Hydraulic Brake Travel Adjustment for Independent Free Stroke Tuning
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Solution Overview
Problem
Current hydraulic brake systems adjust free stroke length by altering the grip distance of the brake lever, which can be inconvenient for riders with different hand sizes or grip habits, potentially affecting operation and control, especially during high-speed riding.
Innovation Solution
A hydraulic brake with a travel adjustment mechanism that includes a pressure cylinder, piston rod, lever, spring, brake hose, and a connecting rod with an adjustable chamber and limiting component, allowing for independent adjustment of the piston rod's initial position and grip distance without changing the lever's grip distance, using a threaded connection and snap spring for stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the free stroke length is adjusted by changing the grip distance of the brake lever, then the free stroke length can be adjusted, but the grip distance changes which affects operation convenience for riders with different hand sizes
Solution Approach 1:
The brake system is segmented into two independent adjustment functions: one for free stroke length (via piston rod position adjustment mechanism) and another for grip distance (via lever position adjustment mechanism). This allows each parameter to be adjusted independently without affecting the other, resolving the contradiction between adjustment precision and operation convenience.
Solution Approach 2:
The system introduces dynamic adjustability through threaded adjustment mechanisms that allow riders to customize both free stroke length and grip distance according to their preferences. The piston rod position can be adjusted independently from the lever position, enabling dynamic optimization of braking performance without compromising ergonomics.
2Manufacturing precision
If the piston rod initial position is adjusted independently, then free stroke length can be precisely adjusted without changing grip distance, but the structure becomes more complex
Solution Approach 1:
The adjustment mechanisms are merged into the existing brake structure. The piston rod position adjustment is integrated into the master cylinder assembly, utilizing the existing threaded connection between the piston rod and master cylinder body. The lever position adjustment is integrated into the lever mounting structure. This merging approach minimizes additional components while achieving independent adjustment capability.
Solution Approach 2:
The adjustment mechanisms are designed to be self-contained and self-adjusting. The threaded connections allow direct adjustment of piston rod position and lever position without requiring external actuators or complex control systems. Riders can perform adjustments themselves using simple tools, reducing the need for additional complexity in the overall system.
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 precise and convenient adjustment of the free stroke length without altering the grip distance, improving operational control and safety by allowing riders to customize the brake according to their preferences, while maintaining the stability of the brake system.
Implementation Method 1
a spring that exerts force on the piston rod to maintain the piston rod in an initial position relative to the pressure cylinder when the lever is not subjected to an external force
Implementation Method 2
When the brake lever is pressed, it actuates the piston rod inside the oil circuit, applying pressure to the disc brake through the brake hose
Data Source
AI summary
Disclosed herein is a hydraulic brake with travel adjustment mechanism, comprising a brake body with a pressure cylinder; a piston rod extending through the pressure cylinder; a lever; a spring connected between the piston rod and the pressure cylinder; a brake hose connected to the other end of the brake body; a connecting rod, one end of which is connected to the lever, and the other end of which extends through the pressure cylinder to form a transmission engagement with the piston rod, a limiting component is arranged inside the pressure cylinder, and the limiting component acts on the connecting rod to restrict the connecting rod from leaving the pressure cylinder; an adjustable chamber is arranged in the connecting rod, and an adjustment element is provided inside the adjustable chamber, one end of which extends out of the adjustable chamber and forms a transmission engagement with the piston rod.