Hydraulic Lever Mechanism with Cam Roller for Reduced Operating Force
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Solution Overview
Problem
Existing hydraulic operating devices for bicycle brakes lack a novel structure that efficiently reduces the operating force required to generate braking force, leading to suboptimal braking response and adjustment flexibility.
Innovation Solution
A hydraulic operating device featuring a base member with a hydraulic cylinder, a piston, a lever, and a connecting member with rollers and cam surfaces that allows the piston to be pulled from an initial to an actuated position through pivotal movement of the lever, enabling a variable lever ratio and reduced operating force, along with an adjustment mechanism for optimal hand size compatibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a conventional connecting mechanism is used between the lever and piston, then the structure is simple, but the operating force required is high and braking response is slow
Solution Approach 1:
The patent employs cam surfaces with curved geometries in the connecting member to transform the lever's rotational motion into linear piston movement. The curved cam profiles create a variable mechanical advantage throughout the stroke, reducing the peak operating force required while maintaining structural compactness.
Solution Approach 2:
The connecting member incorporates rollers that rotate during operation, transforming static friction contacts into dynamic rolling contacts. This dynamic element reduces friction losses and allows the mechanism to adapt its mechanical advantage ratio throughout the braking stroke, lowering the required operating force.
2Adaptability or versatility
If a fixed lever ratio is used, then the structure is simple, but the braking force adjustment flexibility is limited
Solution Approach 1:
The patent implements an adjustable lever pivot point mechanism that allows the lever axis position to be moved along the lever body. This dynamic repositioning capability changes the lever arm lengths and thus the lever ratio, enabling flexible adjustment of braking force without requiring complex multi-component systems.
Solution Approach 2:
The lever is divided into segments with adjustable relative positions, particularly the contact portion that interfaces with the connecting member. This segmentation allows independent adjustment of the contact portion's position relative to the pivot point, providing fine-tuning capability for braking force while keeping the overall structure relatively simple.
3Volume of moving object
If the hydraulic cylinder bore axis is parallel to the handlebar axis, then the layout is straightforward, but the device occupies excessive space and is not compact
Solution Approach 1:
The patent orients the hydraulic cylinder bore axis perpendicular to the handlebar axis, utilizing the vertical dimension rather than extending along the horizontal handlebar axis. This dimensional reorientation allows the hydraulic components to be stacked vertically, creating a compact footprint that fits within the handlebar assembly without protruding forward or backward.
Solution Approach 2:
The hydraulic cylinder and connecting member are arranged to nest within the handlebar assembly volume. The bore extending perpendicular to the handlebar axis allows the cylinder to be positioned within the existing structural envelope, with components nested concentrically or adjacently to minimize overall device volume.
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 device achieves improved braking response with reduced operating force and fine-tuned braking force adjustment, enhanced flexibility in layout, and a compact design suitable for bicycle handlebars, ensuring efficient fluid discharge and smooth operation.
Implementation Method 1
the second end portion includes at least one roller configured to rotatably contact with the contact portion
Implementation Method 2
the contact portion includes at least one cam surface configured to contact with the at least one roller
Implementation Method 3
Movement of the piston discharges fluid (oil, for example) from the hydraulic cylinder to drive a piston in a brake caliper
Data Source
AI summary
A hydraulic operating device includes a base member, a hydraulic cylinder provided on the base member and having a bore, a piston located in the bore to move between an initial position and an actuated position, a lever pivotally coupled to the base member around a lever axis for pivotal movement between a rest position and an operated position and including a contact portion, and a connecting member configured to connect the lever to the piston such that the piston is pulled from the initial position to the actuated position in response to the pivotal movement of the lever from the rest position to the operated position. The connecting member has a first end portion coupled to the piston and a second end portion configured to displaceably contact with the contact portion of the lever.