Brake Switch Rod and Movable Board Integration
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Solution Overview
Problem
The existing switch devices for detecting brake pedal depression operations are complex and costly due to the need for precise alignment and multiple components in the connection between the rod and the movable board, complicating the assembly process and increasing manufacturing costs.
Innovation Solution
A switch device with a connecting mechanism that includes a protruding portion on the rod and a surrounding wall portion on the movable board, allowing the rod to be smoothly pushed into the main body case without interference, using a holder that rotates relative to the main body case to mesh tooth portions, eliminating the need for additional components in the connection part.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a lock mechanism with multiple components is used to connect the rod and movable board, then the connection reliability is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent merges the rod and movable board into a single integrated component, eliminating the need for separate connection mechanisms. The rod directly forms the movable board structure, reducing the number of parts from multiple components to a unified assembly, thereby simplifying manufacturing and assembly processes while maintaining connection reliability
Solution Approach 2:
The rod serves multiple functions simultaneously: it acts as both the pushing element and the movable board structure. By making the rod multi-functional, the patent eliminates the need for separate connection mechanisms, reducing device complexity while ensuring reliable connection between the rod and movable board
2Manufacturing precision
If precise alignment between lock elements is required during rod insertion, then the connection precision is improved, but the ease of manufacture deteriorates
Solution Approach 1:
The patent extracts the alignment requirement from the assembly process by eliminating separate lock elements. Since the rod and movable board are integrated, there are no separate components requiring precise alignment during assembly, thereby improving ease of manufacture while maintaining the necessary connection precision
Solution Approach 2:
The patent segments the functional requirements into the rod's inherent structure rather than requiring separate alignment components. The rod's design inherently provides the necessary positioning and connection functions without requiring precise alignment between separate parts, simplifying the manufacturing process
3Reliability
If additional components are added to prevent rotation and ensure positioning, then the reliability of positioning is improved, but the manufacturing cost increases
Solution Approach 1:
The patent combines the positioning and anti-rotation functions into the integrated rod structure itself. The unified design of the rod and movable board inherently provides stable positioning without requiring additional components, thereby reducing manufacturing cost while maintaining positioning reliability
Data Source
AI summary
A switch device may include a rod movable in association with an operation of a brake pedal, a main body case in which one end side of the rod is disposed, a movable board disposed in the main body case, and a connecting mechanism configured to connect the rod and the movable board. The movable board may be displaceable via the movement of the rod such that a movable contact point of the movable board is in contact with or separate from a fixed contact point. The connecting mechanism may include a protruding portion radially protruding from the rod, and a wall portion provided in the movable board. After pushing the rod into the main body case by a predetermined length, a tooth portion disposed on the protruding portion may mesh with a tooth portion disposed on the wall portion connecting the rod and the movable board.