Abstract: In order to safely and conveniently assemble and service new design spring brake actuators having power springs located in the middle of the actuator, the actuator's rear chamber cover must be able to withstand high localized forces from tools such as power spring compression rods. A reinforcement and method for its installation is provided, in which a plurality of reinforcement plates is stacked on the rear chamber cover about a tool-insertion aperture, and the outermost plate is crimped about the aperture, thereby securing the plates to the rear chamber cover in a cost- and time-efficient manner. Preferably, the lip of the rear chamber cover aperture is stamped when the cover is formed such that the lip protrudes axially outward to help assure that the lip is captured between the crimped reinforcing plate on one side and the remaining reinforcing plates on the other side.

Abstract: An improved self-adjusting automatic slack adjuster for reducing slack in the brake of a vehicle is provided, in which an easily accessible external operating feature actuates a ball detent clutch to permit the automatic slack adjuster's adjustment mechanism to be readily disengaged, so as to allow smooth release and retraction of the brake linings of a vehicle brake without damage to the adjustment mechanism's components. When the torque applied to the external feature exceeds a predetermined torque, the balls of the ball detent clutch move out of their retaining detents, thereby disengaging the slack adjuster's worm shaft from the adjustment mechanism and permitting brake shoe retraction without resistance from the adjustment mechanism.

Abstract: An improved self-adjusting automatic slack adjuster for reducing slack in the brake of a vehicle is provided, in which an easily accessible external operating feature permits the automatic slack adjuster's one-way clutch assembly to be readily disengaged to allow smooth release and retraction of the brake shoes of a vehicle brake without damage to the one-way teeth of the clutch assembly. When the external feature is operated in a brake release direction, the motion of the feature is translated into a motion which axially displaces an output part of the one-way clutch away from an input part of the clutch a distance sufficient to disengage the parts' one-way teeth, thereby disengaging the one-way clutch to permit brake shoe retraction without resistance from the one-way clutch.

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: A drum brake shoe has first and second webs, with the first web including a first end section to be located adjacent a brake shoe actuation element, a second end section to be located adjacent a brake shoe anchor element, and a central section extending between the first and second end sections. Similarly, the second web includes a first end section to be located adjacent the brake shoe actuation element, a second end section to be located adjacent the brake shoe anchor element, and a central section extending between the first and second end sections of the second web. At least one lining table is disposed at circumferentially outer portions of the first and second webs, and a pin or other return spring mounting is provided by at least the first web.

Abstract: An anti lock braking system for commercial vehicles is described. The system includes a rear axle brake assembly having a rear brake for each rear wheel, a relay valve for controlling rear axle brakes and a plurality of pressure modulator valves operatively connected to the relay valve, each having an outlet connected to one of the rear brakes. Multiple connector cartridges are used to sealingly connect the relay valve to each of the pressure modulator valves. The connector cartridges have a first end defining a non rotation-dependent fitting, such as a cartridge fitting, cooperating with a corresponding port cavity to form the sealed connection.

Abstract: A cam for a brake is provided that allows for greater brake shoe travel and thicker brake linings while providing the same or greater mechanical force as compared to conventional cams. One or more lobes of the cam include multiple portions having varying profiles in axial cross-section. The variation in the cam profiles results in a cam in which the outermost ends or tips of the lobes are longer than in conventional cams yet retain the same mechanical strength.

Abstract: A mid-power spring brake actuator includes first, second, and third actuator housing portions, with the first actuator housing portion interposed between the second and third housing portions. A parking brake release actuator is received within the third housing portion, and a connecting shaft is attached at a first end to the parking brake release actuator and extends through a dividing wall defined by the first housing portion. A service brake apply actuator is received within at least one of the first and second housing portions. Between the dividing wall defined by the first housing portion and a second end of the connecting shaft, a brake actuator spring is provided, and a service brake actuation chamber is interposed between the brake actuator spring and the service brake apply actuator. A parking or emergency brake de-actuation chamber is defined between the parking brake release actuator and the first housing portion.

Abstract: A spring-type brake actuator for a pneumatically-operated vehicle brake is provided, with a brake actuator spring located on a front side of the actuator's intermediate flange, between a service brake actuator and a parking brake release actuator. The spring is captured between the intermediate flange and a retaining plate which is connected to the parking brake release actuator via a shaft through the intermediate flange. Because the retaining plate and parking brake release actuator are connected to one another on opposite sides of the intermediate flange, spring expansion is checked, thereby increasing safety during actuator production and servicing by virtually eliminating the potential for uncontrolled spring energy release. The actuator configuration also reduces structural loads on the rear portion of the housing and shifts spring and housing weight closer to the vehicle brake, permitting simpler designs and use of alternative materials, such as plastic or aluminum to lower costs.

Abstract: A guide pin for a sliding disc brake caliper and a carrier for the caliper are attached together by generating a difference in temperatures between a section of the guide pin and a section of the carrier. The section of the guide pin is then inserted into an aperture defined in the section of the carrier. Upon achieving or restoring thermal equilibrium between the guide pin and carrier sections, contact pressure between the section of the guide pin and a surface of the aperture is produced so as to secure the guide pin to the carrier and resist separation of the guide pin from the carrier.

Abstract: An improved seal/bearing arrangement employs an O-ring type seal which has segmented fingers. The seal ring has a recess which is sized to mate with a corresponding projecting lug of a bore use, for example, in brake actuator mechanisms. The seal ring can be made from synthetics such as polyamides and polyethylenes. The fingers are so arranged that locking of the seal rings in the bore occurs with insertion of a sliding, oscillating and/or rotating shaft or the like through the rings.

Abstract: A warning system is adapted to indicate disc brake and wheel component incompatibility. The system includes an element having a section that is disposed so as to extend between a non-rotating disc brake component and a rotating contour of the wheel component at a location of minimum clearance between the non-rotating disc brake component and the wheel component. Optionally, the warning system defines part of a brake pad wear indication device.

Abstract: A brake actuator mechanism has an inner shaft received at least partially within an outer shaft. The overload protection device is disposed between the inner shaft and the outer shaft. The device selectively couples the inner shaft and the outer shaft so that when the outer shaft receives a torque beyond a predetermined limit, the device allows the outer shaft to rotate about the inner shaft without rotating the inner shaft.

Abstract: A pneumatically- or electrically-actuated disk brake, in which a mounting frame supports a brake caliper and a torque plate secures the mounting plate to an axle, are arranged such that fasteners securing the mounting frame to the torque plate are oriented essentially perpendicular to the axle's longitudinal axis. Between the mounting frame and the torque plate are arranged locating features and corresponding recesses which constrain relative motion between the frame and the plate in at least two degrees of freedom. The locator features may include a shear sleeve or locator pin capable of constraining two degrees of motion, and parallel and perpendicular ridges arranged to constrain motion in at least three directions. The locator features aid in avoiding stress concentrations and distortions in the brake mount and caliper during brake application, and improve brake pad wear by better maintaining an optimum geometry of the pads relative to the brake rotor.

Abstract: A pad shield is mountable over an access opening provided in a disc brake caliper and includes a pair of shell sections, a bridge extending between and interconnecting the shell sections, and a resiliently deformable spring also extending between and interconnecting the shell sections. By way of such a construction, upon mounting the pad shield in position over the access opening, the pad shield can be resiliently retained in place by counterbalanced forces acting on the shell sections, the bridge, and the spring. These forces cooperate to retain the pad shield on the caliper, in an essentially vibration-free and noiseless manner, by way of a component that already exists on the brake and without any need for additional parts protruding beyond a current caliper profile.

Abstract: A disc brake assembly wear indicator configured to be examined by physical contact, i.e. touch, as well as by eyesight to determine wear of the brake assembly friction couple. Physical markings are provided on the assembly carrier and caliper in locations selected so that the tactile-sensible markings are furthest away when the friction couple is new or unknown and adjacent each other when the friction couple wear is at the minimally acceptable level.

Abstract: A mid-power spring brake actuator includes first, second, and third actuator housing portions, with the first actuator housing portion interposed between the second and third housing portions. A parking brake release actuator is received within the third housing portion, and a connecting shaft is attached at a first end to the parking brake release actuator and extends through a dividing wall defined by the first housing portion. A service brake apply actuator is received within at least one of the first and second housing portions. Between the dividing wall defined by the first housing portion and a second end of the connecting shaft, a brake actuator spring is provided, and a service brake actuation chamber is interposed between the brake actuator spring and the service brake apply actuator. A parking or emergency brake de-actuation chamber is defined between the parking brake release actuator and the first housing portion.