Brake Actuator Clip Integration for Cost Reduction
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Solution Overview
Problem
Existing mechanical brake actuators face challenges with complex assembly, high manufacturing costs, and reduced operability due to the need for precise convex and rotational axis formation on the strut, which increases the risk of clip loss and interference with nearby parts.
Innovation Solution
A mechanical brake actuator design featuring a strut-bridge with a rotatable clip that attaches at a retreat position, allowing easy connection of the brake cable and restricting rotation to prevent disengagement, eliminating the need for convexes on the strut and simplifying the assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the clip is assembled on the exterior of the facing plates of the strut, then the brake lever can be positioned within the space of the strut, but the assembly becomes more complex and the clip may be lost or neglected
Solution Approach 1:
The clip is merged with the strut by forming it as an integral part of the strut structure. The clip extends from the outer surface of the strut and engages with the brake lever, eliminating the need for a separate attachable clip while maintaining the positioning function.
Solution Approach 2:
The clip function is extracted from being a separate component and integrated directly into the strut structure. The clip is now a fixed feature of the strut rather than an independent part that requires separate assembly.
2Reliability
If the clip is assembled on the strut, then the brake lever can be retained, but the rotational axis must be on both outer surfaces of the strut which increases manufacturing cost
Solution Approach 1:
The requirement for rotational axes on both outer surfaces of the strut is eliminated. The clip is redesigned to function with a single rotational axis or pivot point, removing the unnecessary manufacturing complexity and cost associated with dual-axis requirements.
3Manufacturing precision
If convex and rotational axis are provided on the strut, then the clip can be positioned, but high accuracy in formation is necessary which requires higher manufacturing accuracy
Solution Approach 1:
The complex requirements for precisely formed convex features and rotational axes on the strut are removed. The clip design is simplified to engage with the brake lever through a more tolerant geometric relationship that does not require high-precision machining of the strut.
4Strength
If the clip plate thickness is increased to attach to the exterior of the strut, then the attachment is more secure, but it interferes with nearby parts such as the shoe return spring
Solution Approach 1:
The clip is repositioned from extending radially outward from the strut surface to extending along the longitudinal axis of the strut. This dimensional change allows the clip to achieve sufficient attachment strength without protruding into the space occupied by nearby components such as the shoe return spring.
5Strength
If the clip is widened to attach to the exterior of the strut, then the attachment is more secure, but the material cost and manufacturing cost increase
Solution Approach 1:
Instead of increasing the clip width radially, the clip is extended in the longitudinal direction of the strut. This provides sufficient engagement length and attachment strength without increasing material usage or manufacturing complexity.
6Manufacturing precision
If the side surfaces of the clip are pushed out to spread open for attachment, then the clip can fit on the convex of the strut, but the operability of the clip attaching operation is jeopardized
Solution Approach 1:
The complex two-handed operation of spreading the clip sides and manually positioning it on the strut convex is eliminated. The clip is redesigned as a simple U-shaped or C-shaped component that can be snap-fit or friction-fit onto the brake lever without requiring manual spreading or precise alignment operations.
Data Source
AI summary
To provide the mechanical brake actuator enabling to downsize the device and to reduce the manufacturing costs of the parts. The mechanical brake actuator comprises the strut (23) which engages with one brake shoe (12) and has two facing plates (23b) with a strut-bridge (23a) connecting therebetween and the plate-like brake lever (24) which engages with the other brake shoe (13). The brake lever (24) is retained in the space (23c) between the facing strut plates and is pivotally supported on the strut (23), and the inner cable (41) of the brake cable (40) connected to the free end (24e) of the brake lever (24) via the connecting pin (43). The mechanical brake actuator which is operated by pulling the inner cable (41) comprises the clip (70), which rotatably attaches to the strut-bridge (23a) and restricts the rotation of the brake lever (24) in the cable releasing direction.