Integrated Angle Sensor for Vehicle Handlebar Lever Detection
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Solution Overview
Problem
Existing operation amount detection apparatuses for vehicles with handlebars are costly and prone to measurement errors due to their complex structure and installation requirements, particularly in detecting the rotation angle of brake control levers.
Innovation Solution
A compact angle sensor system is mounted on a control lever with a pivot mechanism, featuring a rotational shaft and sensor main body integrated into a housing, which includes a circular disc portion and connecting arm to accurately detect the rotation amount of the control lever without errors, reducing the number of parts and installation space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a conventional angle sensor with pushing screw, pressing rod, and cam is used to detect control lever rotation, then the rotation amount can be measured, but the number of parts increases leading to higher fabrication cost and larger installation space requirement
Solution Approach 1:
The patent merges the pushing screw, pressing rod, and cam into a single integrated angle sensor assembly that directly detects control lever rotation. The sensor housing is integrally formed with the detection mechanism, eliminating the need for separate components and reducing the overall part count while maintaining detection accuracy.
Solution Approach 2:
The patent extracts the essential detection function from the complex mechanical transmission mechanism (pushing screw-pressing rod-cam chain) and implements it through a simplified direct detection approach using a rotational shaft and detection element that directly engage with the control lever pivot point.
2Measurement precision
If the angle sensor uses pushing screw, pressing rod, and cam mechanism, then rotation detection is achieved, but the installation space required increases
Solution Approach 1:
The patent combines multiple functional elements into a compact integrated housing that accommodates the detection mechanism within a minimal footprint, reducing the installation space required on the vehicle frame.
Solution Approach 2:
The detection mechanism is nested within a compact housing structure that efficiently utilizes internal space, with the rotational shaft and detection elements arranged in a space-efficient configuration that minimizes the overall sensor assembly dimensions.
3Measurement precision
If rotation amount is measured by rotating cam via linearly operating pressing rod, then the measurement is obtained, but measurement errors may occur
Solution Approach 1:
The patent replaces the mechanical pressing rod-cam transmission system with a direct rotational detection mechanism that uses a rotational shaft connected to the control lever pivot, eliminating the intermediate mechanical conversions that cause measurement errors.
Solution Approach 2:
The patent creates a direct rotational copy of the control lever's angular displacement through the rotational shaft, which accurately replicates the lever's rotation angle without the cumulative errors introduced by multiple mechanical conversion stages.
Data Source
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AI summary
An angle sensor (14) includes an operating body (14c) and a sensor main body (14d). The operating body (14c) includes integrally a circular disc portion (14e), a rotational center shaft (14f) which is inserted rotationally into a hollow portion of a pivot (12), a connecting arm (14a) which is locked on a connecting arm mounting portion (5e), and a rotational shaft (14b) which is inserted into the sensor main body (14d). The sensor main body (14d) includes a housing and a rotation detection device (14i).