Brake Lever Pivot Sensing to Block Water Ingress
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Solution Overview
Problem
Existing operation amount detection devices for vehicles with handlebars face issues with water and foreign matter ingress into rotation angle sensors due to complex structures, increased weight, and the need for machining attachment holes, which complicates assembly and increases costs.
Innovation Solution
A pivot-based detection system where a pivot is inserted into an operator, allowing the operator and detection shaft to co-rotate, with a magnetic detection unit in a non-contact configuration, and a communication path to drain water effectively, reducing the need for dedicated holes and simplifying the structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If operation amount is not detected, then the vehicle control unit cannot adjust control based on usage patterns, but the device complexity increases with multiple sensors and detection mechanisms
Solution Approach 1:
The bar handle itself serves as the detection device by incorporating operation detection units directly into its structure. The handle detects operation amounts through integrated sensors that measure physical quantities such as acceleration, angular velocity, or operational states, eliminating the need for separate detection devices and reducing overall system complexity while enabling adaptive control based on usage patterns
Solution Approach 2:
The bar handle performs multiple functions simultaneously: it serves as both the steering/control component and the operation detection device. By integrating operation detection units into the handle structure, the system achieves multi-functionality where a single component handles both control and detection tasks, reducing the number of separate components needed
2Productivity
If operation amount detection is implemented, then maintenance intervals can be optimized, but the manufacturing cost and device complexity increase
Solution Approach 1:
The operation detection units are merged with the bar handle structure, combining detection functionality with the existing control component. This integration approach reduces manufacturing complexity by eliminating separate detection devices and simplifying the assembly process, while still enabling optimized maintenance scheduling based on actual operation amounts
3Loss of information
If multiple operation types are detected, then comprehensive usage analysis is achieved, but the device complexity and information processing requirements increase
Solution Approach 1:
The detection system is segmented into multiple independent operation detection units, each dedicated to detecting a specific operation type (e.g., acceleration detection, angular velocity detection, operational state detection). This segmentation allows for specialized sensing for each operation type while keeping individual unit complexity low, and the vehicle control unit integrates information from all segments to achieve comprehensive usage analysis
Data Source
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AI summary
An operation amount detection device (50A) is for a vehicle with handlebar in which a pivot (40) fixed to a holder (10) is inserted into one end of a pivot insertion hole (25) of a brake lever (20A), and the brake lever (20A) is rotatable around the axis of the pivot (40). The operation amount detection device (50A) comprises a rotation angle sensor (51) fixed to the holder (10), and a detection shaft (55) fitted to the other end of the pivot insertion hole (25). The brake lever (20A) and the detection shaft (55) rotate together, and a magnet (58) is provided on the detection shaft (55). A magnetic detection unit (53) of the rotation angle sensor (51) faces the magnet (58) in a non-contact state and detects the amount of rotation of the magnet (58). With this configuration, it is possible to prevent water and foreign matter from entering the rotation angle sensor (51) with a simple structure.