Interlocking Bellcrank Layout for Compact Master Cylinder Mounting
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Solution Overview
Problem
Conventional master cylinders require significant space between the bulkhead and firewall, making them unsuitable for low-speed vehicles with a cabover design, where space is limited, and they cannot be easily configured to accommodate different transverse motion requirements.
Innovation Solution
An interlocking bellcrank system that includes a first and second portion with wings, allowing for the transformation of linear motion into rotational and transverse motion to pressurize brake fluid, enabling the master cylinder to be installed at a 90-degree angle or any configuration between 0 to 360 degrees, thus fitting in vehicles with limited space and accommodating various designs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional master cylinder is used, then the brake system can function properly, but it requires significant space between the bulkhead and firewall
Solution Approach 1:
The bellcrank is divided into multiple segments (first portion, second portion, third portion) that can be independently positioned and oriented. Each segment contains mounting surfaces and connection points that allow the overall assembly to be configured in different spatial arrangements, reducing the space required between bulkhead and firewall while maintaining brake system functionality
Solution Approach 2:
The bellcrank assembly utilizes three-dimensional spatial configuration with mounting surfaces oriented at various angles (including 90-degree angles). The first, second, and third portions are arranged in different spatial dimensions, allowing the master cylinder to be mounted in a compact footprint that fits within limited space between bulkhead and firewall
2Reliability
If a conventional master cylinder is used, then the brake system can operate, but it cannot be installed in vehicles with cabover design where space is limited
Solution Approach 1:
The bellcrank assembly provides dynamic configurability through its multi-port ion structure, where the first, second, and third portions can be oriented in different directions and angles. This allows the same basic component to be adapted to various vehicle architectures including conventional designs and cabover designs with limited space
Solution Approach 2:
The bellcrank assembly serves multiple functions: it provides the mechanical linkage for brake actuation, offers configurable mounting orientations (including 90-degree angles), and can be installed in different vehicle types (conventional and cabover designs). The multiple portions with various mounting surfaces make it a universal solution for different space constraints
3Ease of operation
If a conventional master cylinder is used, then the system operates with linear motion, but it cannot be easily configured for different transverse motion requirements
Solution Approach 1:
The bellcrank assembly converts the linear motion from the brake pedal into rotational motion and then into transverse motion through its articulated multi-port ion structure. The first portion receives linear motion, the intermediate portions transform this motion through rotation, and the final portion delivers transverse motion to the master cylinder, allowing easy configuration for different motion requirements
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The interlocking bellcrank system allows for efficient installation of the master cylinder in vehicles with limited space and enables various configurations, ensuring proper brake fluid pressurization and operation in vehicles with cabover designs or limited space between the bulkhead and firewall.
Implementation Method 1
a bellcrank that includes a first portion including a first top surface, a first bottom surface, and a first wing... The second portion is disposed directly below the first portion such that the second top surface is configured to interlock with the first bottom surface
Data Source
AI summary
An apparatus, system, and method according to which a bellcrank is used to transfer an output of a lever to a component requiring actuation. For example, a bellcrank that includes two interlocking portions transfers an output of a linear motion around a fixed axis via a rotational motion then to a transverse motion in order to pressurize brake fluid in a master cylinder of a vehicle.