Abstract: A reporting system, employing a microprocessor, tracks the operation of an on-vehicle brake lathe and provides records of the resurfacing operations performed by the lathe. Identification of the vehicle and wheel position of a brake disk to be resurfaced are inputted using an operator interface, and stored in a temporary memory. When tool bits of the lathe are positioned to set a depth of cut, a thickness monitor indicates the resulting thickness for the brake disk, which is compared to a minimum thickness specification for the inputted vehicle and wheel position to determine whether the disk can be resurfaced to meet the specification. If so, a cutting operation evaluator monitors a continuity checker that is responsive to contact of the tool bits and the disk to determine when the resurfacing operation is complete, at which time the collected data can be reported.

Abstract: An on-vehicle disk brake lathe has a motor connected to a right-angle gearbox mounted to a body of the lathe, the gearbox in turn driving a spindle shaft through a flexible drive linkage such as a belt or chain. The spindle shaft extends parallel to a gearbox output shaft, and both are normal to an axis of rotation of the motor. The flexible drive linkage can be tensioned by adjustably mounting the gearbox to the lathe body or by use of an adjustably positioned tensioning element. A cover can enclose the flexible drive linkage. The separate gearbox allows the use of durable bearings for the spindle shaft, and allows these bearings to be spaced apart to provide a high degree of stability. The modular structure of the resulting lathe simplifies fabrication and repair, and allows use of a modular body for the lathe.

Abstract: A system and method for monitoring the contact of tool bits of a lathe with surfaces of a brake disk being machined employs a vibration sensor coupled to the lathe. Signals from the vibration sensor are processed as time-averaged segments that can be grouped within time intervals; a microprocessor employs a qualifying routine to compare the signal level to a background noise threshold value and indicates as “failed” those time periods where the average signal level is not above the background noise threshold. An accumulator records the indications over a number of intervals and compares the result to a standard to make a determination of whether the lathe is likely actively cutting the disk surfaces. To isolate intermittent, high-intensity noises, a consistency routine can check further to see whether individual segments within an interval fall within a range based on the average signal level for that interval.

Abstract: A system and method for monitoring the contact of tool bits of a lathe with surfaces of a brake disk being machined employs a vibration sensor coupled to the lathe. Signals from the vibration sensor are processed as time-averaged segments that can be grouped within time intervals; a microprocessor employs a qualifying routine to compare the signal level to a background noise threshold value and indicates as “failed” those time periods where the average signal level is not above the background noise threshold. An accumulator records the indications over a number of intervals and compares the result to a standard to make a determination of whether the lathe is likely actively cutting the disk surfaces. To isolate intermittent, high-intensity noises, a consistency routine can check further to see whether individual segments within an interval fall within a range based on the average signal level for that interval.

Abstract: A dynamic alignment monitoring system allows an operator to monitor the misalignment of an on-vehicle disk brake lathe with respect to a vehicle axis about which the disk to be machined rotates, and can allow the operator to discontinue further alignment when appropriate in order to speed the overall time of the alignment process. The system processes signals from an angular rate sensor and a tachometer, using a scaling routine to derive a LRO value corresponding to the LRO of the disk which would result from machining in the current alignment condition. A representation of the derived LRO value is displayed to the operator. An operator override can allow the operator to discontinue further alignment adjustments when an acceptable alignment condition is indicated. The system can aid the operator by also presenting a representation of an acceptable LRO value for the particular vehicle being serviced.

Abstract: A cutting head assembly holds a pair of tool bits for an on-vehicle brake disk lathe having a platform. The cutting head assembly has a platform key fixed to the platform and extending parallel to a brake disk axis of rotation. The cutting head assembly also has a plate having a plate keyway that slidably engages the platform key. Tool bit arms are adjustably mounted to the plate and support the tool bits. A locking structure connected to the plate locks the platform key with respect to the plate keyway, and the interaction of the locking structure with the plate and the platform key creates a compressive load between the plate and the platform as the platform key is locked with respect to the plate keyway.

Abstract: An alignment mechanism that employs two slant disks to adjust alignment between the axes of rotation of a lathe spindle and a wheel hub has a float plate positioned between the slant disks. Rotation of the float plate is limited with respect to a base, which affixes to the lathe spindle, and a cap, which affixes with respect to the wheel hub. Limiting rotation of the float plate prevents transfer of torque from one slant disk to the other when one slant disk is rotated with respect to the base and the cap by an alignment adjustment system to vary the angle and orientation of the misalignment between the two axes. Preventing such transfer of torque allows each of the slant disks to be independently adjusted by the alignment adjustment mechanism without applying a drag force to the slant disk.

Abstract: A device for resurfacing a rotor of a vehicle brake system while the rotor is mounted on the vehicle includes a cutting assembly and a finishing assembly. The cutting assembly has a cutting tool that is moveable between a cutting position where the cutting tool is configured to machine a surface of the rotor, and a retracted position where the cutting tool is spaced from the surface of the rotor. The finishing assembly is coupled to the cutting assembly and has a finishing head that is moveable between a disengaged position where the finishing head is spaced from the surface of the rotor, and a finishing position where the finishing head is configured to finish the surface of the rotor.

Abstract: An on-car disc brake lathe system for resurfacing a brake disc of a vehicle brake assembly includes a lathe body with a driving motor, a cutting head operably attached to the lathe body, and a drive shaft. The system also includes an alignment system having an electronic controller, input and output adaptors configured to rotate with the drive shaft, one or more adjustment discs, and an adjustment mechanism. The adjustment disc is positioned between the input adaptor and the output adaptor, and an axial alignment of the input adaptor relative to the output adaptor may be varied based on a rotational orientation of the adjustment disc. The adjustment mechanism is configured to change the rotational orientation of the adjustment disc in response to commands from the electronic controller.

Abstract: An apparatus and method for automatically compensating for the lateral runout between an on-car lathe apparatus and a vehicle hub axis including one or more stop discs that rotate with the drive shaft of the lathe and that can be selectively stopped from rotating with the shaft by a stop mechanism. In response to such stopping, one or more adjustment discs are caused to rotate in order to adjust the relative position of the axis of the lathe with respect to the axis of the disc brake assembly. In this manner, the system compensates for and corrects lateral runout that exists between two concentrically attached rotating shafts.

Abstract: An on-car disc brake lathe system for resurfacing a brake disc of a vehicle brake assembly includes a lathe body with a driving motor, a cutting head operably attached to the lathe body, and a drive shaft. The system also includes an alignment system having an electronic controller, input and output adaptors configured to rotate with the drive shaft, one or more adjustment discs, and an adjustment mechanism. The adjustment disc is positioned between the input adaptor and the output adaptor, and an axial alignment of the input adaptor relative to the output adaptor may be varied based on a rotational orientation of the adjustment disc. The adjustment mechanism is configured to change the rotational orientation of the adjustment disc in response to commands from the electronic controller.

Abstract: An on-car disc brake lathe system for resurfacing a brake disc of a vehicle brake assembly includes a lathe body with a driving motor, a cutting head operably attached to the lathe body, and a drive shaft. The system also includes an alignment system having an electronic controller, input and output adaptors configured to rotate with the drive shaft, one or more adjustment discs, and an adjustment mechanism. The adjustment disc is positioned between the input adaptor and the output adaptor, and an axial alignment of the input adaptor relative to the output adaptor may be varied based on a rotational orientation of the adjustment disc. The adjustment mechanism is configured to change the rotational orientation of the adjustment disc in response to commands from the electronic controller.

Abstract: An apparatus and method for automatically compensating for the lateral runout between an on-car lathe apparatus and a vehicle hub axis including one or more stop discs that rotate with the drive shaft of the lathe and that can be selectively stopped from rotating with the shaft by a stop mechanism. In response to such stopping, one or more adjustment discs are caused to rotate in order to adjust the relative position of the axis of the lathe with respect to the axis of the disc brake assembly. In this manner, the system compensates for and corrects lateral runout that exists between two concentrically attached rotating shafts.