Motorcycle Shift Rod with Integrated Magnetic Sensors

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Solution Overview

Problem

Conventional shift rod devices for motorcycles suffer from issues such as increased size and cost due to the use of load cell sensors, which are prone to noise from engine vibrations, have durability problems, and require additional sensors for shift-up and shift-down operations, leading to erroneous gear shifts and incomplete gear shifts with low operating loads.

Innovation Solution

A shift rod device with a link mechanism incorporating a stroke sensor and a shift load sensor that measures stroke amount and operating loads, featuring a piston, plungers, springs, and a magnet, allowing for non-contact detection of movement and miniaturization, with the stroke sensor and shift load sensor integrated into the shift rod body, enabling both shift-up and shift-down operations with a single sensor configuration.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If load cell type sensors are used for detecting shift rod rotation, then the gear shift operation can be detected, but the device size increases, cost increases, and durability against engine vibration is insufficient

Engineering Contradiction:

Improvegear shift detection reliabilityVSAvoidsensor system complexity and size

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines two separate sensors (stroke sensor for shift-up and load sensor for shift-down) into a single integrated sensor unit mounted on the shift rod. This integration reduces device complexity and size while maintaining the ability to detect both shift-up and shift-down operations through a unified sensing mechanism

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The integrated sensor unit performs multiple functions: it detects both shift-up and shift-down operations, measures stroke amount, and monitors operating loads. This multi-functional approach eliminates the need for separate sensors, reducing overall device complexity while improving reliability

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Measurement precision

If load cell type sensors are used, then gear shift detection is possible, but noise from engine vibration is output and durability is insufficient

Engineering Contradiction:

Improvegear shift detection accuracyVSAvoidengine vibration noise and durability

Core Design Contradiction:

Measurement precisionVSObject-affected harmful factors

Solution Approach 1:

The patent replaces the mechanical load cell type sensor with a magnetic field-based sensing system using magnets and Hall sensors. This substitution eliminates mechanical contact points that are susceptible to vibration noise, thereby improving measurement precision and durability against engine vibration while maintaining accurate gear shift detection

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If switch type sensors are used for shift-up and shift-down, then gear shift detection is possible, but two sensors are required increasing device size

Engineering Contradiction:

Improvegear shift detection capabilityVSAvoidnumber of sensors

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges the functionality of separate shift-up and shift-down sensors into a single integrated sensor unit. By mounting the sensor unit on the shift rod itself, it can detect both upward and downward movements through a unified sensing mechanism, reducing the number of components while maintaining reliable detection of both shift directions

Inventive Principle:

Principle #5Merging (Combining)

4Stability of the object's composition

If load cell type sensor does not extend or contract, then structural stability is maintained, but rotational force is generated on gear shift lever and erroneous operation occurs

Engineering Contradiction:

Improvesensor structural stabilityVSAvoidgear shift operation accuracy

Core Design Contradiction:

Stability of the object's compositionVSReliability

Solution Approach 1:

The patent introduces a flexible cable mechanism that connects the sensor unit to the gear shift lever. This dynamic element allows the system to accommodate rotational movements and flexing during gear shift operations, preventing erroneous operations while maintaining structural stability through the anchored sensor unit

Inventive Principle:

Principle #15Dynamics

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 achieves miniaturization and compactness while ensuring proper gear shift operation, reducing the risk of erroneous shifts and improving durability by using integrated sensors that detect movement and loads effectively, allowing for optimized gear shift control with reduced sensor complexity and cost.

Implementation Method 1

a stroke sensor measuring a stroke amount, and a shift load sensor making a stroke motion in extension and contraction directions

Methodology Applied

Scientific EffectMagnetic field detection: Magnetic Field

Implementation Method 2

a piston, a first plunger, a second plunger, a first spring, a second spring

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS9518649B2Shift rod device of motorcycle

Publication Date: 2016.12.13 SUZUKI MOTOR CORP

AI summary

There is provided a link mechanism configured such that a shift rod driven by an operation of a gear shift pedal drives a shift shaft to rotate via a gear shift lever. A stroke sensor measuring a stroke amount, and a shift load sensor making a stroke motion in extension and contraction directions in accordance with shift-up and shift-down operating loads from the gear shift pedal are integrally provided to the shift rod.