CA2275480A1 - Aligned boring method for two support bearings, for brake camshafts of heavy vehicles - Google Patents

Abstract

A method and a device for aligning a first final composnent channel and a second final compose channel respectively extending through spaced apart first and second components such as bushings part of a brake system and used for rotatably supporting a camshaft. The method includes the steps of: using the first initial compose channel as a reaming guide for reaming the second initial compose channel having the second initial diameter until it becomes the second final compose channel and, once the second final compose channel has been reamed, using the second final compose channel as a reaming guide for reaming the first initial compose channel having the first initial diameter into the first final compose so that the first and second final component channels are in alignment relative to each other. The device includes a boring head mounted on a coupling shaft. A guiding sleeve defining an inner sleeve channel and a generally frustro-conical sleeve outer surface is also provided. A guiding shaft is is provided so as to be at least partially substantially fittingly and slidably insertable within the sleeve channel with the slecve channel longitudinal axis in a generally collinear relationship relative to the guiding shaft longitudinal axis. The guiding shaft has a releasable coupling mechanism for allowing releasable coupling of the guiding shaft selectively to either ose of the coupling shaft first and second longitudinal ends. The guiding sleeve is configured so as to guide the orientation of the guiding shaft longitudinal axis while allowing rotation of the guiding shaft about the guiding shaft longitudinal axis.

Description

Patent Application of Claude Drouin for a s Device and Method for Obtaining Aligned Charnels in Spaced Apart Compornents to Field of the Invention:
The present inventibn relates to the general field of alignment and is particularly concerned with a device and a method for obtaining aligned charnels in spaced apart components.
t 5 Background of the Invention:
There exists a variety of situatic. ~ S where it is desirable to use a shaft rotatably or slidably mounted within at least two spaced apart shaft supporting components. One example of such situations exisfs in the field of air brake systems for relatively large vehicles where a 2o so called "S" -type camshaft rotatably mounted within a pair of corresponding bushings components is used for activating brake pads. The bushing components in such a context are typically mounted on supporting legs attached to tlle vehicle aile sleeve.

____ _. _____., _._ .. ..__ _ _. _._ _ _ CA 02275480 2000-08-18 Some of the brake system components including the camshaft and bushing components are subject to relatively important mechanical stress during use and must therefore be periodically serviced and replaced. f3eretofore, replacement of these brake components involved replacement of the shaft with a new shaft and of the bushings cumponents with pre-bored bushings. Because of the relatively poor alignment of the bushing components once mounted on their respective supporting legs, in order to allow for eventual slidable insertion of the camshaft within the replaced bushings components and to prevent seizing thereof, it was necessary to use bushing components having relatively large bushing channels extending therethrough.
io These relatively large bushing channels create a large and often non-symmetrical peripheral clearance between the outer surface of the camshaft and the inner surface of the bushing channel. This relatively important cleârance, in turn, reduces the contact surface between the components creating a variety of drawbacks including decreased braking performance and durability. It is thus an object of the present invention to provide an improved method and device for obtaining aligned channels in spaced apart components such as spaced apart bushing components.used for supporting a camshaft part of a braking system.
Advantages of the present invention include that the proposed method and device allows an 2o intended user to obtâin aligned channels that are custom fit for a given situation, for example a given shaft. The proposed method allows the channels to be readily obtainable through a set of quick, easy and ergonomical steps without requiring special tooling or manual dexterity.

2 Furthermore, the proposed method allows for in situ forming of the channels even in thigh spaces thus reducing the need for costly manipulation and transportation.
The proposed device is specifically design so as to be manufacturable using conventionat forms of manufacturing so as to provide a device that will be economical, long lasting and generally trouble free in operation. SpeciaP features aJ-e provided for ergonomical ensruing use thereof and accuracy during the channel forming process.
When the proposed device and method are used in the field of brake components overhauling, the obtained aligned and customized channels extending tlirough the bushing components increases the contact surface between the shah and bushing channels and reduces the looseness of the shaft and bushing assembly. This, in turn, provides reduce friction and wear, increased sent and bralcing. peri'nrmance and improved component durability. It is estimated that the proposed method and device may reduce side ptay between the shaft and bushing channels from the typical 0.020 inch up to 0.005 inch.
In accordance with the present invention there is provided a method for aligning a .first final 2o component channel and a second final component channel respectively extending; through spaced apart first and second components, the first and second final component carnal having corresponding first and second predetermined final internat diameters, the first and second components being initialty provided with corresponding first and second

3 initial make up carnales extending therethrouglr, tire first and second initial make up carnals defining corresponding first and second initial internat diameters, the first and second components being initially positioraed so that the first and second initial componeirt charnels are in a generally aligned relationship relative to each other, the method comprising the: .tees oC: a) selecting the first and second components so that shoots first initial internat diameter is srnaller then the first predetennined 6na1 boarding school diameter and the second initial infernal diameter is smaller thon the second final predeternrined internai diameter; b) using the first initial make up carnal as a reaming guide for reaming the second initial make up carnal lraving the second initial diameter until it to becomes the second final cotnponent carnal having the second final internal diameter;
c) once the second final make up carnal has been rearned, using the second final make up carnal as a reaming guide for reaming the first initial cornponent carnal having the first initial diameter into the first final çomponent carnal having the first final diameter so that the first and second final compose chanurels in relative alignment ts to each other; whereby using the first initial cotnponent carnal as a rearning guide for forrrring the second final compose clraunel and thon the newly formed s-,: final cond make up carnal as a reaming guide for frrrning the first final make up charmel ensures that the first and second final make up carnals are aligned relative to each other.
zo There is also provided a method for aligning a. first final make up carnal and a second final make up carnal respectively extending thro4sgh spaced apart first and second components more specifically ttrrough tire use of a device including a boring head, the

4 boring head being mounted on a coupling shaft defining a pair of opposed coupling shaft first and second longitudinal ends; a guiding sleeve, the guiding sleeve defining an inner sleeve carnal and a generally frustro-conical sleeve outer surface, the inner sleeve charnel defining a sleeve charnel longitudinal axis; generally elongated guiding shaft s defining a guiding shaft first longitudinal end, a guirling shaft second longitudinal end and a guiding shaft longitudinal axis, the guiding shatl having a guiding-to-coupling shaft releasable coupling means for allowing releasable coupling of the guiding shaft selectively to either one of the coupling shaft first and second longitudinal ends, the guiding shaft being configured and sized so as to be at least partially substantially to fittingly and slidably insertable withir the sleeve charnel with the sleeve carnal longitudinal axis in a generally collinear relationship relative to the guiding shai ~
longitudinal axis; the guiding sleeve being configured so as to guide the orientation of the guiding shaft longitudinal axis while allowing rotation of the guiding shaft about tlie guiding shaft longitudinal axis, which the steps of using the first initial componewt 15 charnel as a reaming guide for reaming the second initial component charnel until it becomes the second final component carnal and using the second final component charnel as a reaming guide for reaming the first initial component charnel into the first final component carnal respectively involve the steps of a) positioning the guiding sleeve substantially concentrically within the first initial component cham ~ el;
2o b) with the guiding shaft first longitudinal end attached to the coupling shaft first longitudinal end, slidingly inserting the guiding shaft through the second initial component carnal until the guiding shaft second longitudinal end is at least partially inserted within the sleeve carnal; c) driving the boring head attached to the guiding shaft by the coupling shaft through the second initial make up carnal while tea guiding shaft is guided by the guiding sleeve until the boring head produces the second final make up carnal;
d) with the guiding shaft first longitudinal end attached to the coupling shaft second longitudinal end, slidingly inserting the boring head and the guiding shaft attached thereto through second final make up carnal until the boring head reaches first initial make up carnal with the guiding shaft at least partially inserted within the through second final make up carnal; e) positioning the guiding sleeve substantially concentrically within the second final compare carnal by sliding it onto the guiding shaft and at teast partially into the second final make up carnal; f) driving the boring head through the first initial make up carnal while the guiding shaft is guided by the guiding sleeve until the boring head produces the first final compose carnal.
The present invention also relates to a device for alitning about an alignment axis a first final make up carnal and a second final make up carnal respectively extending through spaced apart first and second components, the 6rst and second final make up carnals having corresponding first and second predetermined final internai diauneters, the first and second components being initially provided with corresponding first and second initial make up carnal extending therethrough, the first and second initial 2o make up carnals defining corresponding first and second initial internat diameters, the first and second components being initially positioned so that the first and second initial make up carnales are in a generally aligned relationship relative to each other, the device comprising:

x a) a boring means for boring the first and second final component channels and b) a guiding means for guiding the boring means along the alignrnent axis.
Preferably, the boring means includes a boring head defining a generally cylindrical head base, the head base denning a head base first longitudinal end, a longitudinally ~~ pposed head base second longitudinal end and a head base cylindrical wall, the head based cylindrical wall defining a head base channel extending longitudinally therethrough and a head base longitudinal axis; a set of boring blades extends generally radially from the outer surface of the head base cylindrical wall.
Conveniently, each one of the boring blades defines a tapered Made initiating section positioned adjacent the head base first longitudinal end, each blade initiating section tapering from the blade outer peripheral cutting edge towards the head base cylindrical wall in a direction leading towards the head base first longitudinal end; each blade initiating section forming a first angle having a value substantially in the range of 1.5 degrees with the outer surface of the cylindrical wall; each bla.de initiating section extending over a distance having a value substantially in the range of 1.6 centimeters; each boring blade being longitudinally angled relative to the radius of the cylindrical head base by a second angle having a value substantially in the range of 0.1 degrees. Also, preferably, the boring means 2o includes a releasable coupling means for releasably coupling the boring head to the guiding means and to a torque generating means.

Preferably, the coupling means includes a coupling shaft defining a coupling shaft first longitudinal end, a coupling shaft second longitudinal end and a coupling longitudinal shaft axis; the coupling shaft first and second longitudinal ends being botte provided with con: esponding coupling shaft first and second threaded segnents for allowing releasable threaded coupling to the guiding means at botte longitudinal ends of the coupling shaft; tea coupling shaft being configured and sized so as to be aa least partially substantially fittingly and slidably insertable into the head base carnal with the boring head positioned between the coupling shaft first and second threaded segments.
lo Conveniently, the coupling means includes a releasable locking means for releasably locking together the boring head and the coupling shaft against relative rotational movement and bi-directional axial translation therebetween so as to ensure that the boring head rotates solidarly with the coupling shaft and also for ensuring that the boring head is only allowed to translate axially relative to the coupling shaft in one predetermined axial direction.
Preferably, the releasable locking means includes at least one locking protrusion protruding substantially outwardly and radially from the outer surface of the coupling shaft and a corresponding locking groove formed in the head base cylindrical wall. Tea coupling shaft is conveniently provided with a grasp facilitating means for facilitating the grasping of the 2o coupling shaft.
Conveniently, the grasp facilitating means includes an hexagonal grasping protrusion extending outwardly & om the outer surface of the coupling shaft; the grasping protrusion s being positioned intermediate the protruding section and the coupling shaft second threaded segment; the grasping protrusion also defining an abutment edge adapted to abuttingly contact the longitudinal edge of the head second longitudinal end so as to serve as an additional locking means for limiting the relative axial translational movement between the boring head and the coupling shaft in a predetermined direction.
Preferably, the guiding means includes a guiding sleeve and a guiding shaft, the guiding sleeve having a generally cylindrical slceve wall defining a sleeve first longitudinal end, a sleeve second longitudinal end a ~~ da sleeve iongitudinal axis; the sleeve wall also defining to an inner sleeve carnal having a substantially disc-shaped cross-sectional'configuration and a generally fiustro-conical sleeve outer surface; the sleeve outer surface tapering conically in a direction leading towards the sleeve first longitudinal end.
Conveniently, the guiding shaft has a generally elongated configuration defining a guiding shaft first longitudinal end, a guiding shaft second longitudinal end and a guiding shaft longitudinal axis; the guiding shaft having a guiding-to-coupling shaft releasable coupling means for allowing releasable coupling thereof to both sides of the coupling means; tea guiding shaft having a generally cylindrical guiding shaft body defining a guiding shaft outer surface that is configured and sized for allowing the guiding shaft to be substantially 2o fittingly and slidably inserted within the inner sleeve charnel; tea guiding shaft being configured and sized so as to be inserted within the inner sleeve charnel with the sleeve longitudinal axis in a generally collinear relationship relative to the guiding shaft longitudinal axis longitudinal axis; whereby, the guiding sleeve is adapted to guide the general orientation of the guiding shaft longitudinal axis while allowing rotation of the guiding shaft about its guiding shaft longitudinal axis longitudinal axis and allowing relative translation movement between the guiding sleeve and the guiding shaft.
Preferably, the guiding shaft is provided with a guiding shaft-to-torque generating means releasable coupling means for releasably coupling the coupling shaft and any corraponents attached thereto to a suitable torque generating means. The guiding shaft-to-torque generating means coupling means conveniently includes a generally hexagonal guiding shaft grasping protrusion extending axially and outwardly from the guiding shaft second longitudinal end.
Conveniently the gui; üng means includes a guiding sleeve and a guiding shaft, the guiding sleeve having a generally cylindrical sleeve wall defining a sleeve first longitudinal end, a sleeve second longitudinal end and a sleeve longitudinal axis; the sleeve wall also defining t5 an limer sleeve carnal having a substantially disc-shaped cross-sectional configuration and a generally frustro-conical sleeve outer surface; the sleeve outer surface tape; ring conically in a direction leading towards the sleeve first longitudinal end; the guiding shaft having a generally elongated configuration defining a guiding shaft first longitudinal end, a guiding shaft second longitudinal end and a guiding shaft longitudinal axis; tea guiding shaft having 2o a guiding-to-coupling shaft releasable coupling means for allowing releasable coupling thereof to both sides of the coupling means; the guiding shaft having a generally cylindrical guiding shaft body defining a guiding shaft outer surface that is configured and sized for allowing the guiding shaft to be substantially fittingly and slidably inserted within the inner to .. ._. .....__ _.._ _ _. CA 02275480 2000-08-18 _.
sleeve carnal; the guiding shaft being configured and sized so as to be inserted within the inner sleeve carnal with the sleeve longitudinal axis in a generally collinear relationship relative to the guiding shaft longitudinal axis longitudinal axis; whereby, the guiding sleeve is adapted to guide the general orientation of the guiding shaft longitudinal axis while allowing rotation of the guiding shaft about its gu: ding shaft longitudinal longitudinal axis axis and allowing relative translation movement between the guiding sleeve and the guiding shaft; the guiding-to-coupling shaft releasable coupling means including an internally threaded recess formed in the guiding shaft first longitudinal end for selective threadable coupling to both the coupling sha8 first and second threaded segments.
to Brief Description of the Drawing:
An embodiment of the present invention will now be disclosed, by way of example, in reference to the following drawings in which:
Figure l: in a perspective view with sections taken-out illustrates a pair of bushing 2o components rotatably supporting a camshaft part of a conventional air brake system, the bushing components are shown in full lires while a section of the air brake system is shown in phantom lires, the bushings part of the air brake system exemplify one possible application of the present invention;

Figure 2: in a perspective view illustrates the camshaft shown in Figure 1 with bushings shown in phantom fines mounted thereon;
Figure 3: in a partial elevational view with sections taken-out illustrates a device in accordante with an embodiment of the present invention for creating aligned first and second final component channels in corresponding first .and second components;
Figure 4: in a partial exploded elevational view with sections taken-out illustrates a device in lo accordante with an embodiment of the present invention for creating 'aligned first and second final component channels in comesponding first and second components;
Figure 5: in a partial elevational view with sections taken-out illustrates the device shown in Figures 3 and 4 being used for perfornling a first step of a method also part of the present t5 invention, the device is shown as it begins a boring process performed on a first component;
Figure 6: in a partial elevational view with sections taken-out illustrates the device shown in Figures 3 and 4 being used for performing a second step of a method also part of the present invention, the device is shown as it performs a boring process performed on a first 20 component;
Figure 7: in a partial elevational view with sections taken-out illustrates the device shown in Figures 3 and 4 being used for performing a third step of a method also part of the present invention, the device is shown as it begins a boring process performed on a second component;
Figure 8: in a partial elevational view with sections taken-out illustrates the device shown in Figures 3 and 4 being used for performing a fourth step of a method also part of the present invention, the device is shown as it performs a boring process performed on a second component;
Figure 9: in a partial elevational view with sections taken-out illustrates a shaft extending 1 o through unaligned charnels forn ~ ed in a pair of unaligned bushing components;
Figure 10: in a partial elevational view with sections taken-out illustrates a shaft extending through aligned charnels formal in a pair of unaligned bushing components;
Figure 11: in a partial elevational view with sections taken-out illustrates at. shaft extending through aligned charnels formal in a pair of aligned bushing components;
Figure 12: in a transversal cross-sectional view taken along arrows XII-XII of Figure 9 illustrates the spatial relationship between the shaft and one of the bushing components;
Figure 13: in a transverse cross-sectional view tak ~~ n along arrows XII-XII
of Figure 10 illustrates the spatial relationship between the shaft and one of the bushing components;

_._. . CA 02275480 2000-08-18 Figure 14: in a transversal cross-sectional view taken along arrows XIV-XIV of Figure 11 illustrates the spatial relationship between the shaft and one of the bushing components.
Detailed description:
Refernng to figures 5 through 8, there is shown, in elevational views with taken-off sections, a device 10 in accordance with an embodiment of the present invention being used for creating aligned first and second final bushing channels 12, 14 in corresponding first and lo second bushing components 16, 18. The first and second final bushing channels 12, 14 are shown aligned about a common alignment axis 20 extending longitudinally therethrough.
The device 10 includes a boring means 22 for boring the first and second final bushing channels 12, 14 and a guiding means 24 for guiding said boring means along the alignment axis IS
Referring now more specifically to Figure 4, there is shown in greater details some of the components of then device 10. The boring means 22 includes a boring head 26 defining a generally cylindrical head base 28. The head base 28, in turn, defines a head base first longitudinal end 30, a longitudinally opposed head base second longitudinal end 32, a head 2o base cylindrical wall 34 defining a head base channel 36 extending longitudinally therethrough and a head base longitudinal channel 38.

A set of boring blades 40 extends generally radially from the outer surface of the head base cylindrical wall 34. The boring blades 40 preferably extend from a position located substantially adjacent the head base first longitudinal end 30 to a head base connecting section 42 located adjacent the head base second longitudinal end 32.
Each one of the boring blades 40 defines a tapered blade initiating section 44 positioned adjacent the head base first longitudinal end 30. Each blade initiating section 44 tapers from the blade outer peripheral cutting edge towards the head base cylindrical wall 34 in a direction leading towards the head base first longitudinal end 30.
to Each blade initiating section 44 preferably forms an angle A having a value substantially in the range of 1.5 degrees with the outer surface of the cylindrical wall 34.
Also, preferably, each blade initiating section 44 preferably extends over a distance D having a value substantially in the range of 1.G centimeters.
Furthermore, each boring blade 40 is preferably longitudinally angled relative to the radius of the cylindrical head base 28 by an angle B having a value substantially in the range of 0.1 degrees. In cross-section, each boring blade 40 defines a generally parallelepiped-shaped configuration.
zo The boring means 22 also includes a releasable coupling means 46 for releasably coupling the boring head 26 to the guiding means 24 and to a torque generating means (not shown).
The coupling means 46 preferably includes a coupling shaft 48 defining a coupling shaft first longitudinal end 50, a coupling shaft second longitudinal end 52 and a coupling shaft longitudinal axis 54.
The coupling shaft first and second longitudinal ends 50, 52 are preferably both provided with corresponding coupling shaft first and second threaded segments 62, 64 for allowing releasable threaded coupling to the guiding means 24 at botte longitudinal ends of the coupling shaft 48 for reasons which will be hereinafter disclosed.
The coupling shaft 48 is configured and sized so as to be at least partially substantially lo fittingly and slidably inserted into said head base channel 36, preferably with the boring head 26 positioned between the coupling shaft first and second threaded segments 62, 64.
The coupling means 46 also preferably includes a releasable locking means for releasably locking together the boring head 26 and the coupling shaft 48 against relative rotational movement and bi-directional axial translation therebetween. In other words, the releasable locking means is provided for ensuring tlmi the boring head 26 rotates solidarly with the coupling shaft 48 and also for ensuring that the boring head 26 is only allowed to translate axially relative to the coupling shaft 48 in one axial direction. Preferably, the releasable locking means is adapted to releasably lock together the boring head 26 and the coupling 2o shaft 48 with the caupling shaft 48 at least partially inserted into the head base channel 36.
The releasable locking means preferably includes at least one and preferably two locking protntsions protruding substantially outwardly and radially from the outer surface of the coupling shaft 48 'and a corresponding locking groove 58 formed at the head based connecting section 42 in the head base cylindrical wall 34. In the preferred embodiment, a pair of locking protrusions are formed by a Iocking pin 56 protn. ~ ding radially from a locking pin charnel 60 extending transversally through the coupling shaft 48.
s The coupling shaft 48 is preferably further provided with a grasp facilitating means for facilitating the grasping of the coupling shaft 48. The grasp facilitating means typically takes the form of an hexagonal grasping protrusion 66 extending outwardly from the outer surface of the coupling shaft 48 and preferably positioned intermediate the protruding sections of to the locking pin 56 and the coupling shaft second threaded segment 64. The grasping protrusion 66 also defines an abutment edge 68 adapted to abuttingly contact tea longitudinal edge 70 of the head second longitudinal end 32 so as to optionally serve as an additional locking means for limiting the relative axial translational movement between the boring head 26 and the coupling shaft 48 in a predetermined direction.
ts The guiding means 24 includes a guiding sleeve 72 and a guiding shaft 74. The guiding sleeve 72 has a generally cylindrical sleeve wall 76 defining a sleeve first longitudinal end 82, a sleeve second longitudinal end 84 md a sleeve longitudinal axis 86. The sleeve wall 76 also defmes an intler sleeve charnel 78 having a substa "tially disc-shaped cross-sectional 2o configuration and a preferably generally frustro-conical sleeve outer surface 80.
The outer surface 80 of the guiding sleeve 72 thus preferably tapers conically in a direction 'leading towards the sleeve first longitudinal end 82. Optionally, the sleeve outer surface 80 fiirther defines a sleeve grasping segment 88 positioned adjacent the sleeve second longitudinal end 84 and having a generally canceled configuration.
The guiding shaft 74 has a generally elongated configuration defining a guiding shaft first longitudinal end 90, a guiding shaft second longitudinal end 92 and a guiding shaft longitudinal axis 94. The guiding shaft '74 has a guiding-to-coupling shaft releasable coupling means for allowing rele ~, sable con ~ üng thereof to either one of the coupling shaft first or second longitudinal ends 50, 52. Preferably, the guiding-to-coupling releasable shaft coupling means includes an internally threaded recess 9G formal in the guiding shaft first to longitudinal end 90 for selective tlu-eadable coupling to both the coupling shaft first and second threaded segments G2, G4.
The guiding shaft 74 is also provided with a guiding shaft-to-torque generating means releasable coupling means for releasably coupling the coupling shaft and any components t 5 attached thereto to a suitable torque generating means (not shown) such as a drill-type power tool. The guiding shaft-to-torque generating means coupling means preferably includes a generally hexagonal guiding shah grasping protrusion 98 extending axially and outwardly from the guiding shaft second longitudinal end 92.
2o The guiding shaft 74 has a generally cylindrical guiding shaft body 100 defining a guiding shaft outer surface 102 that is configured and sized for allowing the guiding shaft T4 to be substantially fittingly and slidably inserted within the inner sleeve channel 78. The guiding shaft 74 is configured and sized so as to be inserted within the inner sleeve channel 78 with the sleeve longitudinal axis 86 in a generally collinear relationship relative to the guiding shaft longitudinal anis longitudinal axis 94. The guiding sleeve 72 is thus adapted to guide the general orientation of the guiding shaft longitudinal axis 94 while allowing rotation of the guiding shaft 74 about its guiding shaft longitudinal axis longitudinal axis 94 and allowing relative translation movement between the guiding sleeve 72 and the guiding shaft 74.
Refernng back to Figures S through 8, there is shown that the present invention also relates to a method for creating aligned first a "d second final component channels 12, 14 extending lo respectively through the corresponding spaced apart first and second components 16, 18.
The first and second final component channels 12, 14 being shown aligned about tea common alignment axis 20 extending longitudinally therethrough.
The first and second final component channels 12 and 14 have corresponding first and ~ 5 second predetermined final internai diametrrs 108, 110 that are dependent on the externat diameter of the boring head 26 which will be used. The first and second components 16, 18 are initially provided with conesponding first and second initial component channels 104, 106 extending longitudinally therethrough. 'The first and second initial component channels 104, 106 define corresponding first and second initial internai diameters 112, 2o 114. The first and second components 16, 18 are initially positioned so that the first and second initial component channels 104, 106 are in a generally aligned relationship relative to each other.

The method in accordance with the present invention includes the steps of:
a) first, selecting the first and second components 16, 18 so that the first initial internai diameter 112 is smaller then the first predetermined final internai diameter 108 and the second initial internai diameter 114 is smaller then the second predetermined final boarding school diameter 110;
b) then, as shown in Figures 5 and G, using the first initial component carnal 104 as a reaming guide for reaming the second initial component charnel 106 having the second initial diatneter 114 until it becomes the second final component charnel 14 having the second predetermined final internai diameter 110;
lo c) as shown in Figures 7 and 8, once the second final component charnel 14 has been reamed, using the second final component charnel 14 as a reaming guide for reaming the first initial component carnal 104 having the first initial diameter 112 into the first final component carnal 12 having the first predetermined final diameter 108 so that the first and second final component charnels 12 and 14 are in alignment relative to each other.
The method in accordance with the present invention because be readily performed using the device 10. More specifically, when the device 10, the following steps are involved:
a) as shown in Figure 5, positioning the guiding sleeve substantially concentrically within the first initial component carnal 104;
2o b) with the guiding shaft first longitudinal end 90 attached to the coupling shaft first longitudinal end 50, slidingly inserting the l; uiding shaft 74 through the second initial component charnel l OG until the guiding shaft second longitudinal end 92 is at least partially inserted within the sleeve charnel 78;
zo c) as shows in Figure 6, driving the boring head 44 attached to the guiding shaft by the coupling shaft through the second initial make up carnal while the guiding shap: is guided by the guiding sleeve until the boring head produces the second final make up carnal;
d) as shows in Figure 7, with the guiding shaft first longitudinal end 90 attached to the coupling shaft second longitudinal end 52, slidingly inserting the boring head 44 and the guiding shaft 74 attached thereto through the newly fonmed second final make up charnel 14 towards, the first initial make up charnel 104 until the boring head 44 reaches the first initial make up carnal 104 with the guiding shaf3 74 still at least 1o partially inserted within the newly formed second final compose charuiel 14;
e) positioning the guiding sleeve 72 substantially cuncentrically within the second final make up carnal 14 by sliding it onto the guiding shaft 74 and at least partially into the second final make up carnal 14;
f) as shows in figure 8, driving the boring head 44 through the first initial make up t5 charnel 104 while the guiding sha.ft 74 is guided by the guiding sleeve 76 until the boring head 44 produces the first final make up carnal 16.
Figures 1 and 2 illustrate ose example of a situation where it is desirable to create aligned first and second final bushing charnels 12, 14 extending respectively through 2o corresponding spaced apart first and second bushing components 16, 18. In Figures 1 and 2, the bushing components 16, 18 are shows being used for rotatably supporting a camshaft 116 having a so-called "S" -type camshaft head 118. This type of arrangement is typically found in air brake systems for heavy vehicles such as trucks such as designated generally by the reference numeral 120. The bushing components 16, 18 are shown fixedly mounted on corresponding bushing supporting legs 122 extending radially from the outer peripheral surface of an wing sleeve 124. The "S" -type camshaft head 118 is typically used for activating the brake pads 126.
The conventional prior art method of overhauling such air brake systems involved replacing the camshaft 116 a; id its associated bushings 16, 18 with pre-bored bushings.
Since the supporting legs 122 and associated pre-bored bushings could potentially be poorly aligned, it was necessary to provide a relatively large clearance therebetween. This relatively large t0 clearance, in turn, caused the camshafts 116 to rotate loosely within the associated bushings.
The proposed method and device allow for in situ creation of the final bushing carnal 12, 14. In other words, the final bushing charnels 12, 14 are preferably lbnned once the bushing 16, 18 components are mounted on their respective supporting legs.
This reduces manipulation and transportation. It also ensures accurate alignment. Ace mentioned previously, the guiding-to-coupling shaft releasable coupling means allows for releasable coupling thereof to either one of the coupling shaft first or second longitudinal ends 50, 52.
This, in tum, allows for ergonomical operation of the device 10 even in crowded envirorunents such as is often the case adjacent vehicle brake systems.
Indeed, the guiding-2o to-coupling shaft releasable coupling means allows both bushing charnels 12, 14 to be formed by manipulating the tool 10 in a single predominant axial direction.

Figures 9 through 14 illustrate various types of spatial relationship between shafts and bushings corresponding to different alignment situations. Figures 9 and 12 illustrate a situation where a shaft 128 extends through unaligned charnels 130 formed in a pair of unaligned bushing components 132. As cas be clearly seen in Figure 12, this croatian year non-syrnmetrical clearance 134 be, ~ tween the shaft 128 and the bushing make up 132.
This type of situation could potentially lead to seizing of the shaft 128 at its point of contact 136 with the busl> ing make up 132.
Figures 11 and 14 illustrate a situation where the bushing components 138 and associated 1 o carnales 140 are perfectly aligned. The shaft 142 is thus symmetrically spa ~ ced by a clearance 144 symmetrically disposed therearound from the bushing compose 140. This hypothetical situation is rarely attained in reality because of various constraints. Figures 10 and 13 illustrate a situation where although, as is often the case in real life situations, the bushing components 146 are unaligned, their respective bushing charnels 148 are aligned having been formec? by the herein proposed method and device. As case be seen in Figure 13, oves though the bushing components 146 are unaligned there nevertheless exists a symmetrical clearance 150 between the outer surface of the shaft 152 and the inner surface of the bushing charnels 148.
2o It should be understood that the present invention including the device 10 and the hereinabove disclosed method is in no way limited to ~ .he field of bushing carnal part of air brake systems and that both the method and device could be used for creating aligned charnels or apertures in other types of cornponents and in various other contexts without departing from the scope of the present invention. Furthermore, numerous modifications, variations and adaptations could be made to the hereinabove disclosed invention without departing & om the scope of the present invention as set forth in the following claims.

Claims (18)

1. A method for aligning a first final compose channel and a second final component channel respectively extending through spaced apart first and second components, said first and second final component channels having corresponding first and second predetermined final internal diameters, said first and second components being initially provided with corresponding first and second initial compose channels extending therethrough, said first and second initial compose channels defining corresponding first and second initial internal diameters, said first and second components being initially positioned so that said first and second initial compose channels are in a generally aligned relationship relative to each other, said method comprising the steps of:
a) selecting said first and second components so that said first initial internal diameter is smaller then said first predetermined final internal diameter and said second initial internal diameter is smaller then said second predetermined final internal diameter;
b) using said first initial component channel as a reaming guide for reaming said second initial component channel having said second initial diameter until it becomes said second final compose channel having said second final internal diameter;
c) once said second final compose channel has been reamed, using said second final compose channel as a reaming guide for reaming said first initial component channel having said first initial diameter into said first final component channel having said first final diameter so that said first and second final component channels in relative alignment to each other;
whereby using said first initial component channel as a reaming guide for forming said second final component channel and then said newly formed second final component channel as a reaming guide for forming said first final component channel ensures that said first and second final component channels are aligned relative to each other. 2. A method for aligning a first final component channel and a second final component channel respectively extending through spaced apart first and second components as recited in claim 1 through the use of a device including a boring head, said boring head being mounted on a coupling shaft defining a pair of opposed coupling shaft first and second longitudinal ends; a guiding sleeve, said guiding sleeve defining an inner sleeve channel and a generally frustro-conical sleeve outer surface, said inner sleeve channel defining a sleeve channel longitudinal axis; a generally elongated guiding shaft defining a guiding shaft first longitudinal end, a guiding shaft second longitudinal end and a guiding shaft longitudinal axis, said guiding shaft having a guiding-to-coupling shaft releasable coupling means for allowing releasable coupling of said guiding shaft selectively to either one of said coupling shaft first and second longitudinal ends, said guiding shaft being configured and sized so as to be at least partially substantially fittingly and slidably insertable within said sleeve channel with said sleeve channel longitudinal axis in a generally collinear relationship relative to said guiding shaft longitudinal axis; said guiding sleeve being configured so as to guide the orientation of said guiding shaft longitudinal axis while allowing rotation of said guiding shaft about said guiding shaft longitudinal axis; where the step of using said first initial component channel as a reaming guide for reaming said second initial component channel until it becomes said second final component channel involves a) positioning said guiding sleeve substantially concentrically within said first initial component channel;
b) with said guiding shaft first longitudinal end attached to said coupling shaft first longitudinal end, slidingly inserting said guiding shaft through said second initial component channel until said guiding shaft second longitudinal end is at least partially inserted within said sleeve channel;
c) driving said boring head attached to said guiding shaft by said couplirig shaft through said second initial component channel while said guiding shaft is guided by said guiding sleeve until said boring head produces said second final component channel. 3. A method for aligning a first final component channel and a second final component channel respectively extending through spaced apart first and second components as recited in claim 1 through the use of a device including a boring head, said boring head being mounted on a coupling shaft defining a pair of opposed coupling shaft first and second longitudinal ends; a guiding sleeve, said guiding sleeve defning an inner sleeve channel and a generally frustro-conical sleeve outer surface, said inner sleeve channel defining a sleeve channel longitudinal axis; a generally elongated guiding shaft defining a guiding shaft first longitudinal end, a guiding shaft second longitudinal end and a guiding shaft longitudinal axis, said guiding shaft having a guiding-to-coupling shaft releasable coupling means for allowing releasable coupling of said guiding shaft selectively to either one of said coupling shaft first and second longitudinal ends, said guiding shaft being configured and sized so as to be at least partially substantially fittingly and slidably insertable within said sleeve channel with said sleeve channel longitudinal axis in a generally collinear relationship relative to said guiding shaft longitudinal axis; said guiding sleeve being configured so as to guide the orientation of said guiding shaft longitudinal axis while allowing rotation of said guiding shaft about said guiding shaft longitudinal axis; where the step of using said second final component channel as a reaming guide for reaming said first initial component channel into said first final component channel involves the steps of:
a) with said guiding shaft first longitudinal end attached to said couplin $
shaft second longitudinal end, slidingly inserting said boring head and said guiding shaft attached thereto through second final component channel until said boring head reaches first initial component channel with said guiding shaft at least partially inserted within said through second final component channel;
b) positioning said guiding sleeve substantially concentrically within said second final component channel by sliding it onto said guiding shaft and at least partially into said second final component channel;
c) driving said boring head through said first initial component channel while said guiding shaft is guided by said guiding sleeve until said boring head produces said first final component channel. 4. A method for aligning a first final component channel and a second final component channel respectively extending through spaced apart first and second components as recited in claim 1 through the use of a device including a boring head, said boring head being mounted on a coupling shaft defining a pair of opposed coupling shaft first and second longitudinal ends; a guiding sleeve, said guiding sleeve defining an inner sleeve carnal and a generally frustro-conical sleeve outer surface, said inner sleeve channel defining a sleeve carnal longitudinal axis; a generally elongated guiding shaft defining a guiding shaft first longitudinal end, a guiding shaft second longitudinal end and a guiding shaft longitudinal axis, said guiding shaft having a guiding-to-coupling shaft releasable coupling means for allowing releasable coupling of said guiding shaft selectively to either one of said coupling shaft first and second longitudinal ends, said guiding shaft being configured and sized so as to be at least partially substantially fittingly and slidably insertable within said sleeve channel with said sleeve channel longitudinal axis in a generally collinear relationship relative to said guiding shaft longitudinal axis; said guiding sleeve being configured so as to guide the orientation of said guiding shaft longitudinal axis while allowing rotation of said guiding shaft about said guiding shaft longitudinal axis, where the steps of using said first initial component channel as a reaming guide for reaming said second initial component channel until it becomes said second final component channel and using said second final component channel as a reaming guide for reaming said first initial component channel into said first final component channel respectively involve the steps of:
a) positioning said guiding sleeve substantially concentrically within said first initial component channel;
b) with said guiding shaft first longitudinal end attached to said coupling shaft first longitudinal end, slidingly inserting said guiding shaft through said second initial make up channel until said guiding shaft second longitudinal end is at least partially inserted within said sleeve channel;
c) driving said boring head attached to said guiding shaft by said coupling shaft through said second initial compose channel while said guiding shaft is guided by said guiding sleeve until said boring head produces said second final component channel;
d) with said guiding shaft first longitudinal end attached to said coupling shaft second longitudinal end, slidingly inserting said boring head and said guiding shaft attached thereto through second final make up channel until said boring head reaches first initial make up channel with said guiding shaft at least partially inserted within said through second final make up channel;
e) positioning said guiding sleeve substantially concentrically within said second final make up channel by sliding it onto said guiding shaft and at least partially into said second final make up channel;
f) driving said boring head through said first initial compose channel while said guiding shaft is guided by said guiding sleeve until said boring head produces said first final make up channel. 5) A device for aligning about an alignment axis a first final compose channel and a second final compoiient channel respectively extending through spaced apart first and second components, said first and second final compose channels having corresponding first and second predetermined final internal diameters, said first and second components being initially provided with corresponding first and second initial make up channels extending therethrough, said first and second initial component channels defining corresponding first and second initial internat diameters, said first and second components being initially positioned so that said first and second initial component channels are in a generally aligned relationship relative to each other, said device comprising:
a) a boring means for boring said first and second final component channels and b) a guiding means for guiding said boring means along said alignment axis. 6) A device as recited in Claim 5 where said boring means includes a boring head defining a generally cylindrical head base, said head base defining a head base first longitudinal end, a longitudinally opposed head base second longitudinal end and a head base cylindrical watt, said head base cylindrical watt defining a head base channel extending longitudinally therethrough and a head base longitudinal axis; a set of boring blades extends generally radially from the outer surface of said head base cylindrical watt. 7) A device as recited in Claim 6 which each one of said boring blades defines a tapered blade initiating section positioned adjacent said head base first longitudinal end, each blade initiating section tapering from the blade outer peripheral cutting edge towards said head base cylindrical watt in a direction leading towards said head base first longitudinal end;
each blade initiating section forming a first angle having a value substantially in said range of 1.5 degrees with said outer surface of said cylindrical watt; each blade initiating section extending over a distance having a value substantially in the range of 1.6 centimeters; each boring blade being longitudinally angled relative to the radius of said cylindrical head base by a second angle having a value substantially in the range of 0.1 degrees. 8) A device as recited in Claim 6 where said boring means includes a releasable coupling means for releasably coupling said boring head to said guiding means and to a torque generating means. 9) A device as recited in Claim 8 where said coupling means includes a coupling shaft defining a coupling shaft first longitudinal end, a coupling shaft second longitudinal end and a coupling shaft longitudinal axis; said coupling shaft first and second longitudinal ends being both provided with corresponding coupling shaft first and second threaded segments for allowing releasable threaded coupling to said guiding means at both longitudinal ends of said coupling shaft; said coupling shaft being configured and sized so as to be at least partially substantially fittingly and slidably insertable into said head base channel with said boring head positioned between said coupling shaft first and second threaded segments. 10) A device as recited in Claim 9 where said coupling means includes a releasable locking means for releasably locking together said boring head and said coupling shaft against relative rotational movement and bi-directional axial translation therebetween so as to ensure that said boring head rotates solidarly with said coupling shaft and also for ensuring that said boring head is only allowed to translate axially relative to said coupling shaft in one predetermined axial direction. 11) A device as recited in Claim 10 where said releasable locking means includes at least one locking protrusion protruding substantially outwardly and radially from said outer surface of said coupling shaft and a corresponding locking groove formed in said head base cylindrical wall. 12) A device as recited in Claim 11 where said coupling shaft is provided with a grasp facilitating means for facilitating the grasping of said coupling shaft. 13) A device as recited in Claim 12 where said grasp facilitating means includes an hexagonal grasping protrusion extending outwardly from said outer surface of said coupling shaft; said grasping protrusion being positioned intermediate said protruding section and said coupling shaft second threaded segment; said grasping protrusion also defining an abutment edge adapted to abuttingly contact the longitudinal edge of said head second longitudinal end so as to serve as an additional locking means for limiting the relative axial translational movement between said boring head and said coupling shaft in a predetermined direction. 14) A device as recited in Claim 5 where said guiding means includes a guiding sleeve and a guiding shaft, said guiding sleeve having a generally cylindrical sleeve wall defining a sleeve first longitudinal end, a sleeve second longitudinal end and a sleeve longitudinal axis; said sleeve wall also defining an inner sleeve channel having a substantially disc-shaped cross-sectional configuration and a generally frustro-conical sleeve outer surface;
said sleeve outer surface tapering conically in a direction leading towards said sleeve first longitudinal end. 15) A device as recited in Claim 14 where said guiding shaft has a generally elongated configuration defining a guiding shaft first longitudinal end, a guiding shaft second longitudinal end and a guiding shaft longitudinal axis; said guiding shaft having a guiding-to-coupling shaft releasable coupling means for allowing releasable coupling thereof to both sides of said coupling means; said guiding shaft having a generally cylindrical guiding shaft body defining a guiding shaft outer surface that is configured and sized for allowing said guiding shaft to be substantially fittingly and slidably inserted within said inner sleeve channel; said guiding shaft being configured and sized so as to be inserted within said inner sleeve channel with said sleeve longitudinal axis in a generally collinear relationship relative to said guiding shaft longitudinal axis longitudinal axis; whereby, said guiding sleeve is adapted to guide the general orientation of laid guiding shaft longitudinal axis while allowing rotation of said guiding shaft about its guiding shaft longitudinal longitudinal axis axis and allowing relative translation movement between said guiding sleeve and said guiding shaft. 16) A device as recited in Claim 15 where said guiding shaft is provided with a guiding shaft-to-torque generating means releasable coupling means for releasably coupling said coupling shaft and any components attached thereto to a suitable torque generating means. 17) A device as recited in Claim 16 where said guiding shaft-to-torque generating means coupling means includes a generally hexagonal guiding shaft grasping protrusion extending axially and outwardly from said guiding shaft second longitudinal end. 18) A device as recited in Claim 9 where said guiding means includes a guiding sleeve and a guiding shaft, sais guiding sleeve having a generally cylindrical sleeve wall ~ defining a sleeve first longitudinal end, a sleeve second longitudinal end and a sleeve longitudinal axis; said sleeve wall also defining an inner sleeve carnal having a substantially disc-shaped cross-sectional configuration and a generally frustro-conical sleeve outer surface;
said sleeve outer surface tapering conically in a direction leading towards said sleeve first longitudinal end; said guiding shaft having a generally elongated $ ning a configuration guiding shaft first longitudinal end, a guiding shaft second longitudinal end and a guiding longitudinal axis shaft; said guiding shaft having a guiding-to-coupling shaft releasable coupling means for allowing releasable coupling thereof to both sides ôf said coupling means; said guiding shaft having a generally cylindrical guiding shaft body defining a guiding shaft outer surface that is configured and sized for allowing said guiding shaft to be substantially fittingly and slidably inserted within _ said inner sleeve carnal; said guiding shaft being configured and sized so as ta be inserted within said inner sleeve carnal with said sleeve longitudinal axis in a generally collinear relationship relative to said guiding shaft longitudinal axis longitudinal axis; whereby, said guiding sleeve is adapted to guide the general orientation of said guiding shaft longitudinal axis while allowing rotation of said guiding shaft about its guiding shaft longitudinal axis longitudinal axis and allowing relative translation movement between said guiding sleeve a.nci said guiding shaft;
said guïding-to-coupling shaft releasable coupling means including an internally threaded recess formed in said guiding shaft first longitudinal end for selective threadable coupling to both said coupling shaft first and second threaded segments.