Clutch Pull Reduction Assembly With Pivoted Cable Force Distribution
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Solution Overview
Problem
Riders of motorcycles and all-terrain vehicles face significant strain and potential injury due to the high force required to operate clutch levers, which can vary by model and hydraulic assistance, necessitating a reduction in clutch actuation force.
Innovation Solution
A clutch actuation force reducing apparatus is introduced, featuring an annular housing with pivot plates and idler plates that distribute the pull force over multiple pivot points, reducing the physical effort needed to disengage the clutch assembly by translating the force through a cable connection system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a traditional cable operated clutch lever is used, then the clutch assembly can be disengaged, but significant force is required to operate the lever causing rider strain and potential injury
Solution Approach 1:
A force reduction assembly with pivot plates and idler plates is introduced as an intermediary mechanism between the clutch lever and the cable actuator. This assembly distributes the pull force over multiple pivot points (at least three pivot points), reducing the physical effort needed at the lever while maintaining effective cable tension to disengage the clutch.
Solution Approach 2:
The force reduction assembly segments the force transmission path into multiple stages through stacked pivot plates and idler plates. Each plate pair creates a pivot point that divides the stock pull force, transforming a single high-force connection into multiple lower-force connections distributed across the assembly.
2Reliability
If the clutch lever requires high force to operate, then the clutch can be reliably disengaged, but repetitive operation causes strain and injury to the rider
Solution Approach 1:
The force reduction assembly acts as a mediator that maintains reliable clutch disengagement while reducing the force requirement. The multiple pivot points and distributed force transmission ensure consistent cable actuation force is delivered to the clutch mechanism, preserving reliability while making repetitive operations safer and more comfortable.
3Ease of operation
If a force reduction assembly with multiple pivot plates is used, then the pull force is distributed and reduced, but the device complexity increases
Solution Approach 1:
The force reduction assembly uses a nested structure where multiple pivot plates are stacked and interconnected within a compact housing. The idler plates are positioned between the pivot plates, creating a nested arrangement that distributes force through multiple layers while maintaining a space-efficient design that integrates with the existing clutch lever mechanism.
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
The apparatus significantly reduces the force required to operate the clutch lever, as demonstrated by empirical testing on various models, achieving a 50% reduction in pull force and maintaining low holding force across the lever's range, thereby alleviating rider strain and injury risk.
Implementation Method 1
an operator may urge the clutch lever down to a handle grip to pull the first pair of pivot plates to initiate pivoting thereof about the connection at the pair of anchor plates, the pull force translated to the second pair of pivot plates over the pair of idler plates and dividing the stock pull force over the two pivot points at the pair of anchor plates to reduce the amount of physical force required at the clutch lever to actuate disengagement of an engaged clutch assembly
Data Source
AI summary
A force reducing apparatus includes a housing and cover plate, a pair of fixed anchor plates disposed to the housing and underside of the cover plate, a pivot plate assembly including a first pair pivot plates and a second pair of pivot plates connected to a fixed pair of anchor plates, the first pair of pivot plates connected to a first cable routed through the housing sidewall and connected to a clutch lever, the second pair of pivot plates connected to a second cable routed through the sidewall of the housing and connected to a clutch actuator at a clutch assembly, and a pair of idler plates connected to the pivot plates at the unanchored ends of the pivot plates. An operator pulls the first pair of pivot plates via the clutch lever to operate the plate assembly reducing the amount of force needed to release an engaged clutch.