Motorcycle Lever Collapse Hinge Friction Control
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Solution Overview
Problem
Existing collapsible control lever devices for motorcycles face issues with inconsistent frictional resistance due to size tolerance variations in the hinge components, requiring precise torque adjustments and additional clamping means, which complicates assembly and reliability.
Innovation Solution
A collapsible control lever device with a collapse hinge design featuring a screw that is freely accommodated within co-axial holes in the outer and intermediate wings, where the screw is only secured in one outer wing, allowing the head to abut against the intermediate wing, providing consistent frictional resistance independent of wing size tolerances and enabling assembly at a constant torque.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the screw is tightly fixed in all three holes (first outer wing, second outer wing, and intermediate wing), then the structural strength is improved, but the frictional resistance becomes inconsistent due to size tolerances requiring precise torque adjustments
Solution Approach 1:
The patent extracts the screw from the intermediate wing hole, removing it from the fastening function. The screw is now only threaded into the second outer wing, while freely passing through the first outer wing and intermediate wing holes. This extraction eliminates the dependency on precise torque control for the intermediate wing connection, as the screw no longer fastens to it.
Solution Approach 2:
The intermediate wing acts as an intermediary element that is clamped between the screw head and the second outer wing, rather than being directly fastened to the screw. This intermediary positioning allows the intermediate wing to be held in place through compression and friction without requiring precise screw torque, as it is sandwiched between two rigid elements.
2Stability of the object's composition
If the frictional resistance is increased to prevent accidental collapse, then the lever stability is improved, but the lever cannot collapse in the event of a fall
Solution Approach 1:
The patent changes the frictional resistance parameter by modifying the screw fastening configuration. By removing the screw from the intermediate wing, the frictional resistance at that interface is eliminated, creating a controlled weak point. The overall frictional resistance is now determined only by the connection between the screw and the second outer wing, making it easier to control and adjust to the optimal level that allows both stability and controlled collapse.
3Reliability
If additional clamping means such as snap means are added to ensure proper tightening, then the assembly reliability is improved, but the device complexity increases
Solution Approach 1:
The patent extracts the additional clamping means (snap means) from the assembly by not including them in the design. Instead of adding complex clamping mechanisms, the invention relies on the simplified screw fastening system where the intermediate wing is clamped between the screw head and the second outer wing. This extraction of unnecessary components directly reduces device complexity while maintaining assembly reliability through the inherent mechanical advantage of the sandwich clamping arrangement.
4Ease of manufacture
If the screw is freely accommodated in the intermediate wing hole without threading, then the assembly torque can be constant, but the intermediate wing must be tightly clamped between screw head and outer wing
Solution Approach 1:
The intermediate wing serves as an intermediary element that is compressed between the screw head and the second outer wing. This intermediary positioning transforms the single-screw fastening system into an effective triple-component connection. The clamping force is generated by the screw tightening against the second outer wing, which in turn compresses the intermediate wing, creating a stable assembly without requiring the screw to thread into the intermediate wing.
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
Ensures a consistent collapse moment and reproducible frictional resistance, simplifying assembly and maintaining lever functionality during impacts by decoupling the intermediate wing's rotation, thus preventing damage and ensuring reliable operation.
Implementation Method 1
The screw tightens the two outer wings to the inner wing thereby generating a frictional resistance that holds the grip portion in the normal use position thereof
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
A control lever device (1) for vehicles comprises a support structure (2) connectable to a handlebar, an actuator (2) connected to the support structure (2), a lever (5) having a base portion (S) and a grip portion (7), the base portion (6) being hinged to the support structure (2) and connected to the actuator (4) a collapse hinge (9) pivotally connecting the grip portion (7) to the base portion (6). The collapse hinge (9) comprises a first and a second outer wing (10,11) formed in one (6) of the portions (6, 7) of the lever, an intermediate wing (12) formed in the other portion (7) of the lever (5) and interposed between the two outer wings (10, 11) and a screw (13) accommodated within co-axial holes (14, 15, 16) formed in the wings (10, 11, 12). The screw (13) is freely accommodated within the holes (16, 14) of the intermediate and first outer wing (10,12) and is only screwed in the second outer wing (11) and a head (18) of the screw (13) is directly or indirectly abutted against the intermediate wing (12) such as to tighten the intermediate wing (12).