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: In an actuator for a brake system or a method for making a brake actuator, an attachment mechanism for attaching a diaphragm to a piston includes a plurality of protrusions on one of the piston and diaphragm and a plurality of cavities on the other of the piston and diaphragm, each protrusion being insertable into a corresponding cavity to attach the diaphragm to the piston. Alternatively, a retaining ring is provided that need not be precisely made and yet can attach the diaphragm to the piston securely and sealingly.

Abstract: A disc brake rotor includes at least one friction ring having a friction surface adapted for contact with a brake pad during braking, and an annular mounting portion by which the rotor is attachable to a hub. A connection permitting radial expansion and contraction of the friction ring relative to the mounting portion upon heating and cooling of the rotor is present between the friction ring and the mounting portion. This connection helps to resist cracking and subsequent failure of the rotor near its attachment to a hub.

Abstract: A disc brake for a vehicle such as a commercial vehicle, wherein the brake caliper is provided with an actuator mounting flange surface which is parallel to the brake rotor, and a corresponding pneumatic or electric actuator is provided with a mounting flange surface which is angled, such that when mounted to the caliper, the actuator is offset at a desired angle relative to the caliper and the vehicle axle on which the caliper is located. This approach to brake design reduces brake caliper production and tooling costs by eliminating multi-stage machining operations, and lowers distribution and inventory costs by permitting standardization on a single “zero degree” caliper design, thereby offsetting additional costs associated with producing and distributing brake actuators with differing mounting flange surface angles.

Abstract: A disc brake for a vehicle such as a commercial vehicle, wherein the brake rotor extends from a hub end of an axle inboard a sufficient distance to place the friction surface of the rotor and the brake caliper outside the envelope of a wheel mounted at the end of the axle. The placement of the rotor friction surface and the caliper outside the envelope of the wheel enhances brake cooling, makes the brake more readily accessible for inspection and maintenance without significant vehicle disassembly, and permits the rotor outer diameter to be extended beyond the diameter of the wheel rim, thereby lowering brake components stresses and permitting use of lighter, lower cost brake components.

Abstract: For an air-operated disc brake there is provided an internal brake actuator stroke indicator which provides an indication, readily ascertained from outside the brake caliper, of the amount of actuator stroke remaining in a disc brake apparatus before a remaining available actuator stroke limit is reached. In one embodiment, the stroke indicator is a mechanical device, readable through a sight glass in a caliper port, coupled to the brake actuator in a manner which results in rotary motion of the indicator when the brake actuator is displaced through its stroke. Alternatively, the indicator may be a rotary sensor such as an electrical potentiometer coupled to the actuator, where the potentiometer sends an electrical signal indicative of the actuator stroke to an external display, such as a remote actuator stroke display at a vehicle operator's position.

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 disc brake rotor assembly has a central carrier with a first side and a second side. At least two wear surfaces are releasably secured to the first side and at least two wear surfaces are releasably secured to the second side. A locking mechanism disposed within the central carrier selectively engages and releases the wear surfaces.