Motorcycle Side Stand Switch Resin Design
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Solution Overview
Problem
Conventional side stand switches for motorcycles have complex assembly processes, require multiple parts, and are heavy due to metal construction, with limited power supply angles and uneven contact pressure.
Innovation Solution
A side stand switch with a resin-based design featuring engaging mechanisms for reduced parts and weight, incorporating a base and rotary with a cylindrical portion and fitting portion, and a movable contact with leaf springs for uniform contact pressure and increased power supply angle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a rotary switch is mounted on a rotary shaft using mounting bolts and threaded holes, then the switch can be securely fastened, but the number of assembly steps and parts increases
Solution Approach 1:
The base and rotary are integrated into a single unit where the rotary is embedded within the base structure. The cylindrical portion of the rotary fits into a fitting portion of the base, eliminating the need for separate mounting bolts and threaded holes. This merging of components reduces assembly steps while maintaining secure fastening through the engagement of the cylindrical and fitting portions.
Solution Approach 2:
The rotary is nested within the base structure, with the cylindrical portion of the rotary fitting into the fitting portion of the base. This nesting arrangement allows the rotary to be securely held by the base without requiring additional fastening components, thereby reducing the number of parts and assembly steps while ensuring reliable mounting.
2Strength
If constitutional parts of the rotary switch are made with metal to prevent deformation, then the switch can withstand fastening forces, but the weight of the rotary switch increases
Solution Approach 1:
The base and rotary are made from resin materials that provide sufficient strength to withstand operational forces without requiring metal construction. The integrated design with the cylindrical portion fitting into the fitting portion distributes mechanical loads effectively, allowing the use of lighter resin materials while maintaining the necessary structural integrity and resistance to deformation.
3Device complexity
If a semicircular plate is used for the movable contact, then the structure is simple, but the power supply angle cannot be increased
Solution Approach 1:
The movable contact is segmented into multiple leaf springs arranged radially instead of using a single semicircular plate. This segmentation allows each leaf spring to independently contact the fixed contacts at different angular positions, thereby increasing the power supply angle while maintaining structural simplicity through the modular leaf spring design.
4Volume of moving object
If the rotary switch is designed with a limited power supply angle, then the structure remains compact, but the contact pressure between movable and fixed contacts becomes uneven
Solution Approach 1:
The movable contact uses flexible leaf springs that can dynamically adjust their contact pressure with the fixed contacts. The leaf springs are elastically deformable, allowing them to maintain uniform contact pressure across multiple contact points even when the rotary is rotated to different positions, thereby ensuring manufacturing precision and uniformity of contact pressure while keeping the structure compact.
Data Source
AI summary
On a pivot bolt which rotatably and pivotally supports a side stand bar on a vehicle-body-side bracket, a switch unit which is constituted of a base and a rotary made of a resin and detects a rotational position of the side stand bar is mounted. A first engaging mechanism which is constituted of a groove and a projection is arranged between a cylindrical portion formed on the rotary and an engaging shaft and, at the same time, a second engaging mechanism which is constituted of a groove and a projection is arranged between the base and the cylindrical portion. The rotary on which a movable contact formed of a leaf spring is mounted allows a positioning pin which is formed on one end portion thereof to be engaged with a pin hole formed in a pivot portion and hence, the rotary is integrally rotated with the side stand bar.