Rotationally Adjustable Brake Actuator Housing for Pneumatic Port Alignment
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Solution Overview
Problem
Conventional brake actuators face challenges in accommodating varying vehicle designs due to non-standard pneumatic conduit connections, leading to increased production costs and complexity, as they require specific configurations for different vehicles, making it difficult to position pneumatic ports correctly.
Innovation Solution
A rotationally adjustable brake actuator design featuring a pressure housing, a non-pressure housing, and a diaphragm with a retaining ring that allows for angular adjustment of the housings relative to each other, using a stop pin or set screw to fix the position, enabling flexible alignment with vehicle-specific port orientations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional brake actuators use fixed pneumatic chamber configurations, then manufacturing is simplified, but adaptability to different vehicle designs is reduced
Solution Approach 1:
The brake actuator incorporates a rotationally adjustable mounting bracket that can be positioned at multiple angular orientations (e.g., 0°, 45°, 90°, 135°) relative to the pneumatic chamber. This dynamic positioning capability allows the same actuator model to adapt to different vehicle designs without requiring custom configurations, thereby improving adaptability while maintaining standardized production processes
Solution Approach 2:
The mounting bracket is designed with multiple mounting hole positions and rotational adjustment capabilities, enabling a single actuator design to serve multiple vehicle configurations. This universal design approach allows one actuator model to replace multiple vehicle-specific variants, reducing production line complexity while enhancing adaptability across different vehicle platforms
2Ease of operation
If brake actuators are customized for specific vehicles, then pneumatic port alignment is improved, but production costs increase
Solution Approach 1:
The mounting bracket includes rotational adjustment mechanisms that allow operators to align the pneumatic ports with vehicle conduit connections at various angles. This dynamic alignment capability eliminates the need for expensive custom-designed actuators for each vehicle, achieving proper port alignment while maintaining standardized, cost-effective production processes
Solution Approach 2:
The actuator is divided into separable components including the pneumatic chamber, mounting bracket, and adjustment mechanisms. This segmentation allows the mounting bracket to be independently adjusted and positioned without redesigning the entire actuator, enabling cost-effective alignment solutions while maintaining standardized manufacturing for the core pneumatic components
3Adaptability or versatility
If multiple actuator configurations are produced, then vehicle-specific requirements are met, but material and personnel requirements increase
Solution Approach 1:
A single actuator design with an adjustable mounting bracket can satisfy multiple vehicle-specific requirements, eliminating the need to produce multiple dedicated actuator configurations. This universal design reduces material consumption by using standardized components across different vehicle applications and reduces personnel requirements by simplifying the assembly and customization process
Solution Approach 2:
The rotational adjustment capability of the mounting bracket allows one actuator model to adapt to different vehicle configurations without requiring multiple static designs. This dynamic adaptability consolidates production requirements, reducing the total quantity of materials needed and minimizing personnel training and assembly time across different vehicle platforms
Data Source
AI summary
A rotationally adjustable brake actuator includes a pressure housing with a circumferential rim, a non-pressure housing having a second circumferential rim, and a diaphragm disposed therebetween, where a retaining ring holds the respective housings against each other such that the first rim abuts the second rim, but where the respective housings are able to be rotated with respect to the other. Further, the retaining ring includes a radially-oriented hole and a stop pin that is inserted into the hole and engages the pressure housing to prevent further rotation.