Motorcycle Brake Roller Testing With Automated Lever Actuation
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Solution Overview
Problem
Current methods for testing the braking capacity of motorcycles are inaccurate and unsafe due to manual operation, which can lead to variability in wheel contact and rotation speed, posing risks to operators and vehicles, and are not suitable for two-wheel or three-wheel inclinable vehicles.
Innovation Solution
A method and working area that utilize rotating rollers and a balancing system to securely position the motorcycle, combined with robotic manipulation to automatically operate the brake lever, ensuring precise and repeatable braking capacity testing by compensating for roll and yaw imbalances and using sensors for force and displacement measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If manual operation is used to position and operate the braking system, then the device complexity is reduced, but the measurement precision and reliability deteriorate due to variability in wheel contact and rotation speed
Solution Approach 1:
The system uses automatic detection and positioning mechanisms where sensors detect wheel position and the system automatically adjusts the vehicle positioning and roller rotation speed, eliminating the need for manual operator intervention while maintaining high measurement precision
Solution Approach 2:
Manual mechanical positioning and operation is replaced with an automated control system that uses sensors to detect wheel position and rotation speed, and automatically controls the roller rotation and braking system operation, substituting mechanical manual operations with automated electromechanical systems
2Ease of operation
If manual operation is used to position the vehicle on the bench, then the ease of operation is improved, but the reliability deteriorates due to safety risks and operator instability
Solution Approach 1:
The system automatically detects vehicle position and stabilizes it using feedback control, eliminating the need for manual positioning while ensuring consistent and safe vehicle placement on the test bench
Solution Approach 2:
Sensors continuously monitor wheel position and rotation speed, providing feedback to the control system which automatically adjusts the vehicle positioning and roller operation to maintain stability and prevent accidents
3Productivity
If repeated manual operation of the brake lever is performed, then the productivity is reduced, but the ease of operation is improved, however this causes harmful factors to the operator's health
Solution Approach 1:
The braking system is operated automatically by the test system itself, with the roller controlling the brake lever actuation based on pre-programmed test protocols, eliminating repeated manual operation and its associated health risks while increasing test productivity
Solution Approach 2:
Manual mechanical operation of the brake lever is replaced with automated electromechanical actuation controlled by the test system, substituting repeated manual physical operations with automated control mechanisms
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 provides high precision and safety in braking capacity testing, reducing operator risk and enabling accurate analysis of the braking system on two-wheel and three-wheel vehicles by maintaining stable positioning and automated operation.
Implementation Method 1
The system of sensors present on the roller bench is suitable for measuring the interaction forces between the wheel of the vehicle and the roller of the test bench
Data Source
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AI summary
A method for checking the braking capacity of a vehicle (10), said vehicle (10) comprising a body(11), at least one wheel (15), a braking system arranged to reduce the speed of the or each wheel (15), said braking system comprising an interface device arranged to operate the braking system. The method comprises the steps of arranging the vehicle (10) in a working area (100) comprising at least one rotating roller (110) and a control unit, arrangement of body (11) in a predetermined position and associating each wheel (15) to at least one rotating roller (110) by a constraint of rolling friction, actuating the or each rotating roller (110) to put in rotation at least one wheel (15) to it associated until a predetermined speed ω is reached, actuating the braking system, by the interface device (20), for reducing the predetermined speed ω of the or each wheel (15) put in rotation, detecting the tangential force between each wheel (15) and at least one rotating roller (110) to it associated. Furthermore, downstream of the step of actuating the or each rotating roller (110), a step is provided of locking the vehicle (10) in such a way that the body (11) is maintained substantially in the predetermined position also in case of forces applied to the body (11), said step of locking carried out by means of lock means.