Abstract:
An external, multi-caliper brake for positive torque controlling as well as for controlling the rotation of a shaft is shown in the preferred brake embodiment of this invention as having a hub arranged to be mounted to the shaft with a longitudinally centrally located, finned friction disc mounted to the hub. A brake housing supports multiple brake calipers which are shown as including diaphragm operated, fluid pressure actuated pistons carrying brake pads which are caused to frictionally engage with the friction disc to rotationally control the shaft. The preferred friction disc is formed of two opposed, interlaced, internally finned component discs to create a serpentine, radial and circumferential, air cooling path for the friction disc and provide better heat transfer and brake efficiency. Another embodiment includes double fins to better cool not only the friction disc but the external calipers themselves. The calipers include quick brake pad change apparatus by use of pinned pad supports and positioning bosses.

Description:
BACKGROUND AND SUMMARY 
     The present invention relates most generally to torque and/or rotational control devices such as clutches or brakes, generally to the overall configuration or assembly, friction disc cooling, and pad mounting for clutches or brakes, more particularly to caliper brakes, and most particularly to tension or torque control of external caliper brakes. 
     It is a continuous problem to provide clutches or brakes which are efficient, have high ability to transfer the heat energy generated in the engagement process and/or in a constant slipping arrangement, and are easy to maintain and operate. The present invention provides such apparatus. 
     The device of the present invention, in its most preferred brake form, is then an external, multi-caliper brake arranged to provide controlled torque to a shaft including a hub arranged to be mounted to this shaft. A longitudinally centrally located, internally finned friction disc is in turn mounted to the hub. The brake housing, in a preferred brake form, supports multiple brake cylinders or calipers, each of which in the most preferred form includes a diaphragm operated, fluid pressure actuated piston carrying a brake pad. The external calipers in the most preferred brake embodiment are then fluid actuated to frictionally engage the longitudinally centrally located finned friction disc and control the torque and/or rotation of the shaft. The multiplicity of calipers is for the intended purpose of broadening the range of torque and rotational control. 
     The friction disc described then provides increased cooling and increased brake efficiency by means of a finned arrangement. In the most preferred brake form, the friction disc is formed of two, opposed, interlaced, finned portions to create a serpentine, radial and circumferential air cooling path for the friction disc and provide better heat transfer and increased brake efficiency. Another preferred brake embodiment includes double sided fins to better cool not only the frictional disc itself but the external calipers themselves. 
     In addition to the overall assembly feature of the brake described and the particular feature of the finned disc, the brake described provides quick pad change and maintenance by use of a pinned pad support approach. 
     It is then an object of the present invention to provide more efficient torque and/or rotational control apparatus. 
     It is a further object of the present invention to provide torque and/or rotational control apparatus having increased heat transfer characteristics. 
     It is a further object of the present invention to provide torque and/or rotational control apparatus which is more easily maintained. 
     It is a further object of the present invention to provide torque and/or rotational control apparatus which has increased overall efficiency. 
     It is a further object of the present invention to provide torque and/or rotational control apparatus which has increased overall cooling characteristics. 
     These and further objects and advantages of the present invention will become clearer in the light of the following detailed description of illustrative embodiments of this invention described in connection with the drawings. 
    
    
     DESCRIPTION OF THE DRAWINGS 
     The illustrative embodiments of the present invention may best be described by reference to the accompanying drawings where: 
     FIG. 1 is a front elevational view of a four caliper double sided brake constructed according to teachings of the present invention. 
     FIG. 2 is a cross-sectional view of the brake of FIG. 1 according to section lines 2--2 of FIG. 1. 
     FIG. 3 is a partial cross-sectional view of a portion of the brake of FIG. 1 according to section lines 3--3 of FIG. 1. 
     FIG. 4 is a front elevational view of the finned frictional disc according to the present invention as utilized in the brake of FIGS. 1, 2, and 3. 
     FIG. 5 is a cross-sectional view of the finned frictional disc of FIG. 4 according to the section lines 5--5 of FIG. 4. 
     FIG. 6 is a partial sectional view of a mounting for the brake of FIG. 1 according to section lines 6--6 of FIG. 1. 
     FIG. 7 is an exploded perspective view of the brake pad arrangement of the brake of FIG. 1. 
     FIG. 8 is an exploded perspective view of the hub and finned frictional disc arrangement of the brake of FIG. 1. 
     FIG. 9 is a partial plan view of an eight caliper double sided brake, also constructed according to the teachings of the present invention. 
     FIG. 10 is a partial sectional view of the brake of FIG. 9 according to section lines 10--10 of FIG. 9. 
     FIG. 11 is a partial sectional view of the brake of FIG. 9 according to section lines 11--11 of FIG. 9. 
     FIG. 12 is a partial plan view of an alternate embodiment finned brake friction disc according to the present invention as utilized in the brake of FIGS. 9, 10, and 11. 
     FIG. 13 is a sectional view of the finned brake friction disc of FIG. 12 according to the section lines 13--13 of FIG. 12. 
    
    
     All figures are drawn for ease of explanation of the basic teachings of the present invention only. The extension of the figures with respect to number, position, relationship, and dimensions of the parts to form preferred embodiments will be explained or will be obvious to those skilled in the related technologies from the explanation given. 
     Where used in the various figures of the drawings, the same numerals designate the same or similar parts. Furthermore, when the terms &#34;right&#34;, &#34;left&#34;, &#34;front&#34;, &#34;back&#34;, &#34;vertical&#34;, &#34;horizontal&#34;, &#34;top&#34;, or &#34;bottom&#34;, and similar terms are used herein, it should be understood that those terms have reference only to the structure shown in the drawings as it would appear to a person viewing the drawings and are utilized only to facilitate describing the invention. 
     DESCRIPTION 
     In the figures, an external caliper brake is shown and generally designated 10. Brake 10 includes the parts of: shaft 12 to which braking force is desired to be applied and which is desired to be rotationally controlled; hub 14 forming part of the connection between brake 10 and shaft 12; brake friction disc 16 connected to hub 14; and a plurality of external caliper type brake actuators or cylinders, for example eight are shown as 18-25. Each brake cylinder 18-25 includes a substantially identical piston 26, fluid fittings 28 of various configurations, fluid connection or air lines 30 of various lengths and configurations, and brake friction lining or brake pad 32 engaged by a first face of piston 26 to allow the introduction of pressurized fluid (air in the preferred embodiment) into lines 30 by a conventional controlled source not shown, through fittings 28, to apply pressurized fluid (air) to piston 26 by means of diaphragms 33 to allow pistons 26 to frictionally engage brake pads 32 against the braking surface of friction disc 16 and apply controlled frictional pressure to thereby apply braking power to shaft 12. 
     It is then recognized that brake 10 includes opposed but separated, frictionally engaged wear surfaces, with one of the wear surfaces being the piston 26 operated, replaceable brake pads 32 and the other wear surface being the opposed surface of brake friction disc 16. 
     More particularly, fluid (air) connections 30 are connected to fittings 28 which screw into bladder cylinder caps 34 which connect to cylinder housings 35 by means of screws or bolts 38 and which in turn are mounted to and form a part of an external housing 36 of brake 10 by means of a plurality of screws or bolts 100. As shown, housing 36 is in the form of rings mounting the remaining parts. Brake 10 may then be conventionally mounted to or in a further housing, motor, or other environment to apply a braking force to or to rotationally control shaft 12 in a conventional manner. 
     With this background, the novel differences and subtleties of the present invention over known prior brakes or clutches can be appreciated by those skilled in these technologies. One of such novel differences and subtleties of the present invention relates to the overall configuration or assembly of brake 10. 
     In its overall assembly, it may be noted first that brake actuating cylinders or calipers 18-25 are external or exterior of brake housing 36 and outside of the brake 10. Therefore, these calipers are furthest from the heat source of the frictional engagement between brake friction disc 16 and brake pads 32 and allow increased heat transfer and brake efficiency. 
     The longitudinally centrally located brake friction disc 16 of the overall assembly of brake 10 of a finned configuration has also been found to provide an increased heat transfer and efficiency for brake 10. 
     Still further with regard to the overall assembly and this novel and subtle feature of brake 10 according to the present invention, a pinned brake pad connection assembly combines with the external calipers 18-25 and the internally positioned and finned brake disc 16 to allow a rapid and quite simple brake pad change, thus reducing replacement time, increasing brake utility, and allowing ease of maintenance. 
     Still further, the contribution of a diaphragm operated, external caliper type brake to the overall assembly of brake 10 has been found to provide a brake always ready to work by eliminating the disadvantage of a spring return working against the applied braking force. That is, with the diaphragm approach, a minimum gap will automatically be maintained between the friction disc 16 and the brake pads 32 by use of the air between these two moving surfaces and the differential effect of these two moving surfaces. A minimum gap is then maintained, and the brake is always ready to work with a high efficiency. 
     This combination, configuration, and overall assembly has been found to yield surprisingly and satisfyingly high braking efficiency and to allow a brake such as brake 10 according to the present invention which is easy and simple to maintain, allows rapid interchange of the wear parts, including the brake pads, provides increased efficiency, increased heat transfer characteristics, increased overall cooling characteristics, and greater heat dissipation. 
     With the foregoing explanation, the next novel feature and subtle difference of the present invention may be explained and understood by those skilled in the related technologies. This next feature is that the longitudinally centrally arranged friction disc 16 of the present invention is of a finned configuration. In particular, brake friction disc 16 in a first embodiment shown is in the form of two single sided, similarly configured, component discs 40 having radially extending fins 42 projecting perpendicularly from one side of disc 40. This configuration then allows a dramatically simplified casting over previous known internal cavity discs while outperforming them. 
     Disc 40 then has an outer edge or periphery 44 and an inner circumference or edge 46. Adjacent the center of disc 40, adjacent inner edge 46 and in an integral ring of material 48, are formed a plurality of mounting bores 50 at regular intervals. Mounting bores 50 are then formed, for example, at the 120° /240° /360° circumferential points, circularly around inner edge 46, but out of radial alignment with fins 42 to thus allow the two similarly or identically configured discs 40 to form a single interposed fin, friction disc 16 according to the present invention, as is also explained elsewhere. 
     Also formed in ring 48 are a plurality of circumferentially elongated ventilation or air cooling entry bores or ports 52, 54, and 56. Cooling bores 52, 54, and 56 are then interrelated with mounting bores 50 such that cooling bore 52 is approximately at the 180° circumferential point, and cooling bore 54 is approximately at the 300° circumferential point, and cooling bore 56 is approximately at the 60° circumferential point. 
     Fins 42 are then formed from relatively thin upstanding members which radially extend substantially from a position just beyond ring 48 adjacent the inner disc edge 46 to adjacent the outer disc edge 44, but with end space for the passage of air circumferentially around disc fins 42 when disc 40 is in rotational operation as a part of friction disc 16, as is also explained elsewhere. 
     Each friction disc 16 is then preferably comprised of two substantially identical, single sided component discs 40 overfitted and interrelated to circumferentially regularly interweave fins 42 in a longitudinally spaced relation. Also, the fins 42 extend from the surface of their respective disc 40 a distance along the longitudinal axis of shaft 12 which also allows the passage of air around the longitudinal ends or internal edges of the fins. That is, the fins 42 do not extend the entire longitudinal distance between the facing discs 40, and thus the fins 42 do not touch the surface of the opposing discs 40. Fins 42 then form a true heat radiating fin, and not a bridging, heat conductive path between the surfaces of opposing discs 40. This is important to the present invention. That is, with the spacing of the fins 42 being less than the spacing between the component discs 40, thermal contact of the heat radiating fins 42 of the first component disc 40 with the second component disc 40 and direct heat transfer therebetween is prevented. The interrelationship of the two discs 40 forming friction disc 16 then is of opposed and alternate projections (fins 42) having internal edges or ends spaced from the surface of the opposing disc 40. As shown, a serpentine air path is then created. 
     A cooling cavity is then formed between intake ports 52, 54, and 56 formed adjacent the center of friction disc 16 between the inner surfaces of the first and second component discs 40 of friction disc 16, and the periphery of component discs 40. As friction disc 16 is then rotated about its axis, air can enter the air cooling chamber formed, as described above, through the cooling air entry ports 52, 54, and 56, pass through the air cooling chamber by a serpentine path, radially and also circumferentially, between the first and second component discs, and around the heat radiating fins 42 which are arranged in a meshed but spaced relationship in the air cooling chamber, past the peripheries of the first and second component discs 40, and to the atmosphere to allow increased heat transfer, cooling and efficiency of the device 10. 
     To assemble discs 40 to form friction disc 16, discs 40 are arranged with fins 42 facing one another and moved in an opposed fashion upon hub 14. As shown, hub 14 includes a tab 58 extending radially outward of hub 14. Tab 58 is then captured by opposed rings 48 of opposed discs 40 allowing bolts 106 to pass through opposed bores 50 and through bores 60 in tab 58. Because of the designed nonalignment of fins 42 with bores 50, fins 42 of opposed discs 40 then automatically interweave in a regular, alternate, overfitted, and interrelated manner as shown and described without the necessity of alignment. Brake housings 36 and brake calipers 18-25 may then be assembled to encapsulate friction disc 40. 
     With the foregoing, a further subtlety and novel difference of the friction disc 16 of the present invention can be explained and understood. With the interposed fins 42 and serpentined, radial and circumferential path described, an increased surface cooling area is used to thereby increase the cooling efficiency of brake 10. Further, it will now be appreciated that cooling air entering friction disc 16 adjacent hub 14 and through cooling ports 52, 54, and 56 can then move through friction disc 16 not only radially, as has been accomplished in known prior brakes, but also circumferentially as illustrated in the drawings. This combination of a radial and circumferential movement of cooling air then also allows a mixing and turbulence which has also been found to increase efficiency. It has then been found that the present design takes advantage of a higher proportion of the theoretical cooling area available, increases residence time of cooling air versus cooling surfaces, and operates by conduction and convection rather than by conduction alone. Further, it has been found that the faster shaft 12 moves, the more braking power may be required. It has further been found that the faster shaft 12 moves, the more heat dissipation is achieved by the design of the present invention at least through an increased turbulence. 
     With the foregoing explanation, the next novel feature and subtle difference of the present invention may be explained and understood by those skilled in these technologies, that of the pinned pad arrangement. 
     Calipers or cylinders 18-25 include brake pads 32 shown in a pentagonal shape with the radially outward edge rounded. Four notches 62-65 are formed, one to each side, of brake pad 32, with notch 64 formed in the rounded radially outward edge. 
     Piston 26 is similarly shown as pentagonal in shape and including two bosses 68 and 70 formed in generally radial alignment, with boss 68 formed radially outward of boss 70. That is, bosses 68 and 70 are formed on a first face of piston 26 adjacent the opposed wear surfaces formed by pads 32 and friction disc 16. At generally the same radial position on piston 26 are two circumferentially spaced bores 72 and 74. Pins 76 and 78 are pressed into and carried by brake housing 36 and in cylinder housing 35 in particular to extend longitudinally of brake 10 and thus parallel to shaft 12. Piston 26 includes an outwardly facing reduced portion 80 which interfits with a bore 82 in cylinder housing 35. 
     To assemble brake cylinders 18-25, as reduced portion 80 of piston 26 is then inserted into bore 82, pins 76 and 78 are inserted into bores 72 and 74, respectively. Pistons 26 then reciprocally move upon pins 76 and 78, as is also explained elsewhere. Brake pad 32 may then be placed upon piston 26 such that boss 68 is positioned within notch 64, boss 70 is positioned within notch 62, pin 76 is positioned within notch 63, and pin 78 is positioned within notch 65. Brake pad 32 is then uniquely captured upon piston 26 as between bosses 68 and 70 and pins 76 and 78 and also reciprocally moves on pins 76 and 78. 
     It may now be appreciated that the replaceable brake pad 32 arrangement of the present invention is useable in various environments and devices including opposed but separated frictionally engaged wear surfaces, where at least one of the wear surfaces includes a replaceable pad, such as 32, mounted adjacent an opposed wear surface, such as friction disc 16. 
     The length of pins 76 and 78 is such that they extend to the end of the stroke of piston 26 closest to friction disc 16, and include a further length to extend into the replaceable brake pads 32 carried by pistons 26 to then capture and position replaceable pads 32 over the entire stroke of pistons 26. Pins 76 and 78 must then be of an overall length just less than the minimum separation distance between the face of piston 26 and the opposed wear surface of friction disc 16, at the minimum extension of piston 26 within cylinders 18-25. 
     It can then be further appreciated that the change of replaceable brake pads 32 according to the present invention may be accomplished without the actual removal of any brake parts. This is done by simply loosening screws 100 to thereby retract pins 76 and 78 a distance only equal to the thickness of pads 32. In this fashion, pins 76 and 78 will be withdrawn from pads 32, and the pads may be removed by hand. Since cylinders 18-25 are exterior of brake 10 and since the loosening of screws 100 provides replacement access to brake pads 32, new pads may then be slipped onto bosses 68 and 70, the screws or bolts 100 retightened, and a pad change has been accomplished without the actual removal of any brake part of brake 10. 
     Another subtle feature and novelty of the pin arrangement according to the present invention may now be appreciated by those skilled in the related technologies. Utilizing capturing bosses 68 and 70 may prevent replaceable brake pad or brake lining 32 from actually falling off the face of piston 26 when the lining wear is such as to maintain only a tenuous grip by pins 76 and 78. Bosses 68 and 70 then yet retain a positioning hold on replaceable brake pads 32, and aid in preventing pads 32 from falling off. That is, since capturing bosses 68 and 70 are arranged to extend in the direction of pins 76 and 78 a distance approximately equal to the desired replacement pad thickness at the desired time of pad replacement, bosses 68 and 70 retain their positioning hold on replaceable brake pads 32 over the intended life of the pads. 
     Also because bosses 68 and 70 are arranged to extend from the face of pistons 26 in the direction of pins 76 and 78 a distance designed to be approximately equal to the minimum pad replacement thickness, bosses 68 and 70 are arranged to frictionally contact and rub on friction disc 16 just before pad 32 disappears through use. The attendant metal on metal squeal can then be an audible signal to an operator that new brake pads 32 are needed. 
     Other conventional connection and/or mounting parts 102, 104, 106, 108, 110, 114, 116, 118, and 120 are provided along with mounting and access bores 112 formed around the outer periphery of brake housing 36. Bores 112 are then used for various purposes, for example to allow the positioning of air lines 30 therethrough. 
     It will further be recognized that mounting studs 110 may be suitably connected to a device, platform, or other means against which the rotational movement or slipping of shaft 12 is desired to be controlled, and true positioning of external housing 36 can be achieved by means of shifting nuts 114. 
     It is now clear that the teachings of the present invention are not restricted to the numbers of calipers as shown. For example, the utilization of the teachings of the present invention with respect to an eight caliper double sided brake is illustrated in FIGS. 9-13 where the same or similar parts are given the same or similar numbers. It is then clear that the extension of the present invention with respect to other arrangements is well within the skill of those familiar with related technologies. 
     The embodiment of FIGS. 9-13 does, however, provide an additional advantage. As seen, a second set of exterior fins 42a are provided on friction disc 16. Exterior fins 42a then extend externally of friction disc 16 and adjacent the external calipers shown to thereby cool the external calipers as friction disc 16 rotates. Thus, the friction disc 16 of the FIGS. 9-13 embodiment not only provides the advantages given with respect to the friction disc of FIG. 4, but the additional advantage of additionally cooling the external calipers by use of external fins 42a. 
     Now that the basic teachings of the present invention have been explained, many extensions and variations will be obvious to one having ordinary skill in the related technologies. For example, although the present invention has been explained with respect to a brake, it is now clear that the teachings apply to clutches also. That is, the present invention then applies to devices for providing rotational control between first members and second members, with at least the first member being rotatable about an axis. In the brake described, the first and second members may comprise the shaft 12 and brake housing 36. Generally, however, all that is necessary is that one member include a friction disc, such as friction disc 16, for controlled, selective contact with a friction engagement surface on another member, such as pads 32. It will then be recognized that a friction disc could be a frictional member of a clutch and the other friction engagement surface be the clutch pads. 
     Further, although the present invention has been described with respect to a shaft to be rotationally controlled, it is now clear that the present invention is general in application and therefore provides rotational control between various members, including shafts and hubs, or hubs and hubs, or hubs and shafts, or other like combinations, and it does not matter which is a stationary member and which is desired to be rotationally controlled with respect to the other. 
     Thus, since the invention disclosed herein may be embodied in other specific forms without departing from the spirit or general characteristics thereof, some of which forms have been indicated, the embodiments described herein are to be considered in all respects illustrative and not restrictive. The scope of the invention is indicated by the appended claims, rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are intending to be embraced therein.