Spring Steel Coupling Element for Engine Brake Actuation
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Solution Overview
Problem
The existing connecting device for an actuating lever to a control valve in engine brakes is not robust, durable, or cost-effective, requiring improvements in design and materials to enhance performance and longevity.
Innovation Solution
A resilient coupling element made of spring steel with parallel limbs and a C- or Z-shaped configuration, where the first limb is pivotably mounted in the control slide's bore and the second limb is latched into the actuating lever's locking groove, ensuring a secure, play-free connection without additional securing means, allowing for easy assembly and high durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a U-shaped sheet metal coupling element with slots is used to connect the actuating lever to the control slide, then the connection can be established, but the device lacks robustness and durability
Solution Approach 1:
The coupling element is changed from U-shaped sheet metal with slots to a wire with round cross-section. This parameter change in geometry and material form provides inherent flexibility and robustness while simplifying the manufacturing process to basic wire forming and bending operations.
Solution Approach 2:
Instead of using a rigid U-shaped structure with slots that requires complex assembly, the invention uses a flexible wire that is bent into shape. The wire is inserted through the control slide bore and then bent to engage the actuating lever, inverting the approach from rigid-with-clearances to flexible-with-form-fit.
2Reliability
If additional securing means are used to fasten the coupling element, then the connection becomes more secure, but the assembly process becomes more complex and time-consuming
Solution Approach 1:
The coupling element is designed to be self-securing through its bent wire configuration. The wire engages the actuating lever through elastic deformation and geometric interlocking, eliminating the need for separate fasteners, clips, or securing mechanisms. The assembly is complete simply by inserting and bending the wire into its final position.
3Strength
If the coupling element is made from rigid material, then it can withstand actuating forces, but it cannot accommodate pivoting movements and may cause wear or failure
Solution Approach 1:
The coupling element uses a flexible wire configuration that can bend and pivot to accommodate the movement between the control slide and actuating lever. The wire's flexibility allows it to follow the pivoting motion while maintaining sufficient stiffness to transmit the required actuating forces, combining adaptability with strength.
4Reliability
If deep locking grooves are formed in the actuating lever to secure the coupling element, then the connection becomes more secure, but the actuating lever is weakened and has reduced service life
Solution Approach 1:
The engagement method is changed from deep grooves to a shallow locking groove combined with elastic deformation of the wire. The wire's flexibility provides the securing force through its bent configuration rather than relying on deep mechanical interlocking, thereby preserving the actuating lever's structural integrity and extending its service life.
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 provides a robust, durable, and cost-effective connection that withstands actuating forces, ensuring a long service life with minimal deformation and no weakening of the components, facilitating easy installation and operation of the engine brake system.
Implementation Method 1
the coupling element consists of spring steel
Data Source
Figure 1~4
AI summary
The invention relates to a device for connecting an actuating lever (1) to a control slide (8) of a control valve (7), in which the actuating lever (1) is designed as a pivoting lever and is connected to the control slide (8) by means of a spring-elastic coupling element (11). To make this device robust and cost-effective, the invention provides that the coupling element (11) has two legs (12, 13) aligned parallel to each other and a section (15) connecting the two legs (12, 13), and that the first leg (12) of the coupling element (11) is pivotably mounted on the free end (9) of the control slide (8), and that the second leg (13) can be locked to the free end (3) of the actuating lever (1).