Modular Clutch Cable Coupling for Handlebar Replacement
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing motorcycle clutch cable systems require complete replacement when handlebars are changed, involving time-consuming and complicated disconnection from the transmission.
Innovation Solution
A modular cable coupling assembly with a first and second cable subassembly, each having a core and jacket, connected by a ferrule, compensating component, and lock, allowing selective coupling without disconnecting the first section from the transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single length of clutch cable is used from transmission to handlebar, then the cable provides continuous control, but the entire cable assembly must be replaced when handlebars are changed, increasing time and complexity
Solution Approach 1:
The clutch cable assembly is divided into multiple separable sections: a first cable section connected to the transmission, a coupling assembly with a coupler, and a second cable section extending to the handlebar. This segmentation allows the second section to be replaced independently when handlebars are changed, while the first section remains connected to the transmission, thereby reducing replacement time and complexity while maintaining continuous control.
2Adaptability or versatility
If a two piece control cable with adjuster assembly is used, then cable length can be adjusted, but the cable still requires complete replacement when handlebars are changed
Solution Approach 1:
The cable system is segmented into replaceable sections with a modular coupling assembly. The coupling assembly includes a coupler with a capture socket and access passage, allowing the second cable section to be detached and replaced independently. This maintains the adaptability for different handlebar configurations while eliminating the need to replace the entire cable assembly.
Solution Approach 2:
The coupling assembly acts as an intermediary component between the first and second cable sections. It provides a mechanical interface with a capture socket that retains the first cable section's end and an access passage that allows the second cable section to be inserted and secured. This intermediary enables independent replacement of the second section while maintaining the connection between the transmission and handlebar.
3Stability of the object's composition
If the clutch cable is affixed to both transmission and handlebar, then the cable provides stable operation, but disconnection from transmission is required for any handlebar changes
Solution Approach 1:
The cable assembly is segmented into a first section permanently affixed to the transmission and a second section that can be easily detached and reattached. The coupling assembly provides stable operation through positive mechanical engagement (capture socket retaining the first section) while allowing easy modification by simply detaching and reattaching the second section to accommodate different handlebars without disturbing the transmission connection.
4Adaptability or versatility
If a modular coupling system is implemented, then cable sections can be selectively replaced, but the coupling assembly adds structural complexity
Solution Approach 1:
The coupling assembly is segmented into distinct functional components: a coupler with a capture socket for retaining the first cable section and an access passage for inserting the second cable section. This segmentation provides selective replacement capability while keeping each component's structure simple and straightforward, minimizing overall complexity.
Solution Approach 2:
The coupling assembly extracts only the essential functions needed for selective replacement: mechanical retention of the first cable section and passage for the second cable section. By removing unnecessary components and focusing on core functions, the assembly achieves adaptability without excessive structural complexity.
Data Source
AI summary
The present disclosure provides a cable coupling assembly for releasably coupling a first cable subassembly and a second cable assembly. The second cable subassembly includes a coupler affixed to a core of the second cable subassembly. The coupler is configured to engage a first slug of the first cable assembly in a capture socket of the coupler, wherein the coupler is slidably received within a casing connected to the first cable subassembly. The coupler can be affixed to the core of the second cable subassembly to preclude longitudinal translation or rotation relative to the second core.