Brake Clevis Alignment Device for Misassembly Prevention
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
During the construction of vehicle brake assemblies, there is a risk of misalignment between the brake booster and the pedal arm due to operator error, leading to potential malfunction and costly repairs, posing a safety concern.
Innovation Solution
The implementation of an alignment device with a saddle element and lateral wing elements that guide and position the clevis of the brake booster push rod into alignment with the pedal arm, preventing misassembly by forming a catchment area that ensures proper alignment during the assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a standard clevis connection is used to couple the brake booster to the pedal arm, then the assembly process is simple and easy to perform, but misalignment between the booster and pedal arm may occur due to operator error
Solution Approach 1:
The patent introduces an alignment device as an intermediary component between the clevis connection and the pedal arm. This alignment device includes alignment features such as guide pins or tapered surfaces that physically guide the brake booster into proper alignment with the pedal arm during assembly, eliminating the need for operator skill while maintaining simple assembly procedures
Solution Approach 2:
The alignment device incorporates pre-formed alignment features that are created during manufacturing. These features perform the alignment function in advance, so that when assembly occurs, the components are already predisposed to align correctly without requiring operator intervention or skill
2Device complexity
If operator skill is relied upon to achieve proper alignment during assembly, then no additional alignment devices are needed, but costly repairs may be required due to misalignment and malfunction
Solution Approach 1:
The alignment device is designed to be self-aligning through its geometric features. When the brake booster is installed, the alignment features automatically guide it into the correct position without requiring operator skill or judgment. The system serves itself by using the physical geometry of the alignment device to ensure proper alignment
Solution Approach 2:
The alignment device provides a form of protective cushioning against misalignment errors. By incorporating tolerance-compensating features such as tapered surfaces or adjustable mechanisms, the alignment device absorbs potential alignment errors before they can lead to malfunction or failure of the brake system
Data Source
AI summary
A vehicle brake assembly includes an actuation lever coupled to a brake pedal. The brake assembly also includes a push rod of a brake booster. The push rod has a clevis on an end portion thereof. The clevis comprises two prongs. The brake assembly further includes an alignment device seated on each respective prong of the clevis. The alignment devices are configured to collectively guide and position the clevis into alignment with the actuation lever during construction of the brake assembly.