Motorbike Sensor Bracket with Cable Routing
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Solution Overview
Problem
Existing supporting structures for phonic wheel sensors in motorbikes lack robustness against strikes and accidental bumps, require complex machining, and expose sensor cables to damage, affecting reliability and aesthetics.
Innovation Solution
A supporting structure for the phonic wheel sensor and brake caliper with a main body fastened to a fork stem, featuring a cylindrical housing, divergent ribs for enhanced rigidity, and pass-through openings to protect the sensor and cable, allowing for simple molding and reduced visibility of the cable.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the sensor supporting structure is integrally formed with the fork stem, then structural robustness is improved, but manufacturing complexity increases
Solution Approach 1:
The supporting structure is divided into separate components: a fork stem and a brake caliper bracket assembly. The sensor holder is integrated into the bracket assembly rather than being integrally formed with the fork stem, allowing each component to be manufactured independently using simple molding processes while maintaining overall structural robustness through the assembled configuration.
Solution Approach 2:
The sensor holder is merged with the brake caliper bracket assembly to form an integrated unit. This combination provides robust support for both the brake caliper and the sensor while avoiding the need for complex integral molding of the fork stem, thus resolving the contradiction between structural strength and manufacturing ease.
2Reliability
If the cable is extended externally away from the brake disc, then protection against damage is improved, but aesthetic appearance deteriorates
Solution Approach 1:
The sensor cable is routed through the internal structure of the brake caliper bracket assembly, nesting the cable within the existing structural components. This internal routing protects the cable from external damage while keeping it concealed within the bracket, thus maintaining aesthetic appearance without compromising protection.
Solution Approach 2:
The brake caliper bracket assembly serves as an intermediary structure that provides a protected pathway for the sensor cable. The cable passes through the bracket's internal geometry, which acts as a protective mediator between the cable and external damage sources, while keeping the cable hidden from view.
3Ease of operation
If the cable is made visible and extended externally, then ease of maintenance is improved, but aesthetic appearance and protection are deteriorated
Solution Approach 1:
The cable routing path is nested within the brake caliper bracket assembly, allowing the cable to be accessed through designated access points or by removing the bracket if necessary. This maintains aesthetic appearance by concealing the cable while preserving maintenance accessibility through the modular design.
4Ease of manufacture
If the supporting structure is designed for simple molding, then ease of manufacture is improved, but structural robustness may deteriorate
Solution Approach 1:
The supporting structure is segmented into the fork stem and the brake caliper bracket assembly, which can be manufactured using simple molding processes. The segmentation allows each component to be optimized for its specific function while maintaining manufacturing simplicity, and the assembled structure provides the necessary structural robustness.
Solution Approach 2:
The brake caliper bracket assembly uses a composite construction combining the bracket body with integrated sensor holder features. This composite design allows simple molding of each component while achieving the required structural robustness through the combined assembly and strategic placement of reinforcing features.
Data Source
AI summary
A supporting structure (100) for phonic wheel sensor (200) and brake caliper (300), comprises: a main body (1) fastened or which can be fastened to a stem of a fork (F) of a motorbike; a wheel support (2) connected to said main body (1) for supporting a wheel of the motorbike; and an extension (3) which develops from said main body (1) and comprises a fastening device (30) for a brake caliper (300). Two pass-through openings (31, 32) are formed in said extension (3), a first pass-through opening (31) for housing the phonic wheel sensor (200) and a second pass-through opening (32) for the passage of a cable (201) of the phonic wheel sensor (200).