A kind of hall linear switch oil disc brake handle
Patent Information
- Application Number
- CN202522351529.4
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-10-27
- Publication Date
- 2026-09-08
- Estimated Expiration
- 2035-10-27
AI Technical Summary
[0004]本实用新型的目的在于提供一种霍尔线性开关油碟刹把，以解决现有技术中油碟刹把缺乏高精度电子感应、安装调节不便及集成度低的问题
[0010] Beneficial effects: This utility model achieves linear voltage output during the braking process through the cooperation of Hall switch and magnet, improving sensing accuracy and response speed; the Hall mounting base adopts an adjustable installation structure, which facilitates initial voltage calibration and improves assembly flexibility; the magnet is integrated into the piston body, and the Hall switch is externally designed, realizing a high degree of integration between electronic sensing and hydraulic system, with a compact structure and reliable sealing; multiple sealing elements effectively prevent hydraulic oil leakage and ensure stable braking performance.
Smart Images
Figure CN224727135U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of brake structure technology, specifically to a Hall linear switch hydraulic disc brake lever. Background Technology
[0002] Hydraulic disc brake levers are key braking components in bicycles, motorcycles, and other vehicles. They convert the mechanical force of the lever into the clamping force of the brake caliper through hydraulic transmission, thus achieving the braking function. Traditional hydraulic disc brake levers typically consist of an operating lever, a hydraulic master cylinder, a piston assembly, and a hydraulic circuit system. Their working principle is that pressing the lever pushes the piston to move, compressing the hydraulic oil to generate pressure, which drives the brake caliper to actuate.
[0003] Existing hydraulic disc brake levers mostly rely on mechanical structures to achieve braking function, lacking electronic sensing and feedback of the braking process, and thus failing to meet the requirements of intelligent control. Some brake levers with sensing functions use contact switches or nonlinear sensors, which have problems such as low response accuracy, complex installation and debugging, and susceptibility to environmental interference. Furthermore, the integration of the sensing element with the hydraulic system is not high, affecting the overall structural compactness and reliability. Utility Model Content
[0004] The purpose of this invention is to provide a Hall linear switch hydraulic disc brake lever to solve the problems of lack of high-precision electronic sensing, inconvenient installation and adjustment, and low integration in existing hydraulic disc brake levers.
[0005] This utility model discloses a Hall linear switch hydraulic disc brake lever, including an operating mechanism, a hydraulic circuit system, a piston assembly, an electronic sensing element, and a fixing seal. The operating mechanism includes a handle, which is connected in series with the piston body via a push rod. The piston body is disposed inside the cylinder of the master cylinder, and a magnet is fixed on the piston body, located between the piston oil seal and a first O-ring. The electronic sensing element includes a Hall switch and a Hall mounting base. The Hall switch is placed inside the Hall mounting base, which is installed in a cuboid groove on the outside of the master cylinder and locked with a first screw. The hydraulic circuit system includes an oil cup cover, an oil pipe, a plastic sleeve, a compression nut, a retaining ring, an oil needle, and a master cylinder disc cover. The oil pipe is fixed by the compression nut and the retaining ring, and the plastic sleeve is fitted over the oil pipe. The oil needle is positioned in the oil passage, and the master pump cover seals one end of the master pump. The piston assembly includes a piston return spring, a piston front cover, a piston oil seal, a first O-ring, and a second O-ring. The piston return spring is sleeved on the outside of the piston body, and the piston front cover is fixed to the front end of the master pump by a pin. The piston oil seal, the first O-ring, and the second O-ring are respectively positioned at the piston-cylinder clearance and the oil pipe interface. The fixing seal also includes a setter, a master pump pin, an internal hexagon screw, a plastic washer, a square nut, a flat washer, a C-ring, a plastic sleeve for the square nut, and a second screw. The setter and master pump pin are used for component positioning, the internal hexagon screw and the second screw are used for fastening, the plastic washer and the flat washer are positioned at the connection point, the C-ring axially fixes the piston body, and the plastic sleeve for the square nut is sleeved on the outside of the square nut.
[0006] Preferably, the Hall effect sensor is placed in a cuboid groove on the outside of the main pump. The length of the groove is greater than the length of the Hall effect sensor. After adjusting the starting voltage by moving the Hall effect sensor up and down, the Hall effect sensor is locked onto the main pump with a first screw. The Hall effect switch is rigidly fixed by the Hall effect sensor, and its sensing surface remains parallel to the trajectory of the magnet.
[0007] Preferably, the magnet is fixed between the piston oil seal and the first O-ring on the piston body and is assembled in the cylinder of the master pump. The piston body is connected in series with the handle through a push rod. Pressing the handle drives the piston body and the magnet to reciprocate in the master pump. The piston return spring drives the piston body to reset when the handle is released.
[0008] Preferably, the magnet is inside the cylinder of the master pump, and the Hall switch is outside the cylinder of the master pump. The two are aligned at the center and separated by the wall thickness of the master pump. When the magnet is close to the Hall switch, the Hall output voltage increases linearly and decreases linearly when it is far away. The sensing gap between the magnet and the Hall switch is no more than 2mm.
[0009] Preferably, the push rod is sequentially connected to a plastic sleeve for a block nut, a block nut, a C-shaped buckle, and a flat washer. The C-shaped buckle axially fixes the piston body, the flat washer is placed between the block nut and the piston body, and the plastic washer is located at the rotatable connection between the handle and the push rod. The master pump pin and the pin together ensure the coaxiality of the internal components of the master pump.
[0010] Beneficial effects: This utility model achieves linear voltage output during the braking process through the cooperation of Hall switch and magnet, improving sensing accuracy and response speed; the Hall mounting base adopts an adjustable installation structure, which facilitates initial voltage calibration and improves assembly flexibility; the magnet is integrated into the piston body, and the Hall switch is externally designed, realizing a high degree of integration between electronic sensing and hydraulic system, with a compact structure and reliable sealing; multiple sealing elements effectively prevent hydraulic oil leakage and ensure stable braking performance. Attached Figure Description
[0011] Figure 1 This is a schematic diagram of the structure of this utility model.
[0012] Figure 2 This is an exploded structural diagram of the present invention.
[0013] Figure 3 This is a side view of the structure of this utility model.
[0014] Figure 4 This is a schematic diagram of the assembly of the magnet and Hall switch of this utility model.
[0015] In the attached diagram: 1-Handle, 2-Setting pin, 3-Master cylinder pin, 4-First screw, 5-Oil cup cap, 6-Oil pipe, 7-Plastic sleeve, 8-Compression nut, 9-Clamping ring, 10-Oil needle, 11-Pin, 12-Master cylinder butterfly cover, 13-Hex socket screw, 14-Hall switch, 15-Hall mounting base, 16-Plastic washer, 17-Master cylinder, 18-Piston return spring, 19-Piston front cover, 20-Piston oil seal, 21-Magnet, 22-First O-ring, 23-Square nut, 24-Piston body, 25-Flat washer, 26-C-ring, 27-Square nut plastic sleeve, 28-Push rod, 29-Second screw, 30-Second O-ring. Detailed Implementation
[0016] To make the purpose, technical solution, and effects of this utility model clearer and more explicit, the following description is provided in conjunction with the appendix. Figure 1-4 The present invention will be further described in detail below with reference to the embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the present invention and are not intended to limit the present invention. Figure 1 , Figure 2 , Figure 3 and Figure 4 As shown, a Hall linear switch hydraulic disc brake lever includes:
[0017] The system comprises an operating mechanism, a hydraulic circuit system, a piston assembly, electronic sensing elements, and a fixing seal. The operating mechanism includes a handle 1, which is connected in series with the piston body 24 via a push rod 28. The piston body 24 is located inside the cylinder of the master pump 17. A magnet 21 is fixed on the piston body 24, located between the piston oil seal 20 and the first O-ring 22. The electronic sensing element includes a Hall switch 14 and a Hall mounting base 15. The Hall switch 14 is placed inside the Hall mounting base 15, which is installed in a rectangular groove on the outside of the master pump 17 and locked by a first screw 4. The hydraulic circuit system includes an oil cup cover 5, an oil pipe 6, a plastic sleeve 7, a compression nut 8, a retaining ring 9, an oil needle 10, and a master pump butterfly cover 12. The oil pipe 6 is fixed by the compression nut 8 and the retaining ring 9. The plastic sleeve 7 is fitted over the oil pipe 6. The oil needle 10 is located in the oil passage. The master pump butterfly cover 12 is sealed. One end of the master pump 17 is closed; the piston assembly includes a piston return spring 18, a piston front cover 19, a piston oil seal 20, a first O-ring 22, and a second O-ring 30. The piston return spring 18 is sleeved on the outside of the piston body 24. The piston front cover 19 is fixed to the front end of the master pump 17 by a pin 11. The piston oil seal 20, the first O-ring 22, and the second P-ring 30 are respectively set at the piston-cylinder clearance and the oil pipe interface. The fixing seal also includes a setter 2, a master pump pin 3, an internal hexagon screw 13, a plastic washer 16, a block nut 23, a flat washer 25, a C-ring 26, a plastic sleeve 27 for the block nut, and a second screw 29. The setter 2 and the master pump pin 3 are used for component positioning. The internal hexagon screw 13 and the second screw 29 are used for fastening. The plastic washer 16 and the flat washer 25 are set at the connection part. The C-ring 26 axially fixes the piston body 24. The plastic sleeve 27 for the block nut is sleeved on the outside of the block nut 23.
[0018] The overall structure of the Hall linear switch hydraulic disc brake lever comprises an operating mechanism, a hydraulic circuit system, a piston assembly, an electronic sensing element, and fixed seals. The operating mechanism drives the push rod 28 via the handle 1, which in turn links with the piston body 24. A magnet 21 is integrated between the seals on the piston body 24 to ensure synchronized movement. The Hall switch 14 is rigidly fixed to the outside of the master cylinder 17 via a Hall mounting base 15, enabling non-contact sensing. The hydraulic circuit system forms a closed circuit through components such as the oil pipe 6 and compression nut 8. The piston assembly uses multiple seals to ensure no hydraulic oil leakage. C-shaped retaining rings 26 and flat gaskets 25 in the fixed seals ensure stable assembly of each component. When the handle 1 is pressed, the push rod 28 moves the piston body 24 forward within the master cylinder 17, compressing the piston return spring 18. The magnet 21 moves closer to the Hall switch 14 along with the piston body 24, and the Hall switch 14 outputs a linearly increasing voltage. When the handle 1 is released, the piston return spring 18 returns to its original position, causing the piston body 24 and magnet 21 to move backward, and the Hall output voltage decreases linearly. The hydraulic circuit system regulates the flow rate through the needle 10 when the piston moves, and transmits the pressure to the brake caliper through the oil pipe 6 to achieve the braking function.
[0019] like Figure 1 and Figure 2 As shown, the Hall effect mounting base 15 is placed in a rectangular groove on one side of the main pump 17. The length of the groove is greater than the length of the Hall effect mounting base 15. After adjusting the starting voltage by moving the Hall effect mounting base 15 up and down, the Hall effect mounting base 15 is locked onto the main pump 17 with the first screw 4. The Hall effect switch 14 is rigidly fixed by the Hall effect mounting base 15, and its sensing surface is parallel to the movement trajectory of the magnet 21.
[0020] The rectangular groove on the outer side of the master pump 17 is longer than the Hall effect mounting base 15, providing vertical adjustment margin. It is locked in place by the first screw 4. The sensing surface of the Hall switch 14 is parallel to the movement trajectory of the magnet 21, ensuring a linear relationship between the magnetic field strength and piston displacement, thus improving voltage output accuracy. During assembly, first insert the Hall switch 14 into the Hall effect mounting base 15, then place the Hall effect mounting base 15 into the groove of the master pump 17. Adjust the voltage up and down until the initial voltage meets the standard (typically 0.5-1.5V). Then, use the first screw 4 to pass through the through hole of the Hall effect mounting base 15 and lock it to the master pump 17. During adjustment, a multimeter must be used to monitor the output voltage to ensure that the magnet 21 is within the full piston stroke and that the Hall output voltage variation range meets the design requirements (e.g., 0.5-4.5V).
[0021] like Figure 1 , Figure 2 , Figure 3 and Figure 4As shown, the magnet 21 is fixed between the piston oil seal 20 and the first O-ring 22 on the piston body 24 and is assembled in the oil cylinder of the master pump 17. The piston body 24 is connected in series with the handle 1 through the push rod 28. Pressing the handle 1 drives the piston body 24 and the magnet 21 to reciprocate in the master pump 17. The piston return spring 18 drives the piston body 24 to reset when the handle is released.
[0022] Magnet 21 is positioned between piston oil seal 20 and first O-ring 22, avoiding interference with the hydraulic seal while ensuring synchronous movement with piston body 24. Piston body 24 is rigidly connected to handle 1 via push rod 28, enabling direct force transmission. Piston return spring 18 provides the handle's reset power. Pressing handle 1 drives push rod 28 axially through leverage, causing piston body 24 to overcome the elastic force of piston return spring 18 and move forward linearly within master pump 17 cylinder. Magnet 21 moves synchronously with piston body 24. Releasing handle 1 releases piston return spring 18, pushing piston body 24 and push rod 28 in the opposite direction, resetting handle 1, and magnet 21 returns to its initial position. Throughout this process, piston oil seal 20 and first O-ring 22 maintain a consistent seal against the hydraulic oil.
[0023] like Figure 1 and Figure 2 As shown, the magnet 21 is inside the cylinder of the master pump 17, and the Hall switch 14 is outside the cylinder of the master pump 17. The two are aligned at the center and separated by the wall thickness of the master pump 17. When the magnet 21 is close to the Hall switch 14, the Hall output voltage increases linearly and decreases linearly when it is far away. The sensing gap between the magnet 21 and the Hall switch 14 is no more than 2mm.
[0024] Magnet 21 is located inside the cylinder of master pump 17, while Hall switch 14 is located outside the cylinder. The two are separated by the wall thickness of master pump 17, and their central axes are aligned to ensure perpendicular magnetic field induction. The induction gap (master pump wall thickness) is controlled within 2mm to avoid magnetic field attenuation leading to induction failure, while a non-contact design eliminates the risk of mechanical wear. When piston body 24 moves magnet 21 within the cylinder, the center of magnet 21 remains coaxial with the center of Hall switch 14, ensuring that the magnetic field strength changes linearly with displacement. When the piston approaches, the magnetic field passes through the wall thickness of master pump 17 and acts on Hall switch 14, causing the output voltage to increase linearly from its initial value to its maximum value; when the piston moves away, the magnetic field strength weakens inversely proportional to the square of the distance, and the output voltage decreases linearly back to its initial value.
[0025] like Figure 1 , Figure 2 , Figure 3 and Figure 4As shown, the push rod 28 is sequentially connected to the block nut plastic sleeve 27, the block nut 23, the C-shaped buckle 26, and the flat washer 25. The C-shaped buckle 26 axially fixes the piston body 24. The flat washer 25 is disposed between the block nut 23 and the piston body 24. The plastic washer 16 is located at the rotatable connection between the handle 1 and the push rod 28. The master pump pin 3 and the pin 11 together ensure the coaxiality of the internal components of the master pump 17.
[0026] The square nut plastic sleeve 27 serves as insulation and cushioning; the square nut 23 is used to adjust the axial position of the push rod 28; the C-shaped retaining ring 26 prevents the piston body 24 from falling off; the flat washer 25 disperses pressure to prevent component deformation; and the plastic washer 16 reduces the coefficient of friction at the connection between the handle 1 and the push rod 28. When the handle 1 rotates, torque is transmitted through the rotating joint between the plastic washer 16 and the push rod 28, and the push rod 28 drives the piston body 24 to move axially via the square nut 23. The C-shaped retaining ring 26 is embedded in the annular groove of the piston body 24 to limit its axial movement; the master cylinder pin 3 and the pin 11 respectively position the master cylinder 17 and the piston front cover 19 to ensure the coaxiality of the piston body 24 and the cylinder, and to prevent relative misalignment between the magnet 21 and the Hall switch 14.
[0027] In specific implementation, in the operating mechanism, the handle 1 is connected in series with the piston body 24 via the push rod 28. When the handle 1 is pressed, the push rod 28 drives the piston body 24 to move axially within the cylinder of the master pump 17. The magnet 21 fixed on the piston body 24 is located between the piston oil seal 20 and the first O-ring 22, ensuring that the magnet 21 moves synchronously with the piston without affecting the sealing performance. The assembly process of the electronic sensing element is as follows: the Hall switch 14 is embedded into the reserved groove of the Hall mounting base 15, and then the Hall mounting base 15 is installed into the cuboid groove on the outside of the master pump 17. After adjusting the starting voltage by sliding it up and down along the groove until it meets the standard, the first screw 4 is used to lock it to the master pump 17 through the through hole of the Hall mounting base 15.
[0028] The hydraulic circuit system is connected as follows: the oil pipe 6 is fixed to the oil outlet of the master pump 17 by the compression nut 8 and the retaining ring 9. The plastic sleeve 7 wraps around the outside of the oil pipe 6 for protection. The oil cup cover 5 is screwed onto the oil inlet on the top of the master pump. The oil needle 10 is inserted into the oil passage to control the flow rate. The master pump butterfly cover 12 seals the rear opening of the master pump 17 with the hexagonal screw 13. The piston assembly is assembled as follows: the piston return spring 18, the first O-ring 22 and the piston oil seal 20 are sequentially fitted around the piston body 24. The magnet 21 is attached to the annular groove between the piston oil seal 20 and the first O-ring 22. The piston front cover 19 is then fixed to the front end of the master pump 17 by the pin 11, allowing the piston body 24 to slide back and forth in the cylinder.
[0029] Working principle: When handle 1 is pressed, push rod 28 pushes piston body 24 to compress piston return spring 18 and move forward. Magnet 21 moves with piston body 24 towards Hall switch 14. The magnetic field strength sensed by Hall switch 14 gradually increases, and the output voltage increases linearly. When handle 1 is released, piston return spring 18 releases elastic potential energy, pushing piston body 24 back to its original position. Magnet 21 moves away from Hall switch 14, and the magnetic field strength weakens, causing the output voltage to decrease linearly. Magnet 21 is aligned with the central axis of Hall switch 14, and a non-contact sensing is formed by the wall thickness of master pump 17. The sensing gap is controlled within 2mm to ensure signal stability.
[0030] The grooved design of the Hall effect mounting base 15 and the master cylinder 17 enables an adjustment stroke of ±3mm to meet the starting voltage requirements of different vehicle models; the combination structure of the square nut 23 and the square nut plastic sleeve 27 allows for adjustment of the effective stroke of the push rod 28 by rotation, adapting to the operating habits of different users; the axial fixing method of the C-shaped retaining ring 26 and the flat washer 25 effectively prevents radial displacement of the piston body 24 during high-speed reciprocating motion, thus improving system life.
[0031] The above description is only a preferred embodiment of the present utility model and does not limit the patent scope of the present utility model. Any equivalent structural or procedural transformations made based on the content of the present utility model specification and drawings, or direct / indirect applications in other related technical fields, are similarly included within the protection scope of the present utility model.
Claims
1. A Hall effect linear switch hydraulic disc brake lever, comprising an operating mechanism, a hydraulic circuit system, a piston assembly, an electronic sensing element, and a fixing seal, characterized in that: The operating mechanism includes a handle (1), which is connected in series with the piston body (24) via a push rod (28). The piston body (24) is located in the cylinder of the master pump (17). A magnet (21) is fixed on the piston body (24), and the magnet (21) is located between the piston oil seal (20) and the first O-ring (22). The electronic sensing element includes a Hall switch (14) and a Hall mounting base (15). The Hall switch (14) is placed inside the Hall mounting base (15), and the Hall mounting base (15) is... 15) Installed in the rectangular groove outside the master pump (17) and locked by the first screw (4); the hydraulic circuit system includes an oil cup cover (5), an oil pipe (6), a plastic sleeve (7), a compression nut (8), a retaining ring (9), an oil needle (10), and a master pump butterfly cover (12). The oil pipe (6) is fixed by the compression nut (8) and the retaining ring (9). The plastic sleeve (7) is fitted outside the oil pipe (6). The oil needle (10) is set in the oil circuit channel. The master pump butterfly cover (12) closes one end of the master pump (17); the piston assembly package The piston includes a piston return spring (18), a piston front cover (19), a piston oil seal (20), a first O-ring (22), and a second O-ring (30). The piston return spring (18) is sleeved on the outside of the piston body (24). The piston front cover (19) is fixed to the front end of the master cylinder (17) by a pin (11). The piston oil seal (20), the first O-ring (22), and the second O-ring (30) are respectively located at the piston-cylinder clearance and the oil pipe interface. The fixing seal also includes a locking pin (2), a master cylinder pin (3), and an internal hexagonal screw. The components include a nail (13), a plastic washer (16), a block nut (23), a flat washer (25), a C-ring (26), a plastic sleeve for the block nut (27), and a second screw (29). The locking pin (2) and the master pump pin (3) are used for component positioning. The hexagonal screw (13) and the second screw (29) are used for fastening. The plastic washer (16) and the flat washer (25) are set at the connection part. The C-ring (26) axially fixes the piston body (24). The plastic sleeve for the block nut (27) is sleeved on the outside of the block nut (23).
2. The Hall linear switch hydraulic disc brake lever according to claim 1, characterized in that, The Hall effect mounting base (15) is placed in a rectangular groove on the outside of the main pump (17). The length of the groove is greater than the length of the Hall effect mounting base (15). After adjusting the starting voltage by moving the Hall effect mounting base (15) up and down, the Hall effect mounting base (15) is locked onto the main pump (17) with the first screw (4). The Hall effect switch (14) is rigidly fixed by the Hall effect mounting base (15), and its sensing surface is parallel to the movement trajectory of the magnet (21).
3. The Hall linear switch hydraulic disc brake lever according to claim 1, characterized in that, The magnet (21) is fixed between the piston oil seal (20) and the first O-ring (22) on the piston body (24) and is assembled in the cylinder of the master pump (17). The piston body (24) is connected in series with the handle (1) through the push rod (28). Pressing the handle (1) drives the piston body (24) and the magnet (21) to reciprocate in the master pump (17). The piston return spring (18) drives the piston body (24) to reset when the handle is released.
4. The Hall linear switch hydraulic disc brake lever according to claim 1, characterized in that, The magnet (21) is inside the cylinder of the master pump (17), and the Hall switch (14) is outside the cylinder of the master pump (17). The two are aligned and spaced apart by the wall thickness of the master pump (17). When the magnet (21) is close to the Hall switch (14), the Hall output voltage increases linearly and decreases linearly when it is far away. The sensing gap between the magnet (21) and the Hall switch (14) is no more than 2 mm.
5. The Hall linear switch hydraulic disc brake lever according to claim 1, characterized in that, The push rod (28) is connected in sequence to the block nut plastic sleeve (27), the block nut (23), the C-shaped buckle (26), and the flat washer (25). The C-shaped buckle (26) axially fixes the piston body (24). The flat washer (25) is placed between the block nut (23) and the piston body (24). The plastic washer (16) is located at the rotatable connection between the handle (1) and the push rod (28). The master pump pin (3) and the pin (11) together ensure the coaxiality of the internal components of the master pump (17).