Parking Brake Lever Coupling for Blind Cable Assembly
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Solution Overview
Problem
Existing drum-in-hat type parking brake actuation assemblies are complex to assemble, require multiple components, and often necessitate the use of springs for proper operation, making them cumbersome and prone to accidental uncoupling, which poses safety risks during vehicle assembly and maintenance.
Innovation Solution
A compact brake actuation assembly with a reduced number of components, featuring a thrust and support element with a rotatable lever and a guide channel that allows the traction cable to be coupled without springs, enabling secure and automatic 'blind' assembly by utilizing the cable's elasticity to prevent free rotation and ensure secure coupling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If springs are used to ensure proper operation of the actuation assembly, then the reliability is improved, but the device complexity increases and the assembly becomes cumbersome
Solution Approach 1:
The patent removes springs and clips from the actuation assembly, extracting the problematic components that caused complexity and assembly difficulties. The cable connection is achieved through a direct mechanical coupling between the cable end and the lever's hooking seat, eliminating the need for spring-based retention mechanisms.
Solution Approach 2:
The lever's hooking seat is designed to automatically engage and retain the cable end through its geometric configuration. The undercut arrangement creates a self-locking mechanism where the cable end is mechanically retained by the lever structure itself, without requiring external spring-based retention systems.
2Ease of manufacture
If the assembly is made simple with fewer components, then the ease of manufacture is improved, but the reliability may worsen due to potential accidental uncoupling
Solution Approach 1:
The hooking seat is designed with an asymmetric undercut geometry that allows easy insertion of the cable end in one direction while providing mechanical retention against removal in the opposite direction. This asymmetric design ensures reliable coupling without requiring complex retention mechanisms, achieving both simplicity and reliability.
3Productivity
If blind assembly is implemented to reduce assembly time, then the productivity is improved, but the difficulty of detecting and measuring increases
Solution Approach 1:
The cable end is pre-formed with a specific geometry that is compatible with the hooking seat's undercut configuration. This preliminary preparation of the cable end ensures that when the cable is inserted into the assembly, it automatically engages with the lever's hooking seat in the correct orientation, enabling blind assembly without requiring visual verification of the connection.
4Ease of operation
If the lever can rotate freely in both directions, then the ease of operation is improved, but the reliability worsens due to potential uncoupling in the opposite direction
Solution Approach 1:
The rotational movement of the lever is segmented into two distinct zones: a free rotation zone in the actuation direction (push direction) where the lever can move freely to actuate the brake, and a constrained zone in the opposite direction where the cable end engages with the undercut hooking seat to prevent uncoupling. This segmentation allows easy operation in the useful direction while ensuring reliability against accidental uncoupling.
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 solution simplifies the assembly process, reduces the overall volume of the assembly, and prevents accidental uncoupling while allowing for easy release during servicing, ensuring secure and error-proof coupling without the need for springs or clips, thus enhancing safety and reducing assembly time and costs.
Implementation Method 1
a cable body (15) capable of an elastic flexural deformation which allows it to return to the straight position (resting direction XX of elastic traction cable) when the bending stress is removed
Data Source
AI summary
A brake actuation assembly comprising a thrust and support element comprising a first thrust end adapted to cooperate with a first jaw of a brake; the thrust and support element comprising a second thrust and support element end; a lever rotatably supported to the thrust and support element for rotating at least along a rotation thrust direction; the lever comprising a first lever end adapted to cooperate with a second jaw of the brake; the lever comprising a second lever end, wherein the second lever end comprises a hooking seat; and wherein the hooking seat is adapted to firmly receive a connecting portion of a coupling end of a traction cable, the traction cable having a cable body capable of an elastic flexural deformation; the hooking seat being arranged undercut with respect to the rectilinear development direction of the cable body; the lever being adapted to oscillate; wherein the lever comprises a lever abutment surface which cooperates with a stop abutment counter-surface provided in the thrust and support element to prevent a free rotation of the lever in the opposite direction to the rotation thrust direction; the thrust and support element and the second lever end delimiting a guide channel which allows the passage of at least the coupling end; the guide channel allowing the coupling end to rotate about the second lever end and to be coupled to the hooking seat upon the elastic return of the cable body to a substantially straight cable body position, preventing the rotation of the lever in the opposite direction to the rotation thrust direction.