Hydraulic Brake Piston Adjustment Structure
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Solution Overview
Problem
Hydraulic brake systems face issues with piston and seal position shifts due to brake cable adjustments, leading to blocked fluid ports, incorrect piston positioning, and potential brake failure, especially when brake pads wear or fluid expands due to thermal effects.
Innovation Solution
An adjustment structure comprising a main body with a fluid reservoir, an inner chamber, an adjusting device with an annular fluid guiding passage, a piston connected to the brake cable, and a returning spring, which allows manual adjustment of the piston to a normal operating position relative to fluid ports, using a positioning device with a visible mark for precise alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the brake cable is adjusted to change the brake lever position, then the brake lever operation is optimized, but the piston and seal position shifts occur causing fluid port blockage
Solution Approach 1:
The adjusting device is segmented into a body portion and a rotating member that can rotate relative to each other. The piston rod is connected to the rotating member, allowing independent adjustment of the piston position through rotation of the rotating member without affecting the overall brake system structure.
Solution Approach 2:
The adjusting device enables preliminary adjustment of the piston position before the brake pads wear down. By rotating the rotating member, the piston rod length is adjusted in advance to compensate for future pad wear, preventing the piston from shifting position and blocking fluid ports during operation.
2Stress or pressure
If fluid expands due to thermal effect during operation, then pressure is maintained, but the piston returns to wrong position causing brake lockup
Solution Approach 1:
The adjusting device allows preliminary positioning of the piston at the correct location before thermal expansion occurs. The rotating member fixes the piston rod length, establishing a predetermined piston position that remains stable even when fluid expands thermally, preventing the piston from returning to an incorrect position.
3Ease of operation
If the brake cable length is adjusted, then brake lever control is optimized, but the piston and seal position becomes improper
Solution Approach 1:
The adjusting device separates the brake cable adjustment function from the piston positioning function. The rotating member independently controls piston position through threaded engagement with the piston rod, while the brake cable adjustment is handled separately through the brake lever mechanism, preventing position inaccuracies.
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
Ensures the piston is maintained at a normal operating position, preventing blockages and ensuring proper brake function, even with brake cable adjustments and wear, while allowing for compact design and easy assembly.
Implementation Method 1
The returning spring is abutted between the main body and the piston
Implementation Method 2
The adjusting device is screwed in the opening part of the main body. The adjusting device is rotated so as to move reciprocatedly in the cylinder channel
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
An adjustment structure of a hydraulic brake system is provided, which includes a main body, a piston and an adjusting device. The main body includes at least one fluid reservoir, an inner chamber and at least one fluid passage. The inner chamber includes a cylinder channel and an opening part, and the cylinder channel is communicated with the fluid reservoir by at least one fluid port. The piston is driven by the brake cable to be limitedly moved in the cylinder channel. The piston includes a cable hole for receiving the brake cable, and the piston has a normal operated position relative to the fluid port. The adjusting device is disposed in the opening part and is abutted against the piston. The adjusting device is operated to be moved relative to the brake cable such that the piston is adjusted to be returned to the normal operated position.