Brake Actuator Plug Retention with Alignment Tabs
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Solution Overview
Problem
Conventional brake actuator plugs are difficult to reinstall, prone to incorrect installation, and susceptible to displacement due to vibration, failing to effectively seal apertures and protect components from contaminants and environmental factors.
Innovation Solution
A plug with a retention member featuring alignment tabs and a seal, designed to securely align and lock into a retaining ring, preventing movement and rotation, and including a seal to close the aperture, enhancing ease of installation and stability against vibration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional dust plug is used to seal the aperture, then the aperture can be sealed to prevent contaminants from entering, but the plug is difficult to reinstall and prone to incorrect installation
Solution Approach 1:
The plug assembly is segmented into distinct functional components: a retention member with alignment tabs for positioning, a seal element for contamination prevention, and a locking mechanism. This segmentation allows each component to perform its specific function optimally while simplifying the overall installation process through modular assembly.
Solution Approach 2:
The alignment tabs act as an intermediary mechanism between the plug and the aperture, providing visual and physical guidance during installation. These tabs engage with corresponding features in the aperture to ensure proper orientation, serving as a mediator that prevents incorrect installation without complicating the assembly process.
2Reliability
If a conventional dust plug is used to seal the aperture, then the aperture can be sealed, but the plug is subject to displacement by vibration during normal vehicle operation
Solution Approach 1:
The retention member is designed with alignment tabs that preliminarily position the plug correctly before final installation. This preliminary alignment ensures that the plug is properly oriented and seated, preventing displacement during subsequent vibration events. The alignment features are engaged before the vehicle operation begins, establishing a stable configuration in advance.
Solution Approach 2:
The alignment tabs and retention ring work together in a self-aligning mechanism that automatically positions the plug correctly without requiring external guidance or complex installation procedures. The geometric features of the tabs and ring create a self-correcting system that maintains proper positioning under vibration, allowing the assembly to self-regulate its configuration.
3Ease of operation
If alignment tabs and a locking mechanism are added to the plug, then the plug becomes less likely to be displaced and easier to install correctly, but the device complexity increases
Solution Approach 1:
The alignment tabs are designed with asymmetric geometric features that provide clear directional guidance during installation. The tabs have specific shapes that only fit into corresponding asymmetric features in the retention ring, creating an intuitive one-way insertion path. This asymmetry simplifies the installation process by eliminating the need for complex alignment procedures while adding minimal structural complexity.
Solution Approach 2:
The alignment tabs are nested within or integrated with the retention member body, and the entire plug assembly nests within the aperture opening. This nested configuration allows the alignment features to be incorporated without significantly increasing the overall size or complexity of the plug, as the tabs are part of the retention member's integrated structure rather than separate components.
Data Source
AI summary
A plug for sealing an aperture in a brake actuator housing is provided that provides improvements in installation and retention of the plug and protection for sealing surfaces. The plug includes a retention member including a body defining an aperture configured for alignment with the actuator housing aperture along an axis extending through the apertures. The retention member further includes a plurality of alignment tabs extending radially from the body. The tabs are configured to be received within a plurality of notches formed in a retaining ring affixed to the housing when the retention member is disposed in an unlocked position and configured to be disposed on a first side of the retaining ring when the retention member is rotated about the axis to a locked position. The plug further includes a seal configured to be received within the aperture in the body. The seal closes the second aperture.