Brake Pedal Pushrod Clip Assembly for No-Look Service Access
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Solution Overview
Problem
Conventional booster pushrod interface assemblies in vehicles are complex, expensive, and difficult to assemble/disassemble, especially in limited workspace conditions, due to the need for precise alignment and use of clips and brackets.
Innovation Solution
A vehicle booster pushrod interface assembly featuring a pivoting brake pedal arm with a protruding cylindrical peg structure that is selectively engaged by a c-shaped clip structure on the pushrod, allowing easy assembly/disassembly and pivotability, combined with a ball structure at the other end for additional pivotability with the brake booster actuator.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional clips and brackets are used to secure the ball structure in the socket joint, then the connection is secure and reliable, but the assembly and disassembly process becomes complex and difficult, especially in limited workspace conditions
Solution Approach 1:
The retaining mechanism is segmented into multiple flexible fingers that can independently deflect and engage with the socket joint. This segmentation allows each finger to independently secure the ball structure while collectively providing a reliable connection, yet the entire assembly can be easily disassembled by applying force to any single finger to release all others simultaneously.
Solution Approach 2:
The retaining clips are designed with flexible, deflectable fingers that can dynamically adapt to the socket joint geometry during engagement. The fingers can deflect inward to allow ball insertion and outward to maintain secure retention, providing both ease of assembly and reliable connection without requiring complex alignment procedures.
2Ease of repair
If sufficient slack is provided to disengage and engage the ball structure from the socket joint, then the pushrod can be removed and reinstalled, but the workspace requirements increase and precision alignment becomes more difficult
Solution Approach 1:
The ball structure is nested within the socket joint during normal operation, with the flexible fingers enveloping the ball to provide secure retention. During service, the fingers can be deflected outward to release the ball, allowing removal and reinstallation without requiring excessive workspace or precision alignment, as the nested design naturally guides the ball back into position.
Solution Approach 2:
The flexible finger design provides self-aligning characteristics where the fingers naturally guide the ball structure into the correct position during engagement. This self-service feature eliminates the need for precise alignment procedures or specialized tools, allowing service technicians to easily remove and reinstall the pushrod with minimal workspace requirements.
3Reliability
If a complex pushrod interface housing with clips and brackets is used, then the connection is secure and replaceable, but the manufacturing cost increases and the service technician operation becomes frustrating
Solution Approach 1:
Multiple functions are merged into the flexible finger retaining clips, which simultaneously provide secure retention of the ball structure, allow for easy release during service, and eliminate the need for separate mounting brackets and housing complexities. This merging of functions reduces manufacturing steps and component count while maintaining connection security and serviceability.
Solution Approach 2:
The flexible finger retaining clips serve multiple functions: they secure the ball structure during operation, guide alignment during assembly, and provide easy release during service. This multi-functionality eliminates the need for separate components for each function, reducing manufacturing complexity and cost while improving overall system performance.
Data Source
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AI summary
A vehicle brake pedal booster pushrod interface assembly (50) is provided that includes: a pivotable brake pedal arm (52) including a protruding peg structure (54); and an elongate pushrod (64) including a clip structure (62) disposed at one end thereof and adapted to pivotably engage the protruding peg structure (54) of the pivotable brake pedal arm (52). The brake pedal booster pushrod interface assembly (50) further includes a cylindrical sleeve (80) adapted to be rotatably disposed about the protruding peg structure (54) of the pivotable brake pedal arm (52) and be pivotably engaged by the clip structure (80) of the elongate pushrod (64). Optionally, the cylindrical sleeve (80) includes an opposed conical section (82,84) disposed at either end thereof and separated by a cylindrical center portion (86). The clip structure (62) of the elongate pushrod (64) includes a pair of arms (72,74) defining an opening (68) and an interior space (70) adapted to receive the protruding peg structure (54) of the pivotable brake pedal arm (52).