Bracket Assembly Actuator Mounting Arm Segmentation
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Solution Overview
Problem
Conventional bracket assemblies for vehicle brakes are prone to mechanical stress and structural deflection, requiring thick, costly manufacturing tools and numerous welds, which leads to increased air consumption during braking and limited feature intricacy.
Innovation Solution
A bracket assembly with an actuator mounting arm divided into inboard and outboard members, configured to receive a camshaft tube and brake actuator, reducing material thickness and eliminating the need for a gusset, allowing for improved stiffness and reduced welds, enabling easier manufacturing and enhanced mechanical stress resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the mounting arm is made thick to withstand mechanical stress, then strength is improved, but manufacturing complexity and cost increase due to heavy tooling requirements
Solution Approach 1:
The mounting arm is divided into two separate L-shaped members (first and second members) that are positioned adjacent to each other. Each member can be manufactured independently using lighter tooling, then assembled together to form the complete mounting arm structure. This segmentation allows each component to be produced with less complex tooling while maintaining the overall structural integrity and strength through the combined configuration.
2Strength
If a gusset is added to reinforce the mounting arm, then strength is improved, but device complexity increases due to additional welds
Solution Approach 1:
The reinforcing function traditionally performed by a separate gusset component is merged into the mounting arm structure itself by positioning the two L-shaped members adjacent to each other. The members work together as an integrated structure, eliminating the need for additional gusset components and their associated welds. The combined configuration of the two members provides the necessary reinforcement while simplifying the overall assembly process.
3Stability of the object's composition
If the mounting arm is made thick to reduce deflection, then rigidity is improved, but air consumption increases during braking
Solution Approach 1:
By segmenting the mounting arm into two thinner L-shaped members positioned adjacent to each other, the structure achieves the necessary rigidity through their combined configuration rather than relying on a single thick member. This segmented approach reduces the overall material thickness while maintaining structural stability, thereby reducing the energy (air consumption) required for braking operations.
4Strength
If the mounting arm is made thick to withstand stress, then strength is improved, but manufacturing precision decreases due to limited feature intricacy
Solution Approach 1:
Dividing the mounting arm into two separate L-shaped members allows each component to be manufactured with greater precision and intricate features using lighter tooling. The segmented structure enables more complex geometries and finer details to be incorporated into each member, which would be difficult or impossible to achieve in a single thick component. The combined assembly maintains the necessary strength while benefiting from the enhanced manufacturing precision of the individual members.
Data Source
AI summary
An improved bracket assembly for receiving a brake assembly and a brake actuator is provided. The bracket assembly includes a tube configured to receive a camshaft of the brake assembly. A brake spider mounting flange is disposed proximate a first end of the tube, defines an aperture configured to allow the tube to extend therethrough, and is configured to receive a brake spider of the brake assembly. An actuator mounting arm is disposed proximate a second end of the tube, is configured for coupling to the brake actuator, and has inboard and outboard members. Each of the inboard and outboard members has a body having a first end affixed to the tube and an actuator mounting flange extending from a second end of the body. The actuator mounting flanges define aligned bores configured to receive a fastener extending from the brake actuator.