Adjustable Bicycle Brake Caliper Base Structure for Rotor Alignment
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Solution Overview
Problem
Existing bicycle brake caliper assemblies face challenges in maintaining optimal alignment and adjustment to accommodate brake disc rotors of varying sizes, leading to potential wear and reduced service life due to fixed orientations and angles.
Innovation Solution
A bicycle brake caliper assembly with a base structure that includes a base member and spacer members, allowing for adjustable orientation and inclination between the brake caliper and the bicycle frame, enabling the brake caliper to be positioned at different angles relative to the rotational axis, thereby accommodating brake disc rotors with different outer radii and maintaining optimal pad alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the brake caliper is fixed at a single position and orientation, then the structure is simple, but it cannot accommodate brake disc rotors of varying sizes, leading to misalignment and increased wear
Solution Approach 1:
The base structure is divided into separate components: a base member with mounting features and a caliper mounting member with adjustable positioning features. This segmentation allows each component to perform its specific function while enabling overall adaptability without excessive complexity.
Solution Approach 2:
The base structure incorporates adjustable positioning mechanisms that allow the brake caliper to be positioned at multiple locations and orientations. This dynamic adjustability enables the system to adapt to different rotor sizes while maintaining proper alignment, resolving the contradiction between simplicity and versatility.
2Manufacturing precision
If the brake caliper uses a fixed orientation relative to the bicycle frame, then the alignment is consistent, but it cannot maintain optimal pad alignment for rotors of different outer radii
Solution Approach 1:
The caliper mounting member includes positioning features that enable adjustment of the caliper's position and orientation relative to the base member. This dynamic positioning capability allows optimal pad alignment to be achieved for rotors of different outer radii while maintaining manufacturing precision through defined positioning features.
Solution Approach 2:
The system allows change in positional parameters (location and orientation) of the brake caliper based on the rotor size being used. By adjusting these parameters, optimal pad alignment is maintained across different rotor configurations, balancing precision with ease of adjustment.
3Reliability
If the brake caliper attachment surface is fixed at a single angle, then the mounting is simple, but it leads to increased wear on brake pads and disc rotors when using different rotor sizes
Solution Approach 1:
The mounting structure is segmented into a base member and a caliper mounting member with distinct functions. The base member provides stable mounting to the frame, while the caliper mounting member provides adjustable positioning, reducing wear through proper alignment without excessive complexity.
Solution Approach 2:
The adjustable positioning mechanism allows the caliper to be oriented at different angles relative to the base member depending on the rotor size. This dynamic adjustment ensures optimal pad alignment that reduces wear and extends service life, while the modular design keeps the overall structure manageable.
Data Source
AI summary
A bicycle brake caliper assembly comprises a brake caliper and a base structure. The brake caliper is configured to apply a braking force on a brake disc rotor configured to be rotatable about a rotational axis. The brake caliper has an attachment surface. The base structure has a first base surface. The base structure is configured to be coupled to the attachment surface of the brake caliper and to be attached to a bicycle frame so as to arrange the brake caliper at one of a first position and a second position which is farther from the rotational axis than the first position. The base structure is configured such that a relative angle defined between the attachment surface of the brake caliper and the first base surface of the base structure differs between the first position and the second position.