Abstract: A method of monitoring lateral force of a coil spring having a body and opposing end coils is disclosed. A fixture includes a base defining a planar surface with a shaft that extends from said planar surface at a normal angle to said planar surface. An axis defined by the coil spring is aligned with the shaft. Angular displacement from the shaft of an end coil is measured, and the angular displacement is correlated with a lateral force value.

Abstract: A brake monitoring assembly and method for monitoring a brake system of a train includes a plurality of train bogeys supporting each train car, each bogey having a wheel axle supporting wheels engaging a train track. Each wheel axle includes a tread brake and a disc brake. A tread brake actuator includes an extendable tread brake pushrod for actuating the tread brake. A disc brake actuator includes an extendable disc brake pushrod for actuating the disc brake. A pneumatic system provides pneumatic pressure for actuating the brakes and includes a sensor for monitoring pressure. Each brake actuator includes a sensor for detecting length of extension of a pushrod. A controller identifies a condition of the actuators when the pressure detected by the sensor is inconsistent with a length of extension of any of the pushrods and signals an indicator for indicating a condition of the actuators.

Abstract: A vehicle brake monitor assembly for an air disk brake includes a brake actuator having a pushrod projecting from inside a chamber of said brake actuator. The pushrod releasably actuates a lever arm of a caliper thereby moving the disk brake into a braking position when the pushrod is in an extended position and releasing the disk brake from the braking position when the pushrod is in a retracted position. The pushrod includes a pushrod shaft and a contact member biased in a telescoping relationship relative to the pushrod shaft and the lever arm of the caliper abuts the contact member counteracting the bias of the contact member. A sensor is integrated with the assembly proximate the contact member and detects movement of the pushrod relative to the lever arm and to the pushrod shaft.

Abstract: A brake actuator assembly for an air disk brake includes an actuator housing having a pushrod that is extensible from the actuator housing. A lever arm is disposed inside a caliper housing. The lever arm is actuated by the pushrod for transferring motion from the actuator to a brake pad. A sensor element is disposed between the actuator housing and the caliper housing with the sensor element being sealably engaged to the actuator housing providing an air tight enclosure between the caliper housing and the actuator. An inspection port is disposed in the sensor element providing access to receive a visual sensor and a pressure sensor for identifying a condition of the brake actuator and for identifying a condition of the air tight enclosure.

Abstract: A vehicle brake monitor assembly for an air disk brake includes a brake actuator having a pushrod projecting from inside a chamber of said brake actuator. The pushrod releasably actuates a lever arm of a caliper thereby moving the disk brake into a braking position when the pushrod is in an extended position and releasing the disk brake from the braking position when the pushrod is in a retracted position. The pushrod includes a pushrod shaft and a contact member biased in a telescoping relationship relative to the pushrod shaft and the lever arm of the caliper abuts the contact member counteracting the bias of the contact member. A sensor is integrated with the assembly proximate the contact member and detects movement of the pushrod relative to the lever arm and to the pushrod shaft.

Abstract: A brake monitoring system and method for a vehicle having multiple axles and a plurality of brake actuators and an engine control module, each brake actuator being associated with one of the axle. The system include sensors for measuring, in real-time, brake pressure and brake lining wear, and generating first and second signals. The first and second signals are received and stored in a chassis communications module. The chassis communications module detects fault condition of the brakes as a function of the first and/or second signals and for recording the fault condition, the fault condition being one of a brake monitor warning and a brake lining warning and provides an indication of status via warning lights.

Abstract: A vehicle brake monitor assembly for an air disk brake includes a brake actuator having a pushrod projecting from inside a chamber of said brake actuator. The pushrod releasably actuates a lever arm of a caliper thereby moving the disk brake into a braking position when the pushrod is in an extended position and releasing the disk brake from the braking position when the pushrod is in a retracted position. The pushrod includes a pushrod shaft and a contact member biased in a telescoping relationship relative to the pushrod shaft and the lever arm of the caliper abuts the contact member counteracting the bias of the contact member. A sensor is integrated with the assembly proximate the contact member and detects movement of the pushrod relative to the lever arm and to the pushrod shaft.

Abstract: A vehicle brake monitor assembly for an air disk brake includes a brake actuator having a pushrod projecting from inside a chamber of said brake actuator. The pushrod releasably actuates a lever arm of a caliper thereby moving the disk brake into a braking position when the pushrod is in an extended position and releasing the disk brake from the braking position when the pushrod is in a retracted position. The pushrod includes a pushrod shaft and a contact member biased in a telescoping relationship relative to the pushrod shaft and the lever arm of the caliper abuts the contact member counteracting the bias of the contact member. A sensor is integrated with the assembly proximate the contact member and detects movement of the pushrod relative to the lever arm and to the pushrod shaft.

Abstract: A vehicle brake monitor assembly for an air disk brake includes a brake actuator having a pushrod projecting from inside a chamber of said brake actuator. The pushrod releasably actuates a lever arm of a caliper thereby moving the disk brake into a braking position when the pushrod is in an extended position and releasing the disk brake from the braking position when the pushrod is in a retracted position. The pushrod includes a pushrod shaft and a contact member biased in a telescoping relationship relative to the pushrod shaft and the lever arm of the caliper abuts the contact member counteracting the bias of the contact member. A sensor is integrated with the assembly proximate the contact member and detects movement of the pushrod relative to the lever arm and to the pushrod shaft.

Abstract: An improved diaphragm-type pneumatic brake actuator includes a flange case, a cover cooperable with the flange case, a flexible diaphragm extending between the flange case and the cover forming a lower pneumatic chamber and an upper pneumatic chamber on opposed sides of the diaphragm. A piston assembly is disposed in the cover for moving a spring between compressed and decompressed positions. A spring guide is disposed between the cover and the piston assembly in the upper chamber. The spring guide prevents direct contact of the spring with the cover to prevent formation of a corrosion cell.

Abstract: A apparatus for forming a brake actuator that includes a flange case defining a peripheral groove circumscribing a push rod movable axially in relation to the flange case whereby the push rod presents a push rod guide bushing on the bearing surfaces of the push rod guide bushing being in contact with a seal. An automatic manipulator of the apparatus moves in multi-axial directions relative the flange case. A tucking tool of the automatic manipulator holds the seal. The tool includes at least two members movable relative to one another. First member rotates around the axis of the tucking tool and presents a tucking surface for forcing the seal into the peripheral groove of the flange case. Second member gradually injects the seal into the peripheral groove and pushed the seal into the back wall of the peripheral groove.

Abstract: A driveline vehicle parking brake actuator including a reciprocable piston, a spring guide having a tubular distal portion telescopically received on the piston and a radial proximal portion which is telescopically supported within the housing by an annular wear guide, and nested cylindrical coil springs including an outer cylindrical coil spring biased between the housing and the radial portion of the spring guide and a nested inner coil spring having a greater spring rate biased between the spring guide and the piston functioning in series. The distal end of the piston is attached to a cable and the springs are compressed by hydraulic or pneumatic pressure acting against the piston.

Abstract: A method of monitoring the condition of a power spring of a pneumatic spring brake actuator of a vehicle by comparing the stroke of the push rod during normal braking and by actuating the parking brake, wherein a defective power spring is indicated when the difference in the push rod stroke falls below a predetermined minimum. The brake actuator may also include a sensor determining the push rod stroke and signal a defective power spring.

Abstract: A vehicle monitoring system for monitoring a condition of relatively moving vehicle components, particularly including the pushrod of a brake actuator, including a magnet on one of the components, a sensor on the other component within the magnetic field of the magnet generating a signal indicating a condition of the moving component, an electrically conductive coil preferably surrounding the magnet generating a current and an active RF chip connected to the coil and the sensor, thereby providing current to the active RF chip for signaling a receiver. In the disclosed embodiment of a brake actuator monitoring system, the magnet is fixed on the pushrod and the coil surrounds the pushrod and magnet.

Abstract: A brake monitoring system generally includes a plurality of brake monitors mounted on each of a plurality of brake actuators. Each brake monitor generally comprises a sleeve mounted to a push rod which moves relative to a stone shield on the brake actuator. The displacement of the sleeve relative to the stone shield is measured to determine the stroke of the brake actuator. This information is sent via an RF transmitter to a controller which determines the condition of each of the brakes.

Abstract: An apparatus for assembling a brake monitor upon a brake actuator, wherein the brake monitor includes an annular push rod sleeve having a first sensor element, preferably a magnet, and a second sensor element fixed relative to the brake actuator housing. The installation apparatus includes a push rod sleeve adjustment member which supports the push rod sleeve and movable by a servomotor, a programmable logic controller (PLC), preferably including an analog card, operably connected to the second sensor element including a power supply having a predetermined voltage. The PLC controls the servomotor to adjust the axial position of the push rod sleeve on the push rod until the second sensor element senses a predetermined voltage, and the apparatus then fixes the push rod sleeve on the push rod. The installation apparatus also locates an annular sensor sleeve within the brake actuator housing and disposes the push rod through the sensor sleeve and aligns the components of the housing, push rod, return spring, etc.

Abstract: A vehicle brake monitor for a brake actuator including a housing, a reciprocal push rod extending through an opening in the housing and a stone shield mounted in the housing opening. An annular sleeve surrounds the push rod which is integrally formed of plastic including opposed sleeve portions which are generally semicircular in cross-section and a longitudinal integral flexible hinge portion interconnecting the adjacent sides of the sleeve portions, such that the annular sleeve may be received on the push rod, and an adjustable connector element interconnecting the opposed sides of the sleeve portions. The sleeve includes an elongated magnet, preferably a ceramic magnet having face portions which are magnetized with adjacent north and south poles and the stone shield includes a Hall-effect sensor which senses the location of the sleeve as the push rod reciprocates through the stone shield.

Abstract: A brake monitoring system generally includes a plurality of brake monitors mounted on each of a plurality of brake actuators. Each brake monitor generally comprises a sleeve mounted to a push rod which moves relative to a stone shield on the brake actuator. The displacement of the sleeve relative to the stone shield is measured to determine the stroke of the brake actuator. This information is sent via an RF transmitter to a controller which determines the condition of each of the brakes.

Abstract: An improved spring brake actuator which combines the advantages of piston and diaphragm-type brake actuators having superior performance at reduced cost. The improved spring brake actuator includes a tubular flexible diaphragm having one end secured between the rim portions of the cup-shaped housing and cover and an inverted second end portion which is received around the rim portion of a cup-shaped piston and secured in sealed relation with a flexible band. The power spring is received within opposed cup-shaped portions of the piston and cover and the rim portion of the piston is biased against a generally radial portion of the cover permitting use of a power spring having increased performance.

Abstract: A brake actuator having a stone shield located within the brake actuator housing and surrounding the brake actuator piston which dampens the impact of the brake actuator piston against the end wall surrounding the end wall opening. The damping stone shield includes an annular body portion having a diameter less than the brake actuator end wall opening and opening which receives the reciprocal piston of the brake actuator and an integral radial flange which overlies the inner surface of the brake actuator end wall opening. The annular body portion of the stone shield includes a first end portion extending at least partially through the brake actuator end wall opening having an annular groove surrounding the piston and damping the impact of the piston against the end wall surrounding the end wall opening. In the preferred embodiment, the annular groove extends through the first end portion of the stone shield and is bell-shaped or tapered in cross-section having a rounded end surface.