Brake Lever Repositioning With Detachable Spline Mount
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Solution Overview
Problem
Existing brake systems for wheeled vehicles face challenges in adjusting the lever position to accommodate different hand sizes, grip reach sizes, and grip strengths, requiring labor-intensive manual adjustments or replacement of components.
Innovation Solution
A remote operating lever unit with a detachable main body and holder, connected via a spline-based mechanism, allows easy repositioning of the lever at arbitrary angles, accompanied by a control unit that recalibrates signals based on displacement, and includes features like a biasing mechanism and user profile management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional brake lever adjustment mechanisms are used, then small adjustments (several millimeters) can be made, but large adjustments require releasing the brake wire and using special tools, which is labor-intensive and requires maintenance experience
Solution Approach 1:
The brake lever assembly is divided into separable components: the brake lever body and the handlebar mount. The connecting portion features detachable engagement elements (protrusion and recess) that allow the two parts to be separated and reconnected at different angles, enabling large adjustments without special tools or wire release.
Solution Approach 2:
The connection between the brake lever body and handlebar mount is made dynamic and adjustable rather than fixed. The detachable connecting portion with spline-based engagement allows the user to change the relative angle and position of the components multiple times, adapting to different hand sizes and grip preferences.
2Adaptability or versatility
If the brake wire length is changed to adjust lever position, then the lever can be repositioned for different hand sizes, but the process requires releasing and tightening the brake wire with hexagonal wrenches, which is time-consuming and requires labor
Solution Approach 1:
The system separates the adjustment function from the brake wire tensioning function. The detachable connecting portion allows positional adjustment independent of wire length changes, eliminating the need to release and retension the brake wire during position adjustments.
Solution Approach 2:
The user can perform lever position adjustments themselves without requiring maintenance experience or special tools. The simple detachable connection mechanism with alignment features allows intuitive repositioning and secure reconnection by the end user.
3Adaptability or versatility
If fixed lever position is used, then the brake system structure is simple, but it cannot accommodate different hand sizes, grip reach sizes, and grip strengths
Solution Approach 1:
The brake lever system transitions from a fixed configuration to a dynamically adjustable one. The detachable connecting portion with spline engagement enables multiple stable positions and angles, allowing the lever to adapt to different user anatomies and preferences while maintaining structural integrity during use.
Solution Approach 2:
The brake lever assembly is designed to serve multiple users with different hand sizes and grip preferences through its adjustable configuration. The same lever body can be positioned at different angles and distances from the handlebar to accommodate various user needs, making the system universally applicable.
Data Source
Figure 1A~1B
Figure 2~3
Figure 4~5
AI summary
A remote operating lever unit (20) for operating a brake unit (10) mounted to an wheeled vehicle is provided a lever (22) for operation by a user, a main body (24) holding the lever (22) in a displaceable manner and including a control unit for transmitting a signal to the brake unit (10) based on a displacement amount of the lever (22) from a neutral position thereof, a holder (26) holding the main body (26), and a connecting portion (245, 265) detachably engaging the main body (24) and the holder (26) at an arbitrary angle around an axis (X) perpendicular to a plane in which the lever (22) displaces.