Front Fork Cap Layout for Wire Sealing and Compact Adjustment
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Solution Overview
Problem
Conventional front forks with internal electric devices face design constraints due to the need to accommodate electric wires, leading to enlarged operational portions that interfere with user operation and limit design flexibility.
Innovation Solution
The front fork design misaligns the electric wire from the axial center line of the fork main body, allowing the operational portion of the adjuster to be downsized independently of the electric wire, and positions the operational portion apart from the electric wire within the cap, enabling flexible placement without interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the operational portion is positioned around the electric wire to ensure sealing, then the electric wire can be sealed, but the operational portion becomes enlarged and interferes with user operation
Solution Approach 1:
The electric wire is routed along the outer circumference of the cylindrical portion rather than through its interior, changing the spatial dimension of wire placement. This allows the operational portion to be positioned independently without being constrained by the wire's presence, resolving the conflict between sealing requirements and operational ease.
Solution Approach 2:
The cap is divided into functionally independent regions: the cylindrical portion for electric wire routing and the lid with operational portion for user interaction. This segmentation allows each component to be optimized independently, with the wire sealed along the cylindrical outer surface while the operational portion remains accessible and unobstructed on the lid.
2Reliability
If the operational portion is enlarged to seal the electric wire, then the electric wire can be securely sealed, but the degree of freedom in design is reduced
Solution Approach 1:
The electric wire routing is moved from the interior space to the outer circumferential surface of the cylindrical portion. This dimensional change liberates the interior design space, allowing the operational portion to be independently positioned and sized without being constrained by the need to accommodate the wire, thereby enhancing design freedom while maintaining sealing reliability.
Solution Approach 2:
The outer circumference of the cylindrical portion serves as an intermediary pathway for the electric wire, separating the wire routing function from the operational portion. This intermediary arrangement allows both the sealing requirement and design flexibility to be satisfied, as the wire can be sealed along the cylindrical surface while the operational portion is freely positionable on the lid.
3Device complexity
If the electric wire is passed through the interior of the operational portion, then both electricity supply and vehicle height adjustment can be achieved, but the operational portion must be upsized to accommodate the wire
Solution Approach 1:
The functions of electric wire routing and operational adjustment are segmented into separate spatial zones. The cylindrical portion handles wire routing along its outer circumference, while the lid accommodates the operational portion independently. This segmentation eliminates the need for the operational portion to be enlarged, as the wire does not pass through its interior.
Solution Approach 2:
The electric wire is routed along the outer surface of the cylindrical portion rather than through its interior or through the operational portion. This dimensional change in wire placement allows the operational portion to maintain a compact size while still achieving both electricity supply and vehicle height adjustment functions through the separated routing paths.
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
This design reduces the operational portion size, enhances user interaction, and increases design freedom by preventing the electric wire from disturbing the operational portion, while maintaining efficient power supply to the electric device.
Implementation Method 1
a suspension spring (10) mounted inside the fork main body (2), the suspension spring (10) biasing the fork main body (2) in an extending direction
Implementation Method 2
a damper that is mounted inside the fork main body and that expands/contracts in response to extending or shortening of the fork main body
Data Source
AI summary
A front fork (1) of the present invention includes: a fork main body (2) having a vehicle body side tube (3) and an axle side tube (4); a cap (5) placed in the vehicle body side tube (3); a cylinder (6) provided inside the axle side tube (4); a rod (7) inserted into the cylinder (6) so as to be movable in an axial direction; an electric device (6) mounted inside the cylinder (6); an electric wire (9) connected to the electric device (8); a suspension spring (10) biasing the fork main body (2) in an extending direction, and an adjuster (11) capable of adjusting a support position of a spring seat (12). The electric wire (9) is drawn from the cap (5) at a position misaligned from an axial center line of the fork main body (2) to an outside of the fork main body (2). An operational portion (17) of the adjuster (11) is provided in the cap (5) at a position misaligned from the axial center line (A).