Brake actuator

1. A method for forming a brake actuator for applying tension to a brake cable connected to the brake system of a motor vehicle, the method comprising:

providing a brake actuator lever;

providing a cam member, including progressively stamping a sheet metal flange portion that is part of and integral and continuous with the cam member to (a) initially bend, by stamping, the flange portion at an angle to the cam member and then (b) further bend, by subsequent stamping, the angle portion of the flange portion into a general U-shape so as to define a cable guide with opposing side walls for receiving the brake cable and enabling winding thereof onto the cam member, wherein the opposing side walls are integral and continuous as one-piece with 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.

2. A method according to claim 1 , wherein said mounting the brake actuator lever and the cam member comprises pivotally mounting the actuator lever for pivotal movement relative to the mounting bracket.

3. A method according to claim 2 , wherein the cam member is formed separately from the brake actuator lever, and wherein said providing the cam member comprises: stamping a piece of sheet metal to initially form a cam member having the sheet metal flange portion; and then progressively stamping the flange portion as aforesaid into the general U-shape so as to define the cable guide.

4. A method according to claim 3 , wherein said mounting the brake lever and the cam member comprises rotatably mounting said cam member for rotation relative to said brake actuator lever; and

wherein said method further comprises:

providing a clutch releasably coupling said cam member to said brake actuator lever such that said cam member rotates relative to said mounting bracket with movement of said brake actuator lever at least in the brake applying direction, thereby winding the brake cable onto the cam member and applying tension to the cable for activating the brake system, said clutch being operable to release said cam member from the lever such that said cam member is able to rotate relative to said brake actuator lever at least when said lever is in a brake released position; and

connecting a spring to the cam member, said spring biasing said cam member in a slack take-up direction relative to said lever to wind the cable thereon for taking up cable slack when said clutch releases said cam member from the lever.

5. A method according to claim 1 , wherein the brake actuator lever includes a wall, and wherein the cam member is a portion of the wall and integral and continuous as one-piece with the wall,

wherein the act of providing the cam member includes stamping the sheet metal flange portion from the wall of the brake actuator lever comprising the cam member.

6. A method for forming a brake actuator for applying tension to a brake cable connected to the brake system of a motor vehicle, the method comprising:

stamping a single piece of sheet metal to initially form a cam-and-drum member as an integral and continuous one-piece part including a protruding drum portion and a cam portion integral and continuous with the drum portion, the cam portion having a flange portion integral and continuous with the cam portion;

progressively stamping the flange portion to (a) initially bend, by stamping, the flange portion at an angle to the cam member and then (b) further bend, by subsequent stamping, the angle portion of 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, wherein the opposing side walls are integral and continuous as one-piece with the cam-and-drum member;

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.

7. A method according to claim 6 , wherein said mounting the brake actuator lever comprises pivotally mounting the actuator lever for pivotal movement relative to the mounting bracket.

8. A method for forming a brake actuator for applying tension to a brake cable connected to the brake system of a motor vehicle, the method comprising:

stamping a piece of sheet metal to initially form a cam member having an integral and continuous flange portion;

progressively stamping said flange portion to (a) initially bend, by stamping, the flange portion at an angle to the cam member and then (b) further bend, by subsequent stamping, the angle portion of the flange portion into a general U-shape with opposing side walls integral and continuous as one-piece so as to define a cable guide for receiving the brake cable and enabling winding thereof onto the cam member, wherein the opposing side walls are integral and continuous as one-piece with the cam member;

providing a mounting bracket;

pivotally mounting a brake actuator lever for pivotal movement relative to the mounting bracket; rotatably mounting said cam member for rotation relative to said brake actuator lever;

providing a clutch releasably coupling said cam member to said brake actuator lever such that said cam member rotates with pivotal movement of said brake actuator lever relative to said mounting bracket at least in a brake applying direction relative to said mounting bracket, thereby winding the brake cable onto the cam member and applying tension to the cable for activating the brake system, said clutch being operable to release said cam member from the lever such that said cam member is able to rotate relative to Said brake actuator lever at least when said lever is in a brake released position; and

connecting a spring to the cam member, said spring biasing said cam member in a slack take-up direction relative to said lever to wind the cable thereon for taking up cable slack when said clutch releases said cam member from the lever.