Brake Actuator Housing Locking Element Design
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Solution Overview
Problem
Existing brake actuator housings face challenges in securely locking housing parts together to prevent accidental disintegration under positive pressure and large forces, leading to potential damage and safety risks during assembly or operation.
Innovation Solution
A brake actuator housing design featuring recesses between bayonet locking members for a locking element that fits in a collapsed state and expands to secure the parts in a positive and non-positive fit, preventing incorrect assembly and ensuring secure locking during operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a locking screw is installed on the periphery of the housing to prevent rotation of housing parts, then the housing parts are securely locked together, but narrow fabrication tolerances are required that are hard to realize and the housing parts can be damaged after removing the screw
Solution Approach 1:
The locking element is divided into multiple locking portions (at least two) that can be independently formed or positioned. Each locking portion engages with corresponding features on the housing parts, distributing the locking function across multiple points rather than relying on a single precision-critical screw hole. This segmentation reduces the impact of individual tolerance deviations.
Solution Approach 2:
The locking function is extracted from the traditional screw-based system and integrated into the bayonet coupling structure itself through the locking element. The locking element is formed as part of the coupling mechanism, eliminating the need for separate screw holes and threads that require tight tolerances. The locking element can be removed without damaging the housing parts.
2Reliability
If a locking screw is used to secure housing parts, then the housing parts remain locked together under pressure, but the housing parts can be damaged after removing the screw
Solution Approach 1:
The locking function is extracted from the housing parts and embodied in the removable locking element. The locking element carries the locking features (locking portions) that engage with the housing parts, rather than requiring threaded holes or recesses in the housing parts themselves. This allows the locking element to be removed without leaving damage in the housing parts.
Solution Approach 2:
The locking element is designed as a disposable or replaceable component that can be easily removed and replaced. Rather than permanently modifying the housing parts with screw holes, the locking element serves its purpose and can be discarded or replaced without affecting the integrity of the expensive housing parts.
3Ease of operation
If bayonet locking members are used to couple housing parts, then the housing parts can be assembled and disassembled, but the housing parts may accidentally separate under positive pressure and large forces
Solution Approach 1:
The locking element is designed to be installed after the bayonet coupling is assembled, providing an additional locking stage. The locking element engages with the bayonet locking members to prevent accidental separation under pressure, while the bayonet coupling itself remains accessible for controlled disassembly when needed.
Solution Approach 2:
The locking element provides a preliminary protective measure against accidental separation before any failure of the bayonet coupling could occur. The locking portions of the locking element engage with the bayonet locking members to create a mechanical interlock that prevents unintended separation under operational forces.
Data Source
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AI summary
The invention relates to a brake actuator housing, in particular a spring brake actuator housing (1), comprising: a first housing part (10) having a number of first bayonet locking members (12) and a second housing part (20) having a number of bayonet locking members (22), wherein the bayonet locking members (12) are configured to engage one another in a positive fit in a coupled state of the brake actuator housing (1). The invention suggests that the first and the second housing parts (20) are formed such that they define a recess (40) between them in the coupled state, the recess (40) being externally accessible, and the brake actuator housing (1) comprises a locking element (30, 30', 30", 30"', 30"") that is dimensioned such that it fits in the recess (40), locking the first and the second housing part (10, 20) in the coupled state.