Tool-less Pedal Assembly Spring Clip Mechanism
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Solution Overview
Problem
Conventional assembly of pedaled vehicles, such as bicycles and tricycles, requires tools and can be complex and costly, leading to consumer frustration and potential product returns due to the need for threaded connections and multiple movable parts in quick-connect designs.
Innovation Solution
A tool-less pedal assembly system using a spring clip with flexible tabs that secures the pedal to the crank assembly, allowing for easy insertion and secure locking without the need for tools, featuring a U-shaped or disc-shaped spring clip design that flexes to accommodate the pedal shaft and restricts removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional threaded connections are used to secure pedals to the crank assembly, then the connection strength is sufficient, but the assembly requires tools and becomes complex and time-consuming
Solution Approach 1:
The pedal assembly system is divided into separate components: a pedal with shaft, a crank assembly with bore, and a separate securing mechanism (set screw or spring clip). This segmentation allows the pedal to be inserted without tools, while the securing mechanism provides the necessary connection strength through simple manual tightening or spring pressure.
Solution Approach 2:
The threading function is extracted from the main pedal shaft and placed into a separate securing mechanism (set screw or spring clip with locking feature). This allows the main assembly action to be tool-less while the securing function is handled by a separate, simple component that can be manually operated.
2Ease of operation
If quick-connect designs with multiple movable parts are used, then tool-less assembly is achieved, but the device complexity increases and manufacturing costs rise
Solution Approach 1:
The complex quick-connect mechanism with multiple movable parts is replaced by extracting the essential function into a simple set screw or spring clip. These simplified components have fewer moving parts while still achieving tool-less assembly through manual operation.
Solution Approach 2:
The design uses simpler, potentially single-use or easily replaceable components like set screws or spring clips instead of complex, expensive quick-connect mechanisms. This reduces manufacturing costs and device complexity while maintaining ease of assembly.
3Strength
If threaded stems with non-circular portions are used, then the connection can be securely tightened, but tools such as wrenches are required for assembly
Solution Approach 1:
The threading and tightening function is extracted from the main pedal shaft into a separate set screw or spring clip mechanism. This allows the pedal shaft itself to be a simple cylindrical form that can be inserted without tools, while the securing function is handled by the separate component that provides connection strength.
Solution Approach 2:
The set screw or spring clip is designed to be manually operable without tools. The user can directly tighten the set screw or compress the spring clip with their fingers to achieve secure connection, eliminating the need for external tools while maintaining connection strength.
4Strength
If stainless steel or similar materials are used for the quick-connect housing, then the structural loads are withstood, but the manufacturing cost increases
Solution Approach 1:
The design replaces expensive stainless steel quick-connect housings with simpler, potentially less expensive materials such as standard steel or aluminum for the crank assembly and securing mechanisms. The simplified design with fewer parts reduces material costs and manufacturing complexity.
Solution Approach 2:
The complex housing structure required for quick-connect mechanisms is eliminated. The securing function is handled by separate, simpler components (set screw or spring clip) that can be made from standard materials at lower cost, removing the need for expensive specialized housings.
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
Enables quick, easy, and tool-free assembly of pedals to pedaled vehicles, reducing complexity and cost while ensuring secure attachment, thus enhancing user experience and reducing product return rates.
Implementation Method 1
a spring clip for securing the pedal to the crank assembly including at least one flexible tab or leg capable of flexing between a first configuration and a second configuration
Data Source
AI summary
A pedaled vehicle includes a frame, a wheel rotatably coupled to the frame, a crank assembly operatively coupled to the wheel and having a bore, a pedal received in the bore, and a spring clip for securing the pedal to the crank assembly. The spring clip includes at least one flexible tab or leg capable of flexing between a first configuration, where the spring clip allows a shaft of the pedal to pass through the bore, and a second configuration, where the pedal shaft is prevented from being removed from the bore. A method for coupling a pedal to a vehicle in a tool-less manner is also disclosed.