponding retention feature receiving hole are sized so that the spring bushing is radially compressed when the brake pad is installed in the brake caliper by an amount sufficient to retain the brake pad in the caliper while still allowing the brake pad to move tangentially as necessary to transfer braking torque to the axle on which the caliper is mounted.

Abstract: An improved self-adjusting automatic slack adjuster for reducing slack in the brake of a vehicle, in which a one-way clutch assembly is arranged in the housing of the automatic slack adjuster housing such that a thin-wall region of the housing associated with the gear drive of the one-way clutch assembly is located outside of a load path through which brake applications forces are conveyed from a brake actuator to a brake cam shaft upon which the automatic slack adjuster is located. The new positioning of the one-way clutch assembly drive results in unexpectedly lower stress levels in the automatic slack adjuster, resulting a more durable slack adjuster and permitting surprisingly large increases in slack adjuster capacity rating.

Abstract: An improved automatic slack adjuster for reducing slack in the brake of a vehicle, in which a one-way clutch assembly is arranged at a side of the automatic slack adjuster housing, and one-way motion-inhibiting pawls in the one-way clutch assembly act on one-way gear teeth disposed on an inner radius of a gear wheel within the assembly whose outer circumference drives a slack adjuster unit. The incorporation of the one-way clutch within the anchor unit of the adjuster provides an automatic slack adjuster which can be produced at a reduced cost, manufactured more easily, and provides for improved adjustment performance with much reduced dependence on the lubricity of grease used.

Abstract: An arrangement for securing a carrier for a brake to an axle housing of a vehicle includes a torque plate having an attachment portion securable to the carrier and an annular mounting section securable to a backing plate on the axle housing. The annular mounting section is provided with pluralities of alignment holes and mounting slots, permitting adjustment of a torque plate clocking angle. By way of a torque plate configured in accordance with this invention, clocking angle adjustments can be made in increments of under three degrees.

Abstract: A support arrangement, operable to clamp a cam tube for a drum brake assembly in position relative to an adjacent vehicle component, includes a first jaw having a first pair of arms, each of which has an one opening in an inclined end section, a second jaw having a second pair of arms, each of which has an opening in an inclined end section, and a base associated with the vehicle component and having a third pair of arms. Each of the third pair of arms also has an opening in its end section. Bolts or other such fastener elements are receivable within aligned sets of openings in the first, second, and third pairs of arms, permitting displacement of the first and second jaws relative to the base upon adjustment of the fasteners so that the jaws grip the tube and clamp the tube in its proper position. A clamping process is also described.

Abstract: A cast iron brake caliper with improved fatigue life, and a process and process equipment for pre-stressing a cast iron brake caliper to provide improved fatigue life, is provided. In the process, a load is applied to a cast iron caliper, where the load is high enough to locally yield and plastically deform the cast iron material, but not high enough to cause material failure, such as cracking. Upon load removal, residual compressive stresses in the cast iron caliper lower the mid-point of the stress range the plastically-deformed region of the caliper sees during in-service use, and thereby lowers the peak stress seen in this region, increasing fatigue life. The process permits a cast iron brake caliper to be designed to use less material and thus fit within constrained wheel rim envelopes, without the need to resort to high cost materials or other alternative design strategies.

Abstract: An improved integral spring brake actuator and mount is provided in which a portion of the spring brake actuator is integrally formed with a connecting flange and a brake cam shaft support tube. The improved integral spring brake actuator and mount is significantly lighter than previous multi-part built-up spring brake actuators and mounting brackets, decreasing vehicle weight, eliminating the need for costly high-quality welding and lowering manufacturing costs. The integral spring brake actuator and mount may be formed from cast aluminum.

Abstract: An automatic slack adjuster one-way clutch includes a first part, which is rotatable about an axis in both a drive direction and a slip direction opposite to the drive direction, and a second part, which is driven about the axis by the first part only when the first part rotates in the drive direction. The second part is not driven by the first part when the first part rotates in the slip direction. Multiple movable teeth, carried by one of the parts, are displaceable axially relative to both of the parts and engage between teeth immovably fixed on the other of the parts. The first part may be either an input part or an output part of the clutch.

Abstract: An anchor assembly is provided that permits adjustment of the brake shoes in a drum brake to account for wear. The assembly includes first and second adjuster shafts each having a plurality of threads and first and second pilot connectors. The pilot connectors each have a plurality of threads in engagement with the threads of a corresponding adjuster shaft. The pilot connectors each engage one end of a corresponding brake shoe. Rotation of each adjuster shaft causes longitudinal movement of a corresponding pilot connector in engagement with a corresponding brake shoe along an axis to adjust a position of the brake shoe.

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: A cast iron brake caliper with improved fatigue life, and a process and process equipment for pre-stressing a cast iron brake caliper to provide improved fatigue life, is provided. In the process, a load is applied to a cast iron caliper, where the load is high enough to locally yield and plastically deform the cast iron material, but not high enough to cause material failure, such as cracking. Upon load removal, residual compressive stresses in the cast iron caliper lower the mid-point of the stress range the plastically-deformed region of the caliper sees during in-service use, and thereby lowers the peak stress seen in this region, increasing fatigue life. The process permits a cast iron brake caliper to be designed to use less material and thus fit within constrained wheel rim envelopes, without the need to resort to high cost materials or other alternative design strategies.

Abstract: A cast iron brake caliper with improved fatigue life, and a process and process equipment for pre-stressing a cast iron brake caliper to provide improved fatigue life, is provided. In the process, a load is applied to a cast iron caliper, where the load is high enough to locally yield and plastically deform the cast iron material, but not high enough to cause material failure, such as cracking. Upon load removal, residual compressive stresses in the cast iron caliper lower the mid-point of the stress range the plastically-deformed region of the caliper sees during in-service use, and thereby lowers the peak stress seen in this region, increasing fatigue life. The process permits a cast iron brake caliper to be designed to use less material and thus fit within constrained wheel rim envelopes, without the need to resort to high cost materials or other alternative design strategies.

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.

Abstract: An improved integral spring brake actuator and mount is provided in which a portion of the spring brake actuator is integrally formed with a connecting flange and a brake cam shaft support tube. The improved integral spring brake actuator and mount is significantly lighter than previous multi-part built-up spring brake actuators and mounting brackets, decreasing vehicle weight, eliminating the need for costly high-quality welding and lowering manufacturing costs. The integral spring brake actuator and mount may be formed from cast aluminum.

Abstract: A brake actuator having a plurality of actuator housing portions includes a diaphragm seal partially delimiting a parking brake de-actuation chamber and retained between adjacent portions of the housing. To produce brake actuation upon depressurization of the parking brake de-actuation chamber, a push rod extends into and out of a service brake actuation chamber upon release of fluid pressure from and supply of fluid pressure to the chamber. A clip or similar element receivable over the end section of the push rod is securable on the end section to compress the diaphragm seal axially relative to the push rod against a seat carried by the push rod while permitting a radial inner edge of the diaphragm seal to remain spaced from an outer surface of the end section.

Abstract: A cast iron brake caliper with improved fatigue life, and a process and process equipment for pre-stressing a cast iron brake caliper to provide improved fatigue life, is provided. In the process, a load is applied to a cast iron caliper, where the load is high enough to locally yield and plastically deform the cast iron material, but not high enough to cause material failure, such as cracking. Upon load removal, residual compressive stresses in the cast iron caliper lower the mid-point of the stress range the plastically-deformed region of the caliper sees during in-service use, and thereby lowers the peak stress seen in this region, increasing fatigue life. The process permits a cast iron brake caliper to be designed to use less material and thus fit within constrained wheel rim envelopes, without the need to resort to high cost materials or other alternative design strategies.

Abstract: An improved brake spider and anchor pin assembly in which weight, cost, manufacture, axle installation and maintenance is improved over prior brake spider designs. The improved brake spider is built up from light weight, relatively inexpensive stampings which are joined together, for example by welding, to form a strong built-up brake spider component. In one embodiment, two steel stampings formed with flanges and stamped strengthening ribs are welded together to form a hollow, structure which has the strength to withstand high brake force loads and large numbers of brake cycles. The built up brake spider may include one or more captured inserts in the form of anchor pin assemblies and a brake actuator rod pass-through support. The anchor pin insert may be in the form of a trunion having a middle section with a greater diameter than corresponding holes in the shell plates to preclude axial motion.