Bicycle Axle Assembly With Tool-Free Lever Locking
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Solution Overview
Problem
Current bicycle axles, especially for high-stress applications, lack ergonomic design and are often multi-component, leading to increased production costs and susceptibility to separation under extreme forces, with existing designs not being tool-free or cost-effective in manufacturing.
Innovation Solution
A one-piece, ergonomically designed bicycle axle with a tubular body and distinct ends, featuring a smooth bearing surface and threads for secure mounting to dropouts, along with a pivotable lever for tool-free assembly and a grip portion with wings for comfortable handling, reducing the need for complex machining and enhancing robustness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multi-component axles are used, then ease of manufacture is improved, but reliability deteriorates due to susceptibility to separation under extreme forces
Solution Approach 1:
The patent merges multiple axle components into a single monolithic axle body formed from one piece of material. This eliminates the interfaces between components that could separate under extreme forces, thereby improving reliability while maintaining manufacturability through single-piece forming processes.
2Manufacturing precision
If complex machining is used, then manufacturing precision is improved, but productivity deteriorates due to increased production costs and time
Solution Approach 1:
The patent incorporates thread formations directly into the monolithic axle body during the initial forming process, rather than adding threads through subsequent machining operations. This preliminary action eliminates complex post-forming machining, thereby improving productivity while maintaining the precision of thread formations through controlled forming processes.
3Ease of manufacture
If traditional axle designs are used, then ease of manufacture is improved, but ease of operation deteriorates due to lack of tool-free assembly
Solution Approach 1:
The patent incorporates a lever mechanism that enables the axle to be assembled and disassembled without external tools. The lever self-actuates to manipulate the thread formations, allowing tool-free operation while maintaining the simplicity of the monolithic axle body design for ease of manufacture.
4Reliability
If monolithic axle design is used, then reliability is improved by avoiding separation, but device complexity increases due to single-piece construction requirements
Solution Approach 1:
While the axle body is monolithic, the patent segments the thread formations into distinct, independently formable features within the single piece. This segmentation allows each thread formation to be optimized and formed separately during manufacturing, reducing the overall complexity of creating a reliable monolithic structure with multiple functional features.
Data Source
AI summary
A suspension for a two-wheeled vehicle includes first and second fork legs. Each fork leg includes a dropout. Each dropout has an opening therethrough. At least a portion of one of the openings is threaded. Each of the dropouts includes a split-damp pinch bearing defining the opening and operable between an open position and a locked position, and a hand operable actuator pivoted to the bearing for operation thereof. The suspension further includes a one-piece axle. The axle is disposed through the openings. The axle has a threaded first end engaged with the threaded portion. The axle has an ergonomic grip formed at a second end. The bearing tightly engages an outer surface of the axle in the locked position, thereby rotationally coupling the axle to the dropout.