Mechanical Brake Actuator Strut-Clip Integration
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Solution Overview
Problem
Existing mechanical brake actuators face challenges with complex assembly, high manufacturing costs, and operability issues due to the need for precise convex and rotational axis formation on the strut, which increases the risk of brake cable disengagement and interferes with nearby parts.
Innovation Solution
A mechanical brake actuator design featuring a strut-bridge with a clip that attaches in a movable manner, restricting the brake lever's rotation in the cable releasing direction, eliminating the need for convexes on the strut and allowing for simpler assembly and reduced material costs by attaching to the strut-bridge, which reduces interference with adjacent parts.
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 risk of losing the clip increases
Solution Approach 1:
The invention merges the clip with the strut-bridge by forming the clip as an integrated part of the strut-bridge structure. This eliminates the need for separate clip components and their associated assembly steps, while maintaining the function of positioning and retaining the brake lever within the strut space.
Solution Approach 2:
The strut-bridge is designed to serve multiple functions: it provides structural support, positions the brake lever, and integrates the clip function to prevent brake cable disengagement. This multi-functionality reduces the number of separate components needed in the system.
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 invention extracts the clip function from the strut structure and relocates it to the strut-bridge. This allows the rotational axis to be positioned on only one outer surface of the strut, eliminating the need for complex dual-surface axis formation and reducing manufacturing costs.
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 clip and its positioning features are merged with the strut-bridge structure. This integration simplifies the manufacturing process by eliminating the need for high-precision separate features on the strut, as the positioning is achieved through the integrated strut-bridge design rather than requiring precise convex and rotational axis formation on separate components.
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 shoe return spring
Solution Approach 1:
The invention relocates the clip attachment from the exterior surface of the strut to the strut-bridge structure. This dimensional relocation allows the clip to achieve secure attachment without increasing plate thickness, thereby avoiding interference with 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:
The clip is merged with the strut-bridge structure, eliminating the need for a separate widened clip component. This integration maintains secure attachment functionality while reducing the quantity of additional material required, thereby lowering both material and manufacturing costs.
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 (30), which attaches to the strut-bridge (23a) and restricts the rotation of the brake lever (24) in the cable releasing direction.