Two-wheeled electric vehicle brake cable testing machine
By designing a two-wheeled electric vehicle brake cable testing machine, which uses a motor to simulate braking action and reduce frictional resistance, the reliability problem of brake cables was solved, the testing accuracy and safety were improved, the accident rate was reduced, regulatory requirements were met, and product competitiveness was enhanced.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- ZHEJIANG YADEA MOTORCYCLE
- Filing Date
- 2025-05-28
- Publication Date
- 2026-05-01
AI Technical Summary
In existing technologies, reliability issues with brake cables lead to unstable braking response speed and braking force transmission efficiency, increasing the risk of traffic accidents.
A two-wheeled electric vehicle brake cable testing machine was designed. It uses a motor to simulate braking action and reduces frictional resistance through rollers and buffer strips to ensure smooth testing and accurate and reliable results.
This improved the testing accuracy and reliability of brake cables, reduced the incidence of safety accidents, met regulatory requirements, enhanced product competitiveness, and ensured user safety.
Smart Images
Figure CN224189533U_ABST
Abstract
Description
Two-wheeled electric vehicle brake cable testing machine Technical Field
[0001] This utility model relates to the field of fatigue testing tooling technology for two-wheeled vehicles, and in particular to a two-wheeled electric vehicle brake cable testing machine. Background Technology
[0002] With the surge in popularity of two-wheeled electric vehicles, traffic accidents caused by brake system failures (such as excessive braking distances and cable breakage) are becoming more frequent, directly threatening user safety.
[0003] As a core transmission component of a mechanical braking system, the reliability of the brake cable directly affects the braking response speed and the efficiency of braking force transmission. Summary of the Invention
[0004] In response to the shortcomings of the existing production technology, the applicant provides a two-wheeled electric vehicle brake cable testing machine with a reasonable structure. The machine uses a motor to continuously simulate braking actions multiple times and uses rollers to reduce the frictional resistance of the braking action, ensuring that the testing process is smooth and the test results are accurate and reliable.
[0005] The technical solution adopted in this utility model is as follows:
[0006] A testing machine for brake cables of a two-wheeled electric vehicle includes a fixture table, on which at least one set of simulation mechanisms are provided, each set of simulation mechanisms including:
[0007] The fixed base is installed on the tooling table.
[0008] A cylinder is mounted on a tooling table, with the cylinder's piston rod pointing towards the brake to be tested, which is limited by a fixed seat.
[0009] The brake cable to be tested is led out, and an anti-wear structure is set on the side of the tooling table. The brake cable is wrapped around the anti-wear structure and a counterweight is set.
[0010] As a further improvement to the above technical solution:
[0011] The piston rod end of the cylinder is equipped with a roller, which abuts against the brake lever of the brake to be tested during the simulated braking process.
[0012] The piston rod end of the cylinder is fixedly connected to a clamping arm, and a roller is rotatably connected to the clamping arm. During the braking process, the circumferential surface of the roller abuts against the brake lever.
[0013] The circumferential surface of the roller is recessed, and the recessed position is coplanar with the brake lever of the brake to be tested.
[0014] In the initial state, there is a gap between the roller and the brake lever of the brake to be tested.
[0015] The wear-resistant structure includes an extended angle steel set on the side of the tooling table, with holes in the extended angle steel to allow the brake cable to pass through; the brake cable passing position on the extended angle steel and the side wall of the tooling table are reserved with a counterweight suspension distance.
[0016] The brake cable is protected by a protective tube.
[0017] A buffer strip with an arc surface is installed at the connection between the tooling table and the extended angle steel.
[0018] The wear-resistant structure uses only a buffer strip, which has an arc-shaped structure, and the brake cable and counterweight that pass through the buffer strip are suspended.
[0019] The testing machine is suitable for single-sided braking tests or double-sided braking tests.
[0020] The beneficial effects of this utility model are as follows:
[0021] Behind the brake cable test lies the inevitable process of the industry shifting from "extensive growth" to "quality and safety driven" development. This not only responds to regulatory requirements but also serves to enhance product competitiveness, with the ultimate goal of reducing accident rates and ensuring user safety. It is an irreplaceable component of the vehicle safety system, addressing potential risks proactively through scientific verification, while balancing legal compliance, user trust, and corporate economic benefits.
[0022] This application uses a motor on a tooling table to simulate braking action and conducts multiple fatigue tests on a brake cable with counterweight. The counterweight can also be adjusted according to the actual simulated object, such as a light vehicle or a heavy vehicle, to test the service life of the brake cable. The aim is to ensure that the cable can maintain braking performance under extreme conditions, such as sudden braking, high load, and long-term wear. Attached Figure Description
[0023] Figure 1 is a three-dimensional view of the overall structure of this application.
[0024] Figure 2 is an enlarged view of part A of this utility model, used to illustrate a set of simulation mechanisms.
[0025] Figure 3 is a schematic diagram of the buffer strip structure on the side of the tooling table of this utility model.
[0026] The components include: 1. Tooling table; 2. Fixed base; 3. Power base; 4. Cylinder; 5. Clamping arm; 6. Roller; 7. Brake cable; 8. Extending angle steel; 9. Buffer strip. Detailed Implementation
[0027] The specific embodiments of this utility model are described below with reference to the accompanying drawings.
[0028] As shown in Figures 1-3, the two-wheeled electric vehicle brake cable testing machine of this embodiment includes a tooling table 1, on which at least one set of simulation mechanisms is provided. Each set of simulation mechanisms includes:
[0029] Fixed base 2 is installed on tooling table 1.
[0030] Cylinder 4 is mounted on tooling table 1, with the piston rod of cylinder 4 pointing towards the brake to be tested, which is limited by the fixed seat 2.
[0031] The brake cable 7 is led out from the brake to be tested. An anti-wear structure is set on the side of the tooling table 1, and a counterweight 10 is set around the anti-wear structure of the brake cable 7.
[0032] The piston rod end of cylinder 4 is equipped with a roller 6, which abuts against the brake lever of the brake to be tested during the simulated braking process.
[0033] A clamping arm 5 is fixedly connected to the end of the piston rod of cylinder 4. A roller 6 is rotatably connected to the clamping arm 5. During the simulation of braking, the circumferential surface of the roller 6 abuts against the brake lever.
[0034] The circumferential surface of roller 6 is recessed, and the recessed position is coplanar with the brake lever of the brake to be tested.
[0035] In the initial state, there is a gap between roller 6 and the brake lever of the brake to be tested.
[0036] The wear-resistant structure includes an extension angle steel 8 set on the side of the tooling table 1, with holes in the extension angle steel 8 to allow the brake cable 7 to pass through; the position where the brake cable 7 passes through the extension angle steel 8 is reserved with a counterweight suspension distance between it and the side wall of the tooling table 1.
[0037] The brake cable 7 is protected by a protective tube.
[0038] A buffer strip 9 is installed at the connection edge between the tooling table 1 and the extended angle steel 8. The buffer strip 9 has an arc surface structure.
[0039] The wear-resistant structure uses only the buffer strip 9, which has an arc-shaped structure, and the brake cable 7 and counterweight 10 that pass through the buffer strip 9 are in a suspended state.
[0040] The testing machine is suitable for single-sided braking tests or double-sided braking tests.
[0041] The specific structure and working principle of this application are as follows:
[0042] This application sets up two sets of simulation mechanisms on a tooling table 1, which can simulate the left brake alone, simulate the right brake alone, or simulate both brakes simultaneously.
[0043] As shown in Figure 1, the testing machine includes a tooling table 1, on which two sets of simulation mechanisms are set. Additional simulation mechanisms can be added as needed. In this embodiment, two sets of simulation mechanisms are used as an example for explanation.
[0044] Referring to Figure 2, each simulation mechanism includes a fixed base 2, with the brake lever portion to be tested extending through the fixed base 2, allowing for swinging. A power base 3 is located on the side of the fixed base 2 facing the brake lever. The power base 3 is made of angle steel with a right-angle structure, and a through hole is formed on the vertical wall of the power base 3 perpendicular to the tooling table 1. A cylinder 4 is mounted on the side of the vertical wall of the power base 3 facing away from the fixed base 2. The piston rod of the cylinder 4 extends out of the through hole to press the brake lever.
[0045] In this embodiment, in order to reduce the frictional resistance when pressing the brake lever, a clamping arm 5 is connected to the piston rod end of the cylinder 4. A roller 6 is rolled on the clamping arm 5 by a pin. The outer surface of the roller 6 faces the brake lever. When the roller 6 is pressed on the brake lever, the roller 6 continues to press forward and roll. From the middle position of the brake lever, it moves to the swing end of the brake lever as the brake lever swings. Then the cylinder 4 resets, completing one press to simulate braking.
[0046] In this embodiment, the roller 6 has a groove in the middle section, which makes the roller 6 form an I-shaped structure with a concave middle, and the bottom wall of the groove on the roller 6 is arc-shaped, which further conforms to the outer contour of the brake lever.
[0047] In the initial state, the brake lever is divided into segment a, which is close to the hinge end, and segment b, which is on the swing side, with the point on which the roller 6 corresponds to the brake lever as the dividing point. In order to prevent the cylinder 4 from extending too far at one time and the roller 6 from disengaging from the brake lever during the pressing of the brake lever, in this embodiment, the piston rod of the cylinder 4 is limited to a single extension length that is less than the length of segment b.
[0048] Each brake to be tested has a brake cable 7 extending from its end, with a counterweight 10 at the end of the brake cable 7 suspended outside the fixture table 1. In order to provide sufficient vertical movement space for the counterweight 10 and prevent it from rubbing against the side wall of the fixture table 1, an extension angle steel 8 is added to the side wall of the fixture table 1. A hole is made in the extension angle steel 8 to allow the brake cable 7 to pass through, and the brake cable 7 hangs through the hole.
[0049] In order to reduce the wear between the brake cable 7 and the edge of the tooling table 1 during repeated braking actions, this application proposes two anti-wear structures.
[0050] One type of wear-resistant structure is: a protective tube is installed outside the brake cable 7, the relative position of the protective tube is unknown, and the brake cable 7 can be subjected to smooth friction in the protective tube, simulating the rubber tube installed outside the brake cable 7 during actual riding.
[0051] Another wear-resistant structure, as shown in Figure 3, involves a buffer strip 9 with a rounded outer surface at the line contact between the extending angle steel 8 and the tooling table 1. The buffer strip 9 has a smooth surface and can be coated with Teflon to reduce friction and prevent other factors from affecting the test results. Furthermore, the size of the buffer strip 9 can be flexibly adjusted. For example, by setting the radius of the arc of the buffer strip 9 large enough, the brake cable 7 can be routed around the buffer strip 9 and pass through the hole in the extending angle steel 8 to achieve a suspended state. Alternatively, the extending angle steel 8 can be omitted entirely, as the buffer strip 9 already provides sufficient suspension width.
[0052] In the second type of wear-resistant structure, the protective tube of the first type of wear-resistant structure can be retained, or the protective tube can be discarded directly.
[0053] During the test, the brake to be tested is first mounted on the fixed base 2. The front end of the brake cable is attached to the brake to be tested, and the rear end of the brake cable is passed through the hole in the extension angle steel, or wrapped around the buffer strip 9 and then a weight is hung on it as a load. The number of weights is selected according to the test standard. The power switch is turned on, the cylinder is started, and the test begins. If an alarm occurs during the test, the parameters at the corresponding time point are recorded and the power is turned off. After the test is completed, the relevant data is saved as test results for reference on the production line.
[0054] The main purpose of this application is to test the life of the cable after multiple braking operations. Therefore, this application minimizes the impact of other factors on the life of the brake cable 7 during the testing process. However, considering that the brake cable 7 will also have a small amount of friction with components such as rubber hoses during actual driving, the tooling of this application is closer to the actual use environment, which can effectively resolve potential risks in advance, and take into account legal compliance, user trust and corporate economic benefits.
[0055] The above description is an explanation of the present utility model and not a limitation thereof. The scope of the present utility model is defined by the claims. Within the protection scope of the present utility model, any form of modification may be made.
Claims
1. A testing machine for brake cables of a two-wheeled electric vehicle, characterized in that: The tooling includes a tooling table (1), on which at least one set of simulation mechanisms are provided. Each set of simulation mechanisms includes: a fixed seat (2) installed on the tooling table (1), a cylinder (4) installed on the tooling table (1), and the piston rod of the cylinder (4) pointing to the brake to be tested which is limited by the fixed seat (2). The brake to be tested has a brake cable (7) leading out. An anti-wear structure is provided on the side of the tooling table (1), and a counterweight (10) is provided around the anti-wear structure of the brake cable (7).
2. The two-wheeled electric vehicle brake cable testing machine as described in claim 1, characterized in that: The piston rod end of the cylinder (4) is provided with a roller (6), which abuts against the brake lever of the brake to be tested during the simulated braking process.
3. The two-wheeled electric vehicle brake cable testing machine as described in claim 2, characterized in that: The piston rod end of the cylinder (4) is fixedly connected to a clamping arm (5), and a roller (6) is rotatably connected on the clamping arm (5). During the simulated braking process, the circumferential surface of the roller (6) abuts against the brake lever.
4. The two-wheeled electric vehicle brake cable testing machine as described in claim 2, characterized in that: The circumferential surface of the roller (6) is recessed, and the recessed position is coplanar with the brake lever of the brake to be tested.
5. The two-wheeled electric vehicle brake cable testing machine as described in claim 2, characterized in that: In the initial state, there is a gap between the roller (6) and the brake lever of the brake to be tested.
6. The two-wheeled electric vehicle brake cable testing machine as described in claim 1, characterized in that: The wear-resistant structure includes an extension angle steel (8) set on the side of the tooling table (1), with holes on the extension angle steel (8) to allow the brake cable (7) to pass through; the position where the brake cable (7) passes through the extension angle steel (8) is reserved with a counterweight suspension distance between it and the side wall of the tooling table (1).
7. The two-wheeled electric vehicle brake cable testing machine as described in claim 6, characterized in that: The brake cable (7) is protected by a protective tube.
8. The two-wheeled electric vehicle brake cable testing machine as described in claim 6, characterized in that: A buffer strip (9) is provided at the connection edge between the tooling table (1) and the extended angle steel (8). The buffer strip (9) has an arc surface structure.
9. The two-wheeled electric vehicle brake cable testing machine as described in claim 1, characterized in that: The wear-resistant structure uses only a buffer strip (9), which is an arc-shaped structure, and the brake cable (7) and counterweight (10) that pass through the buffer strip (9) are in a suspended state.
10. The two-wheeled electric vehicle brake cable testing machine as described in claim 1, characterized in that: The testing machine is suitable for single-sided braking tests or double-sided braking tests.