Hydraulic Brake Master Cylinder Tool-Free Free Stroke Adjustment
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Solution Overview
Problem
Conventional hydraulic brake master cylinders capable of pad contact point adjustment are complex to manufacture and assemble, and require tools for adjustment, making them inconvenient for users.
Innovation Solution
A hydraulic brake master cylinder design featuring a cylinder unit, piston, springs, seal, and rotatable adjuster that allows for tool-free adjustment of the free stroke by changing the distance between the seal and channel outlet, simplifying construction and assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional hydraulic brake master cylinders are designed to be adjustable, then pad contact point adjustment capability is improved, but device complexity increases and manufacturing becomes difficult
Solution Approach 1:
The adjuster mechanism is nested within the cylinder body structure. The adjuster (23) is disposed inside the main cylinder body (21), and the seal (36) is movable along the rod (32) within the cylinder. This nested arrangement allows the adjustment function to be integrated into the existing cylinder structure without adding external components, thereby improving adaptability while controlling complexity.
Solution Approach 2:
The rod (32) serves multiple functions: it connects the piston (31) to the brake lever, transmits hydraulic force, and serves as a guide for the movable seal (36) during adjustment. The adjuster (23) simultaneously controls both the free stroke length and the pad contact point position. This multi-functionality reduces the need for separate components, improving versatility while managing device complexity.
2Adaptability or versatility
If conventional adjustable master cylinders are designed with adjustment mechanisms, then pad contact point adjustment is enabled, but ease of operation deteriorates due to tool requirements
Solution Approach 1:
The adjuster (23) is designed with a knurled outer surface that can be directly gripped and rotated by hand. The adjuster threads onto the rod (32) and moves the seal (36) along the rod through direct manual operation. This self-service design eliminates the need for external tools, allowing users to adjust the free stroke and pad contact point conveniently without requiring special adjustment tools.
3Speed
If the free stroke is shortened to improve brake response, then brake reaction speed is improved, but the risk of over-adjustment increases requiring precise control
Solution Approach 1:
The movable seal (36) provides tactile feedback during adjustment. As the seal moves along the rod (32) toward the channel end, the user can feel the increasing resistance and the approaching contact point. When the seal reaches the channel end, the feedback indicates the maximum adjustment limit. This feedback mechanism allows users to control the free stroke precisely without requiring high manufacturing precision, enabling safe shortening of free stroke for faster brake response.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables easy adjustment of the brake pad contact point without tools, improving usability and manufacturing simplicity while maintaining effective brake performance.
Implementation Method 1
The first spring applies an elastic force to the piston
Implementation Method 2
The second spring applies an elastic force to the second end portion of the rod
Implementation Method 3
The seal is attached to the rod and movable with the rod to seal the channel so as to block the first space from communicating with the second space
Data Source
AI summary
A hydraulic brake master cylinder includes a cylinder unit having first and second spaces, a channel communicating the spaces and an adjuster exposed outside; a piston slidably disposed in the first space; a first spring applying an elastic force to the piston; a rod moving relative to the piston; a second spring applying an elastic force to the rod; a seal attached to the rod and moving controllably to seal the channel; and a nut threaded onto the rod. The adjuster is rotatable to make the nut and the rod rotate with respect to each other so as to change the distance between the seal and the end of the channel to adjust the free stroke.