Brake Actuator Cable Connector Wear Protector
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Solution Overview
Problem
The existing methods for attaching an input cable to a brake actuator in vehicle brake systems are costly and prone to dislodgment, as they rely on a pivoted clevis that requires additional components and may not securely maintain the connection.
Innovation Solution
A cable connector with a wear protector made of a wear-resistant material is used to connect the input cable to the actuator, allowing for movement in both brake applying and releasing directions, and featuring a design that includes a cable connector portion and an actuator connector portion with a wear protector to engage with the actuator's receiving space, ensuring secure and adjustable attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a pivoted clevis is used to attach the input cable to the output member, then the connection can adjust itself as the output member rotates, but the cost increases and the enlarged head may become dislodged
Solution Approach 1:
A wear protector is introduced as an intermediary component between the cable connector and the output member surface. The wear protector features a wear-resistant material that prevents direct contact and potential dislodgment of the cable connector, while still allowing the necessary relative movement for adjustment. This mediator maintains connection security while preserving adaptability.
Solution Approach 2:
The wear protector is designed as a simpler, more cost-effective component compared to a full pivoted clevis assembly. It provides the necessary wear protection and connection stability without requiring the complex pivoting mechanism, enlarged heads, and additional attachment hardware of traditional clevis designs.
2Adaptability or versatility
If a pivoted clevis is used to attach the input cable to the output member, then the connection can adjust itself as the output member rotates, but the manufacturing cost increases
Solution Approach 1:
The wear protector serves as a simple intermediary component that can be manufactured independently and attached to the output member or cable connector. This approach avoids the need to manufacture complex pivoted clevis assemblies, reducing manufacturing complexity and cost while maintaining the adjustability function.
Solution Approach 2:
The solution segments the function of adjustment from the function of wear protection. The cable connector provides adjustability through simple relative movement, while the wear protector separately provides wear resistance and connection security. This segmentation allows each component to be optimized and manufactured independently at lower cost.
3Strength
If the cable connector is made of metal, then strength is provided, but wear between the connector and output member surface increases
Solution Approach 1:
The solution employs composite material properties by combining a metal cable connector for strength with a wear-resistant material on the wear protector for protection. The wear-resistant material may be a different metal alloy, ceramic coating, or polymer that complements the metal connector, creating a composite system that exhibits both high strength and low wear characteristics.
Solution Approach 2:
The wear protector acts as an intermediary layer between the metal cable connector and the metal output member surface. This mediator prevents direct metal-to-metal contact, reducing wear while allowing the metal connector to maintain its structural strength. The wear protector material is selected to be compatible with and protective of both contacting surfaces.
Data Source
AI summary
The present application discloses a cable connector for use in attaching an input cable to an actuator in a vehicle braking system.