Motorcycle Brake Lever Stop Mechanism Design
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Solution Overview
Problem
Existing lever actuated devices for motorcycle brakes and clutches face challenges in manufacturing cost-effectiveness and dust/dirt infiltration, with prior solutions being inconvenient and expensive, and prone to hydraulic contamination.
Innovation Solution
An actuation device with a stop mechanism where the stop is partially inserted inside the tank of liquid and comprises branches that cross the housing seat of the piston through insertion holes, providing a reliable and cost-effective solution without modifying the piston seats, thus preventing dust and dirt infiltration and simplifying construction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an elastic ring is inserted in a dedicated seat on the cylindrical side wall of the housing seat to stop the piston movement, then the piston can be reliably stopped and the float spring can be preloaded, but the manufacturing cost increases and the device becomes more complex
Solution Approach 1:
The invention extracts the stop function from the housing seat structure and relocates it to the piston itself. The piston is provided with a stop projection that directly engages with the housing seat, eliminating the need for separate elastic rings and dedicated seats on the housing. This integration simplifies the overall device structure while maintaining reliable piston stopping and float spring preloading.
2Reliability
If an elastic ring is inserted in a dedicated seat on the cylindrical side wall of the housing seat to stop the piston movement, then the piston can be reliably stopped, but the manufacturing cost increases
Solution Approach 1:
The invention merges the stop function with the piston component itself. The stop projection is formed as an integral part of the piston, combining multiple functions (piston movement, sealing, and stopping) into a single component. This eliminates the need for separate elastic rings and dedicated housing seats, reducing the number of parts and simplifying the manufacturing process while ensuring reliable piston stopping.
3Reliability
If the stop is positioned at the entrance of the device body in the vicinity of the actuation lever, then the piston can be stopped, but dust and dirt can infiltrate through the gap between the seat, device body and float, contaminating the hydraulics
Solution Approach 1:
Instead of positioning the stop at the entrance of the device body (external position), the invention inverts the approach by placing the stop projection on the piston itself (internal position). This internal positioning ensures that the stop function is achieved within the sealed hydraulic environment, preventing dust and dirt infiltration through gaps between external components while maintaining effective piston stopping.
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 solution ensures a reliable and cost-effective locking mechanism for the piston, preventing hydraulic contamination and simplifying the manufacturing process while maintaining normal hydraulic operation.
Implementation Method 1
The piston or float is in turn elastically influenced by a floating spring which is compressed during the braking action and which, at the end of the user's manual action on the actuation lever, extends thus bringing the piston and the same actuation lever to the rest condition
Implementation Method 2
The rotation of the actuation lever, thanks to the interposition of the pusher and of the push rod, allows obtaining a translation of the piston and hence the actuation, by means of the hydraulic circuit, of the brake and/or clutch
Data Source
Figure 1~2
Figure 3~4
Figure 5b~6
AI summary
Actuation device (4) for actuating a hydraulic actuator such as a brake and/or clutch, in particular for motorcycles, comprising: a device body (8) provided with a tank of liquid (12), the device body (8) defining a housing seat (16) for at least one piston (20), the seat (16) having a main extension which defines an actuation direction (X-X) of the piston (20) and being in fluidic connection with the tank of liquid (12), the device body (8) supporting at least one actuation lever for the piston (20) according to a workingv stroke (28) parallel to the actuation direction (X-X), the piston (20) comprising a stem (36) which extends between an actuation end (40), at which it interfaces with the actuation lever and a thrust head (44) for pressurising the liquid in the hydraulic circuit of the actuator, wherein the piston (20) is elastically pressed by elastic means (48) in contrast with the action of the actuation lever, adapted to influence the piston (20) according to a relief stroke (52) opposite the working stroke (28). The device (4) comprises at least one stop (56) for determining the position at rest of the piston (20), the stop (56) forming an end stop or stop to the relief stroke (52) of the piston (20) under the thrust of the elastic means (48). The stop (56) is at least partially inserted inside the tank of liquid (12), and comprises at least one branch (60) which crosses at least partially the housing seat (16) of the piston (20) through at least one insertion hole (64), the branch (60) comprising an abutment (68) which intercepts a portion of the piston (20), forming the stop to the relief stroke (52); wherein the stop (56) comprises at least one branch (60) which intercepts the stem (36), the stem (36) having at least one recess (72) in relation to the thrust head (44), so as to form a support and an undercut for said branch (60), along the actuation direction (X-X), and a limit stop abutment for the relief stroke (52).