Brake actuator

The present application discloses a brake actuator for applying tension to a brake cable. The actuator includes: a mounting bracket; a brake actuator lever mounted for pivotal movement relative to the mounting bracket in brake applying and brake releasing directions; and a cam-and-drum member mounted for rotation relative to relative to the brake actuator lever. The cam-and-drum member is formed as one integral part including a protruding drum portion and a cam portion integral with the drum portion. The present application also discloses a brake actuator with a one-piece cam member.

FIELD OF THE INVENTION

The present invention relates to brake actuators.

BACKGROUND OF THE INVENTION

There is an ever-present pressure in the automotive industry to lower costs, both with respect to the overall cost of the vehicle, and the various parts and components used in the vehicle. With respect to brake actuators, these devices are found in many vehicles, but their design is relatively complex, which leads to relatively high costs. The present invention endeavors to provide improvements to a brake actuator that enable part count and manufacturing complexity to be reduced relative to known brake actuators.

SUMMARY OF THE INVENTION

One aspect of the present invention provides a brake actuator for applying tension to a brake cable connected to the brake system of a motor vehicle. The actuator of this aspect of the invention comprises: a mounting bracket; a brake actuator lever mounted for movement relative to the mounting bracket in brake applying and brake releasing directions; and a cam-and-drum member mounted for rotation relative to the brake actuator lever. The cam-and-drum member is formed as one integral part including a protruding drum portion and a cam portion integral with the drum portion. The cam portion provides at least one side of a groove defining a cable guide for receiving the brake cable and enabling winding thereof onto the cam portion. A clutch releasably couples the cam-and-drum member to the brake actuator lever such that the cam-and-drum member rotates with movement of the brake actuator lever relative to the mounting bracket at least in the brake applying direction, thereby winding the brake cable onto the cam portion and applying tension to the cable for activating the brake system. The clutch is operable to release the cam-and-drum member from the lever such that the cam-and-drum member is able to rotate relative to the brake actuator lever at least when the lever is in a brake released position. A spring is connected to the cam-and-drum member and biases the cam-and-drum member in a slack take-up direction relative to the lever to wind the cable thereon for taking up cable slack when the clutch releases the cam-and-drum member from the lever.

The use of the cam portion integral with the drum portion provides a structurally sound construction that can be formed at a lower cost relative to two-piece designs.

Another aspect of the invention provides a brake actuator with an improved cam member design. The actuator of this aspect of the invention comprises a mounting bracket, a brake actuator lever, and a sheet metal cam member on the brake lever. The cam member has a flange portion deformed to define a generally U-shaped groove with integral side walls for receiving the brake cable and enabling winding thereof onto the cam member by movement of the lower in a brake applying direction relative to the mounting bracket. This applies tension to the cable for activating the brake system.

The use of a sheet metal cam member with a flange deformed in this manner is advantageous because it reduces part count relative to using two parts assembled to form the sides of the grove, as is often the case with prior art designs. It also prevents the wedging action of the brake cable between the parts in prior art designs, as the U-shape is formed by a one-piece sheet metal member.

Other objects, features and advantages of the present invention will be appreciated by the following detailed description, the accompanying drawings and the appended claims.

Another aspect of the invention provides a method of forming a brake actuator for applying tension to a brake case connected to the brake system of a motor vehicle, the method comprising: providing a brake actuator lever; providing a cam member, including deforming a sheet metal flange into a general U-shape so as to define a cable guide for receiving the brake cable and enabling winding thereof onto the cam member; providing a mounting bracket; and pivotally mounting the brake actuator lever and the cam member for pivotal movement relative to the mounting bracket in brake applying and releasing directions, the cam member being provided on the brake lever such that the movement of the brake lever in the brake applying direction winds the cable onto the cam member for applying tension to the cable for activating the brake system.

Another aspect of the invention provides a method of forming a brake actuator for applying tension to a brake cable connected to the brake system of a motor vehicle, the method comprising: forming a piece of sheet metal to initially form a cam-and-drum member having a flange portion; deforming the flange portion into a general U-shape so as to define a cable guide for receiving the brake cable and enabling winding thereof onto the cam portion; providing a mounting bracket; mounting a brake actuator lever for movement relative to the mounting bracket in brake applying and releasing directions; rotatably mounting said cam-and-drum member for rotation relative to the brake actuator lever; providing a clutch releasably coupling the cam-and-drum member to the brake actuator lever such that the cam-and-drum member rotates relative to the mounting bracket with movement of the brake actuator lever at least in the brake applying direction, thereby winding the brake cable onto the cam portion and applying tension to the cable for activating the brake system, the clutch being operable to release the cam-and-drum member from the lever such that the cam-and-drum member is able to rotate relative to the brake actuator lever at least when the lever is in a brake released position; and connecting a spring to the cam-and-drum member, the spring biasing the cam-and-drum member in a slack take-up direction relative to the lever to wind the cable thereon for taking up cable slack when the clutch releases the cam-and-drum member from the lever.

DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENT(S)

A prior art self-adjusting parking brake actuator is shown generally in theFIGS. 1-9at10. The actuator10is shown and described herein in a hand-operated embodiment; however, one skilled in the art will appreciate that the present invention is easily adaptable to a foot-operated configuration (not shown) and, thus such adaptation need not be discussed further in this description. This prior art construction is being described to illustrate an exemplary context for the invention and should not be considered limiting in any way.

Referring toFIGS. 1 and 2, actuator10comprises a brake actuator lever assembly A, a position locking assembly B, and a tension self-adjust assembly C having a self-adjusting cam subassembly160and a clutch subassembly170. A brake cable30is connectable to self-adjust assembly C, as will be described below.

Lever assembly A comprises a lever handle12, an intermediate plate46and a cover plate48connected by a rivet120positioned through holes196,198, and200, respectively. Lever12and intermediate plate46are also joined by a rivet122, via holes192and194, and by a pivot rivet124, through holes186and190. Intermediate plate46and cover plate48are also joined by a cam rivet128, through holes204and206, and a pinion rivet134, through holes272and274. Pivot rivet124, cam rivet128and pinion rivet134also have other functions which are described in more detail below.

Lever12has a free end11having a hand grip14to facilitate the grasping of lever12by the vehicle operator. An undulating surface15on grip14is provided for the operator's comfort and increased control. Lever assembly A is rotatably mounted on a mounting bracket44, for rotation about a fulcrum or lever axis25defined by pivot rivet124positioned through holes186,188, and190in lever12, mounting bracket44, and intermediate plate46, respectively. The lever assembly A moves in opposing brake applying and releasing directions.

Mounting bracket44has lugs43and45for connection in any suitable manner to a motor vehicle body V, via holes180. Brake cable30may be of any type and construction known in the art.

Position lock assembly B comprises a pawl subassembly150and a pawl release subassembly155. Pawl subassembly150comprises a ratchet sector50, having a shoulder51and teeth56, and a pawl52, having a nose58for engagement with teeth56, as will be described below. Ratchet50also comprises a finger54(see alsoFIG. 4) for actuating clutch subassembly170, as will be described further below. Ratchet50is fixedly mounted on mounting bracket44. Pawl52is pivotably mounted between lever handle12and intermediate plate46by a pawl rivet126positioned through holes57,102and208. Pawl52is positioned on lever assembly A such that, as lever assembly A is rotated about lever axis25, nose58of pawl52is continuously capable of operative engagement with teeth56on ratchet50, as will be understood by one skilled in the art. Any suitable mechanism may be used in place of the pawl mechanism.

Release subassembly155comprises a push button18operatively connected to a rod22having ends21and26. Rod22is substantially rigid and positioned longitudinally in an interior space20of lever12. Rod end21is positioned adjacent lever free end11and cooperates with a push button18and a release spring24(seeFIGS. 4 and 5). Push button member18is slidably mounted in grip14and is depressible inwardly. Release spring24biases push button18outwardly. Rod end26is connected to pawl52at a guide slot53, on an opposite side of a pawl pivot57from nose58. Spring24also biases rod22away from pawl subassembly150(i.e. spring24simultaneously pushes button18away from lever end11and pulls rod22towards lever end11), and thereby biases guide slot53away from ratchet50, causing nose58to be biased into engagement with the teeth on ratchet50.

Self-adjust assembly C, which comprises self-adjusting cam subassembly160and clutch subassembly170, is mounted to lever assembly A between intermediate plate46and cover plate48, as will be described further below.

Referring toFIGS. 2 and 6, self-adjusting cam subassembly160comprises a drum72, an inner cam78, an outer cam80, a cam sector74having a plurality of engagement teeth76, and a helical self-adjust spring70. The inner and outer cams78and80together constitute a cam or cam member (both terms may be used interchangeably) with a groove or trough defining a cable guide231for receiving and winding up the cable30therein. This may also be referred to as a take-up reel. Cam sector76, outer cam78and inner cam80are secured to one another by bosses226upset in holes228and229. Drum72, inner cam78and outer cam80are secured together through the cooperation of tabs220and slots222and224. Cam subassembly160is rotatably mounted to lever assembly A between cover plate48and intermediate plate46by cam rivet128, mounted in holes204and206, respectively, and passing through holes214,216, and218, respectively. Intermediate plate46thus positions cam subassembly160axially adjacent to lever12. Cam rivet128provides a cam axis55for the rotation of cam subassembly160therearound, as described further below. The drum72functions to occupy the distance between the cam and the cover plate48so as to provide lateral support for the cam and also maintain suitable distance for the various internal components of the actuator10.

Referring briefly toFIGS. 6,7and8, cam axis55is parallel to, and offset from, lever axis25. The offset amount, indicated by reference letter “e” in the Figures, is less than the outer radius “r” of cam subassembly160, as will be described in more detail below.

Referring again toFIGS. 2 and 6, spring70, having an outer tang250and an inner tang252, is positioned between cam subassembly160and lever assembly A and preferably between cam subassembly160and cover plate48. Self-adjust spring70is mounted around drum72, with outer tang250fixed to cover plate48, by engagement of slot260therewith, and inner tang252inserted into a retention slot261in drum72. The self-adjust spring70is installed in a pre-stressed state so as to bias the self-adjusting cam subassembly160in the brake-apply direction, for reasons described in more detail below. This may also be referred to as a slack take-up direction, as in certain instances the cam will rotate independently of the lever to take-up cable slack, and thus will not actually be applying the brakes. Since spring70is provided prior to installation in a prestressed state, suitable caging means for cam subassembly160may be provided.

Cam subassembly160has slots210and212for receiving a cable head32, positioned on the actuator end of brake cable30, for connecting brake cable30to cam subassembly160. Outer cam78and inner cam80have flanges230and232, respectively, which cooperate to form a cable guide231for ensuring an orderly peripheral positioning of cable30around cam subassembly160, as cam subassembly160is rotated in the brake-apply or slack take-up direction (as seen inFIGS. 7 and 8and described further below).

Referring again toFIG. 2, clutch subassembly170comprises a pinion90, having a hub91and teeth92, and a helical clutch spring94wrapped around hub91. Pinion90is rotatably mounted to lever assembly A, preferably between cover plate48and intermediate plate46by pinion rivet134extending between holes272and274, respectively. Spring94is positioned on hub91such that an embracing friction occurs therebetween, permitting the windings of spring94to securely grip hub91. A pinion spacer ring100is preferably provided to impede interference between clutch spring94and teeth92. Teeth92operatively engage teeth76of cam sector gear74. Clutch spring94has tangs96and98.

Referring toFIGS. 7 and 8, tang96is fixed to cover plate48by an anchor clip110held by a pair of anchor rivets132in holes270. Tang98, however, remains free for selectively tabbing thereof by finger54, which is on ratchet sector50and constitutes a clutch spring release, as will be described in more detail below.

As will be understood by one skilled in the art, spring94is oriented on hub91of pinion90such that rotation of pinion90in a clockwise direction (with reference toFIGS. 5,7,8) tends to wind spring94more tightly around hub91, through the frictional contact of hub91and spring94. Further, it will be understood by one skilled in the art that, while spring94may be fabricated from stock having a rounded cross-section, a rectangular cross-section spring is desired to increase the contact surface area between spring94and hub91, thereby increasing the gripping ability of spring94. Also, it will be understood by one skilled in the art that the friction between spring94and hub91is sufficient to permit clutch subassembly170to resist counter-rotation of cam subassembly160, in response to an induced tension in cable30. As a result, when lever assembly A is moved from the brake-released to brake-applied positions, clutch subassembly170locks cam subassembly160sufficiently so that cam subassembly160rotates with lever assembly A without slipping. Finally, it will be understood that the interference fit of spring94must also be loose enough so that, when free tang98is tabbed by finger54when actuator10is in the brake-released position (as will be described below), pinion90is permitted to rotate freely within spring94, thereby unlocking cam subassembly160from lever assembly A.

Referring toFIG. 3, in use actuator10is operated by selectively positioning lever assembly A in either the brake-released position (shown in solid lines) or one of a plurality of brake-applied positions (one such position shown in stippled lines at12′). As indicated above, lever assembly A rotates about lever axis25, by manipulation of lever12by the vehicle operator.

Referring toFIG. 7, when actuator10is in the brake-released position, lever assembly A is positioned relative to mounting bracket44such that finger54engages free tang98of spring94, thereby slightly unwinding spring94and allowing pinion90to rotate freely about pinion rivet134, thus disengaging clutch subassembly170. As a result, the self-adjusting cam subassembly160, having sector teeth76engaged with pinion teeth92, is “unlocked” relative to lever assembly A and capable of rotation in response to selfadjust spring70. Any slack which may be present in cable30, such as slack introduced during installation or introduced over time by casual cable stretch, is thus automatically taken up by a rotation of cam subassembly160in the brake-apply direction (clockwise inFIG. 7) when the actuator is in the brake-released position. Spring70is sized and of sufficient strength to provide a desired minimum residual tension in cable30but not cause an unintentional application of the vehicle parking brakes.

Also, referring toFIG. 4, when actuator10is in the brake-released position, position locking assembly B maintains nose58in contact with sector50, adjacent un-toothed shoulder51and, thus out of engagement with teeth56.

Referring toFIG. 8, when lever assembly A is rotated out of the brake-released position to a brake-applied position, the rotation of lever assembly A moves clutch subassembly170away from finger54, causing finger54to release tang98and permitting clutch spring94to contract and thereby tightly grasp or embrace pinion90. As described above, since tang96of clutch spring94is anchored to cover plate48(i.e. part of lever assembly A), spring94cannot rotate and, thus, pinion90is thus not permitted to rotate, particularly in the clockwise direction (as viewed inFIGS. 7,8). Cam subassembly160is thus “locked” to lever assembly A through the co-action of pinion teeth92and sector74. The rotation of lever assembly A in the brake-apply direction tends to further wind the clutch spring94around hub91, thereby increasingly prohibiting rotation of pinion90. As a result of the locked condition, pinion90is unable to rotate and an operative locked connection is established between the lever assembly A and the self-adjusting cam subassembly160. As lever assembly A is rotated towards a brake-apply position, cam subassembly160thus also travels around lever axis25due to the eccentric mounting of cam subassembly160, and cable30is wound on to guide231(seeFIG. 8) to increasingly tension and take up cable to apply the parking brake system.

Also, as lever assembly A is advanced in the brake-apply direction, pawl52is rotated about lever axis25to permit nose58to come into contact with teeth56of sector50. The angle of teeth56of sector50relative to nose58of pawl52permits nose58to advance over teeth56without depressing button18of pawl release subassembly155. Thus, the vehicle operator may simply rotate lever12, although button18may be depressed if desired. Once nose58has advanced from shoulder51to engage teeth56, pawl subassembly150will ratchet over the teeth of ratchet sector50and act to prevent the reverse rotation of lever12in the brake-release direction (i.e. clockwise inFIG. 4). Lever12is advanced in the brake-apply direction, thereby tensioning cable30, until a desired lever of brake cable tension is achieved to set the vehicle parking brakes sufficiently to the operator's satisfaction. The lever may have an operable rotation range of about 40 degrees, for example. To release the brakes, button18is depressed to release nose58from teeth56for enabling movement of the lever in the releasing direction. When button18is depressed, pawl nose58rotates about the pawl pivot57to disengage nose58from sector teeth56. Lever12may then be rotated, while button18is depressed, back to the brake-released position.

By providing an eccentric positioning of cam axes55relative to lever axis25, the actuator achieves a variable mechanical advantage as the actuator lever is stroked to full position. Thus, the amount of operator input force necessary to apply the parking brake throughout the lever stroke is reduced. Also, advantageously, the overall lever length can be reduced. For example, an eccentric offset “e” of 15 mm results in a significant increase in the maximum mechanical advantage achievable for an actuator given size.

The benefits of the illustrated actuator, in terms of available mechanical advantage per a given amount of cable travel, is shown inFIG. 9. The “Eccentric” line ofFIG. 9represents an actuator according to the present invention having a 350 mm lever, 45 mm radius cam and a 15 mm offset between the cam and lever axes. Also shown inFIG. 9, for comparison purposes, is a comparably-sized (in terms environmental space requirements) concentric actuator (“Concentric” v line). The “Eccentric” line clearly demonstrates that a small eccentric mounting yields a marked benefit, in terms of mechanical advantage, over a comparably-sized concentric design.

Turning now toFIG. 10, it illustrates a one-piece take-up reel or cam member400. The cam member400may be used in the prior art construction discussed above, or any other type of brake actuator. The cam member400includes a generally circular disc-shaped body402. The body402has a central opening403for mounting to the pivot rivet128in the above-described construction. Slots may be formed as in cam portions78and80for mounting a separately formed drum thereto. The peripheral edge of the body400has an integrally formed flange404that is bent into a trough or U-shape with integral opposing side walls to define a groove406to act as a cable guide. An aperture408is provided for receiving a cable head, such as cable head32.

The body402is formed by a progressive stamping operation from a piece of suitable gauge sheet metal, such as steel. Specifically, the body402is initially stamped to form its general shape along with flange404, hole403, aperture408, and any other slots or holes, such as for mounting a drum, such as drum72. The body is further stamped in a subsequent die to bend the flange404generally perpendicularly to the body400; however, the bending of the flange may be done in the same stamping as the formation of the cam body402. The free end of the flange404is then deformed further to bend it over to create the U-shape and define the groove406. The deforming of the free end of the flange408is preferably done by a subsequent stamping die. One skilled in the art can readily appreciate the particular die shapes required to form the cam member400as illustrated, and thus detailed illustrations of the particular stamping dies are not being provided. Other methods of forming these structures may also be used.

One advantage of using the integrally formed U-shaped cable guide is that part count is reduced, as two cooperating parts do not have to be assembled to define the two side walls of the U-shaped guide. Additionally, in prior art constructions where two parts are assembled to define the two sides of the U-shaped guide, there is a tendency for the brake cable to “wedge” between those parts, which is undesirable. In contrast, by having the two side walls of the U-shaped guide integral, this problem is eliminated, as there is no interface between two parts for the cable to wedge into.

FIG. 11shows a foot-operated type brake actuator500. The actuator500includes a mounting bracket502for mounting the actuator500within the passenger compartment of a vehicle, usually beneath the driver's side of the dashboard. A pedal lever506is pivotally mounted to the bracket502on a pivot rivet508and a cover plate504is fixedly mounted to the lever506opposite the bracket502. The lever506includes a body portion510having an arcuate sector512thereon and a lever arm514fixed to the body portion510. In the Figure, the brake apply direction is counterclockwise, and a spring516is connected between the lever506and the bracket502to bias the lever in the brake releasing direction (clockwise inFIG. 11) opposite the brake applying direction (counterclockwise). This ensures that the lever506is returned to the full released position in the event there is insufficient cable tension to pull it to that position.

A one-piece cam-and-drum member520is rotatably mounted to the lever506about the pivot rivet508. The member520is formed as one integral part including a protruding drum portion522and a cam or take-up reel portion524integral with the drum portion522. The cam portion524provides a groove526defining a cable guide for receiving the brake cable30and enabling winding thereof onto the cam portion524. This manner in which this component is formed will be described in further detail hereinbelow.

A take-up spring530is mounted within the hollow of the drum portion522and has one end connected to the cover plate504and another end connected to the drum portion522, or some other portion of the cam-and-drum member520. The spring530rotatably biases the cam-and-drum member520in a slack take-up direction (which. is the same as the brake applying direction) relative to the lever506to wind the cable thereon for taking up cable slack in a manner which is described hereinbelow.

A clutch spring532embraces an exterior surface of the drum portion522and is connected to the lever506to releasably couple the cam-and-drum member520to the brake actuator lever506. Generally, the clutch spring operates much in the way described above. One end of the clutch is fixed to the lever506and the other end536is free. Normally, as the brake lever506is being moved in the brake applying direction, the spring532remains contracted to frictionally embrace the exterior surface of the drum portion522(and thus the drum portion522may be referred to as a spring embraceable structure). This frictional engagement, together with an end of the spring532being fixed to the lever506, couples the cam-and-drum member520to the lever506so that they move together, thus enabling tension to be applied to the brake cable for purposes of activating the brake system of the vehicle. When the lever506is returned to its brake released position, the free end536of the spring532engages a tab or other surface on the bracket502so that the spring532is expanded. The decouples the cam-and-drum member520from the lever506so that the take-up spring530can take-up and slack in the brake cable and ensure it has proper tension. Upon movement of the lever506in the brake applying direction, the slight friction between the spring532and the drum portion522will cause the cam-and-drum member520to rotate sufficiently to disengage the free end536from the bracket, whereby the spring532again contracts as discussed above.

A torsion clutch assembly546has the same general construction and functions in the same general way as clutch subassembly170discussed above, with the following exceptions. In the embodiment ofFIG. 11, a pinion gear of the clutch assembly546engages the sector512on the lever506to prevent it from being moved in the brake releasing direction, but functions in a one-way manner to enable the lever to be moved in a brake-applying direction. A clutch release lever534is pivotally mounted to the bracket502and has a spring receiving portion535for retaining a free end of a torsion clutch spring in the clutch assembly546. The lever534is connected to a manual release handle (not shown) by which operation of the handle pivots the lever534. This movement in turn moves the free end of the torsion clutch spring in the clutch assembly, which in turn expands the clutch spring and enables a pinion gear of the assembly546to freely rotate. This enables the tension of the brake cable to pull the lever and cam-and-drum member520back in the brake releasing direction.

A contact switch548is provided on the lever506and engages the bracket504when the brake lever506is in the fully released position. This can be used to send a signal to turn off an indicator light in the passenger compartment indicating that the brake has been applied.

Referring more specifically to the cam-and-drum member520, as illustrated inFIGS. 12 and 13, the cam-and-drum member520is formed in a similar fashion to the one-piece cam400described above, with the exception that the drum portion522is formed integral with the cam portion524. Specifically, member520is formed by a progressive stamping operation from a piece of sheet metal, such as steel. The member520is initially stamped to form its general shape, including the drum portion522and the general disc-shape of the cam portion524. This may be done in a single stamping operation, or in multiple operations. A flange550is formed along the edge of the cam portion524. This flange550is further stamped in a subsequent die to bend the flange550at an angle, preferably generally perpendicularly, to the body; however, the bending of the flange550may be done in the same stamping as the formation of the cam portion524. The free end of the flange550is then deformed further to bend it over to create the U-shape and define the groove526. The deforming of the free end of the flange550is preferably done by a subsequent stamping die. One skilled in the art can readily appreciate the particular die shapes required to form the cam-and-drum member520as illustrated, and thus detailed illustrations of the particular stamping dies are not being provided. Other methods of forming these structures may also be used.

This cam-and-drum member520may be used in the construction ofFIGS. 1-9, or any other brake actuator. Additionally, it is contemplated that the cam portion may be provided by one flanged part that is integral with the drum portion, and another part that is attached thereto to define the cable guide. This would be similar to the construction inFIGS. 1-9wherein the inner and outer cams78and80are assembled to define cable guide231, but the drum would be integral as one piece with the inner cam78. Thus, the cam portion integral with the drum portion would define only one side of the guide, while the other side of the guide would be defined by the separately attached cam member (e.g., cam member80).

FIG. 14illustrates another embodiment of a brake actuator600. This brake actuator600has a mounting bracket602with an upstanding vertical wall604. A brake lever606is pivotally connected to the wall604by a pivot rivet605. The brake lever606has a hand grip608at the free or distal end thereof. A contact switch610is mounted on the wall604and is contacted by the lever602in its brake released position to transmit a signal indicating that the brake is released.

On the side of the lever602that cannot be seen inFIG. 14is a conventional pawl and ratchet sector arrangement for securing the lever602in a brake applying position. As is conventional in the art, a toothed arcuate sector is mounted on the wall604concentric with the pivot rivet605, and a spring-biased pawl engages that sector to maintain the brake lever602in a brake applying position. A rod (also not shown) is connected between the pawl and button612such that depressing the button612(usually with the user's thumb) shifts the rod to disengage the pawl and free the lever602for movement back to its brake releasing position. This mechanism is similar to that shown inFIGS. 1-9.

On the side of the lever602seen inFIG. 14, there is provided a cam member614. The cam member614is fixed to the lever602by riveting, welding, or in any other suitable way. The cam member614is shown in detail inFIGS. 15 and 16.

As shown inFIGS. 15 and 16, the cam member614is formed from a piece of sheet metal, and is preferably formed using the types of stamping operations discussed above. The cam member614has a main body616with an aperture618for the pivot rivet605. Other apertures620are provided for rivets that may be used to fix the cam member614to the lever602.

A flange622is provided concentric to the opening618and is bent into a general U-shape to form a cable guide624. This guide624may be formed in the same manner as discussed above and enables a brake cable626to be wound thereon as the brake lever602is pivoted in its brake applying direction. When attaching the brake cable626it is extended around the guide624and its free end is inserted through a straight channel628, which is formed by deforming the main body614. The cable626has a head630thereon that engages the end of the channel628.

A guide tube632is shown and sheaths the cable626as it extends away from the actuator602.

As an alternative to using a cam member that is formed separately and fixed to the actuator lever, the cam member may be stamped or otherwise formed integral with the wall of the actuator lever. For example, when forming the lever by stamping, a flange similar to flange622could be punched from the sheet metal wall of the lever's main body concentrically with the lever's pivot axis. Then, the flange could be bent by further stamping, or some other operation, to deform it into a generally U-shaped cable guide, similar to the guide624. This is advantageous because it further reduces the part count and assembly costs.

It should be understood that any aspects described herein can be applied to any type of brake actuator, whether hand or foot generated. As such, the disclosed embodiments are not intended to be in any way limiting.

While the above description constitutes the preferred embodiments, it will be appreciated that the present invention is susceptible to modification and change without departing from the fair meaning of the proper scope of the accompanying claims.