Spring Brake Actuator Snap-Fit Cover for Faster Service Assembly

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Solution Overview

Problem

Existing spring brake actuators for commercial vehicles require complex and time-consuming assembly processes, often involving multiple components and processes like clamp rings, bolts, nuts, rolling, or crimping, which complicate maintenance and replacement.

Innovation Solution

The spring brake actuator employs a snap-fit connection between the service chamber cover and the housing base, utilizing cuts in the rim of the service chamber cover to create flexible segments that snap over the flange lip, simplifying assembly and allowing for easy disassembly and replacement.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If clamp rings with screws and nuts are used to connect the service chamber cover with the housing base, then a secure mechanical connection is provided, but the assembly process becomes complex and time-consuming

Engineering Contradiction:

Improvemechanical connection strengthVSAvoidassembly complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The rim of the service chamber cover is divided into multiple flexible segments by cutting, allowing each segment to independently snap over the flange lip of the housing base. This segmentation enables simple snap-fit connection without requiring clamp rings, screws, or nuts, thus reducing assembly complexity while maintaining connection strength

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The traditional mechanical fastening system (clamp rings with screws and nuts) is replaced by a snap-fit connection mechanism. The flexible segments utilize elastic deformation and snap-fit geometry to create a secure mechanical connection without requiring threaded fasteners, thereby simplifying the assembly process

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Strength

If permanent connections like rolling or crimping are used to connect the housing base with the service chamber cover, then a secure mechanical connection is provided, but disassembly and replacement become difficult

Engineering Contradiction:

Improvemechanical connection strengthVSAvoiddiaphragm replacement ease

Core Design Contradiction:

StrengthVSEase of repair

Solution Approach 1:

The connection transitions from a static permanent connection (rolling or crimping) to a dynamic reversible connection. The flexible segments can be elastically deformed to release from the flange lip, enabling easy disassembly and reassembly. This dynamic connection maintains security during operation but allows simple maintenance when needed

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The snap-fit connection allows the service chamber cover to be easily removed and recovered for maintenance. The flexible segments can be deliberately deformed to release the connection, enabling diaphragm replacement, and then reconnected by simply snapping the segments back over the flange lip

Inventive Principle:

Principle #34Discarding and recovering

3Strength

If additional components like clamp rings, screws, and nuts are used for connection, then a secure mechanical connection is provided, but the number of parts and assembly steps increases

Engineering Contradiction:

Improvemechanical connection strengthVSAvoidassembly speed

Core Design Contradiction:

StrengthVSProductivity

Solution Approach 1:

The connection function is integrated directly into the rim structure of the service chamber cover through the flexible segments. This eliminates the need for separate clamp rings, screws, and nuts, reducing the total part count to essentially zero additional components while maintaining secure connection strength

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The flexible segments perform multiple functions: they provide the connection structure, create the mechanical interlock with the flange lip, and enable the assembly/disassembly mechanism. The connection system is self-contained within the rim segments themselves, eliminating dependency on external fastening components

Inventive Principle:

Principle #25Self-service

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 snap-fit connection significantly simplifies the assembly process, reduces the need for additional components and complex assembly steps, and allows for easier maintenance and replacement of components, enhancing operational efficiency and reducing assembly time.

Implementation Method 1

the rim comprises cuts for providing a snap-fit connection with the flange lip

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentEP4292894B1Spring brake actuator comprising flexible segments for providing a snap-fit connection, and commercial vehicle comprising a respective spring brake actuator

Publication Date: 2025.01.29 ZF CV SYST EURO BV

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AI summary

The spring brake actuator (50) comprises a service brake part (52) and a parking brake part (54) conjoined by a housing base (72) of the spring brake actuator (50), wherein the service brake part (52) comprises a service chamber cover (56), a diaphragm, a service chamber, and a push rod for providing a service brake function. The service chamber cover (56) comprises an outside wall (74) with a rim for connecting the service chamber cover (56) with a flange lip of the housing base (72), wherein the rim comprises cuts (78) for providing a snap-fit connection with the flange lip (84).