JP4236086B2 - Lever holder assembly - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention is an oil that is attached to the tip of a handlebar in a vehicle having a handlebar such as a two-wheeled vehicle to support a brake lever or a clutch lever, and is pressurized according to a swinging operation of the brake lever or the clutch lever. The present invention relates to a lever holder assembly in which a master cylinder for housing the housing is formed.
[0002]
[Prior art]
Normally, a lever holder assembly for swingably supporting a brake lever or a clutch lever is fixed to both ends of a handlebar in a motorcycle. In such a lever holder assembly, a master cylinder for containing oil for transmitting a swinging operation of a brake lever or a clutch lever to each mechanism (brake mechanism or clutch mechanism) is integrally cast, The master cylinder is configured with a piston fitted in a reciprocating manner (see, for example, Patent Document 1).
[0003]
That is, when the brake lever or clutch lever is operated to swing, a part of these brake lever or clutch lever presses the piston fitted in the master cylinder, and pressure is applied to the oil inside the master cylinder, thereby An operation or a clutch operation was performed. Note that a reservoir tank containing a predetermined amount of oil is integrally or separately attached to the lever holder assembly.
[0004]
[Patent Document 1]
Japanese Utility Model Publication No. 62-1833 [0005]
[Problems to be solved by the invention]
However, the conventional lever holder assembly has the following problems because the part where the master cylinder is formed and the other part are integrally molded. In other words, general-purpose casting methods can be broadly divided into high pressure casting that applies high pressure to the molten metal, such as die casting, and low pressure casting that does not apply pressure to the molten metal. Although the dimensional accuracy is good, there is a drawback that a nest is likely to be formed inside, and the low pressure casting has an advantage that it is difficult to form a complicated shape and the dimensional accuracy is relatively poor, while the nest is difficult to be formed inside.
[0006]
Since the lever holder assembly has a complicated shape as a whole, it is desired to be molded by high pressure casting. However, since the master cylinder is integrated, it must be molded by low pressure casting. That is, the master cylinder needs to reciprocate the piston with high precision while containing oil in a liquid-tight manner, so strict dimensional control is necessary. This is likely to occur, and there is a risk of quality degradation and yield deterioration.
[0007]
In this way, when the entire lever holder assembly is formed by low pressure casting, the shape of the portion other than the master cylinder and the complicated shape is not performed well. There was a problem that it was necessary to perform cutting work and lead time was increased.
[0008]
This invention is made | formed in view of such a situation, and provides the lever holder assembly which can reduce lead time by shape | molding taking advantage of each advantage of high pressure casting, low pressure casting, or cutting. There is.
[0009]
[Means for Solving the Problems]
The invention according to claim 1 is attached to the tip of the handlebar in a vehicle having a handlebar to support the brake lever or the clutch lever in a swingable manner, and according to the swinging operation of the brake lever or the clutch lever. In the lever holder assembly in which the master cylinder for containing the pressurized oil is formed, the part where the master cylinder is formed and the other part are separated, and the part where the master cylinder is formed is low-pressure cast Alternatively, it is formed by cutting, the other part is formed by high-pressure casting , and the part where the master cylinder is formed accommodates a cylinder part formed in a cylindrical shape to contain oil and the cylinder part. characterized in that it consists of a reservoir joint which connects the inside of the reservoir tank cylinder portion while
[0011]
According to a second aspect of the invention, the lever holder ASSY according to claim 1, wherein the cylinder portion, characterized in that it is cut into a substantially cylindrical shape in a lathe.
[0012]
According to a third aspect of the present invention, in the lever holder assembly according to the first or second aspect , the reservoir joint portion is a substantially rectangular member in which a fitting hole for fitting the cylinder portion is formed. It is characterized by comprising.
[0013]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, embodiments of the present invention will be specifically described with reference to the drawings.
As shown in FIGS. 1 to 3, the lever holder assembly according to the present embodiment is attached to the right end (position adjacent to the throttle grip G) of the handlebar H of the two-wheeled vehicle and supports the brake lever R in a swingable manner. Therefore, it is mainly composed of a part 1 where the master cylinder is formed and other parts. That is, the part 1 where the master cylinder is formed and the other parts are configured separately. In the figure, reference numeral 7 denotes a stop lamp switch for turning on the stop lamp of the vehicle in response to the swinging operation of the brake lever R.
[0014]
As shown in FIGS. 4 and 5, the part 1 where the master cylinder is formed includes two parts, a cylinder part 2 and a reservoir joint part 3. By assembling the cylinder part 2 to the reservoir joint part 3, It functions as a master cylinder.
[0015]
The cylinder part 2 is formed in a cylindrical shape so as to accommodate oil, and has openings 2a and 2b formed at one end and the other end, and is configured to fill the internal space with oil. Further, the piston 4 is inserted from the opening 2a of the cylinder part 2 via the return spring 8, and when the piston 4 moves to the inside of the cylinder part 2, the retained oil is pushed out from the opening 2b side. Yes. Further, a pair of grooves 2d are formed on the outer peripheral surface of the cylinder portion 2 at a predetermined distance, and an O-ring 2e that seals oil is fitted into these grooves 2d.
[0016]
Note that the opening 2b is fitted with the tip of a tube t1 (see FIG. 8) extending to the brake mechanism of the vehicle, so that the operation of the piston 4 can be transmitted to the brake mechanism via oil. Yes. Further, two large-diameter and small-diameter through-holes 2c that penetrate to the inside of the cylinder part 2 are formed from the side surface of the cylinder part 2, and when the cylinder part 2 is fitted into a reservoir joint part 3 described later, the through-hole 3b And the inside of the cylinder part 2 can be communicated with each other.
[0017]
The protruding end of the piston 4 forms a working end 5 that can come into contact with the protrusion R1 (see FIG. 1) of the brake lever R. As a result, when the brake lever R is swung, the protrusion R1 comes into contact with the working end 5 and the piston 4 is pushed into the cylinder part 2 to pressurize the oil inside the cylinder part 2. The brake mechanism acts by the pressurized oil, and the vehicle can be stopped or decelerated.
[0018]
The reservoir joint part 3 is for connecting the reservoir tank T (see FIG. 1) and the inside of the cylinder part 2 while accommodating the cylinder part 2, and as shown in FIG. 4, the cylinder part 2 is inserted into the inside. It consists of a substantially rectangular member in which a fitting hole 3a is formed. By inserting the cylinder portion 2 into the insertion hole 3a, a master cylinder in the lever holder assembly can be formed. Note that a communication hole 3b communicating with the insertion hole 3a is formed from the upper surface of the reservoir joint portion 3, and a tip ta of a tube t2 extending from the reservoir tank T is fitted into the opening. (See FIG. 8).
[0019]
On the other hand, as shown in FIG. 1, the other part of the lever holder assembly in the present embodiment is composed of a lever holder 6, and the lever holder 6 has a holding part 6 a for holding the handle bar H, The support portion 6b for swingably supporting the brake lever R and the fitting portion 6c for fitting the reservoir joint portion 3 of the master cylinder are mainly configured. The entire lever holder 6 including the sandwiching portion 6a, the support portion 6b, and the fitting portion 6c is integrally formed by casting.
[0020]
As shown in FIG. 2, the sandwiching portion 6 a includes a portion where an arc shape 6 aa that matches the outer peripheral surface of the handle bar H is formed, and an arc shape 6 ab that matches the outer peripheral surface of the handle bar H facing the portion. It is comprised from the formed separate member 6ac, and when these parts adjoin by the volt | bolt B, it is set as the structure which can clamp the handle bar H from both sides.
[0021]
The support portion 6b is composed of a pair of upper and lower plate-like portions 6ba and 6bb (see FIG. 3) protruding to the front side of the vehicle in a state where the lever holder assembly is fixed to the handlebar H, and the brake lever R is provided on these plate-like portions. It is comprised so that it can attach with the volt | bolt Ba, pinching | interposing the base end of. The bolt Ba serves as a swing shaft of the brake lever R, and the brake lever R can be swung.
[0022]
The fitting portion 6c is a portion that is cut out in substantially the same shape as the outer peripheral shape of the reservoir joint portion 3, and a through hole 6d that penetrates the lever holder 6 in the left-right direction is formed from the fitting portion 6c. The through hole 6d is a hole for fitting the cylinder part 2 and has an inner diameter slightly larger than the outer diameter of the cylinder part 2. The fitting portion 6c and the through hole 6d can be held by the lever holder 6 in a state where the cylinder portion 2 is assembled to the reservoir joint portion 3 (that is, a state forming a master cylinder).
[0023]
Thus, in the state which attached the master cylinder to the insertion part 6c and the through-hole 6d, it is comprised so that protrusion part R1 of the brake lever R can contact | abut to the action end 5 of piston 4. As shown in FIG. That is, when the brake lever R swings around the bolt Ba, the projection R1 formed on the base end side presses the working end 5 and the piston 4 can be pushed into the cylinder part 2. It is.
[0024]
The reservoir tank T is supported and attached by stays ST1 and ST2 extending from the reservoir joint portion 3 and the lever holder 6. More specifically, the stay ST1 has one end fixed to the front surface of the reservoir joint portion 3 in a state where the lever holder assembly is attached to the handle bar H, and the other end formed on the side surface of the reservoir tank T. On the other hand, the stay ST2 has one end fixed to the end surface of the lever holder 6 facing the protrusion R1 of the brake lever R and the other end fixed to a rib (not shown) protruding from the lower surface of the reservoir tank T. ing.
[0025]
As shown in FIG. 2, one end (side fixed to the lever holder 6) of the stay ST2 is fixed by a bolt Bb, and further extends a protrusion ST2a to be extended and press the end of the cylinder part 2. Have.
[0026]
Next, the manufacturing method of the lever holder assembly of the said structure is demonstrated.
In order to manufacture the lever holder assembly, the part 1 where the master cylinder is formed and the other parts are manufactured separately and assembled together. Of the portion 1 where the master cylinder is formed, the cylinder part 2 is obtained by cutting a cylindrical member made of a metal material into a cylindrical shape with a lathe. It is configured to be managed according to machining accuracy.
[0027]
Thereafter, an opening 2b, a through hole 2c, and a pair of grooves 2d are formed on the cylindrical member cut by a lathe to obtain a cylinder portion 2 having a desired size. Then, the O-ring 2e is fitted into each of the pair of grooves 2d formed on the side surface of the cylinder part 2, and the return spring 8 and the piston 4 are accommodated therein, whereby the manufacturing process of the cylinder part 2 is completed. .
[0028]
Thus, since the cylinder part 2 is mainly formed by a lathe process, a work man-hour is not increased so much and a dimensional accuracy can be improved. Moreover, since dimensional accuracy can be improved, the oil which should be filled inside can be kept liquid-tight. Further, in contrast to manufacturing by high pressure casting or the like, it is possible to obtain the cylinder part 2 that can withstand high pressure while improving the yield without generating nests.
[0029]
On the other hand, in the portion 1 where the master cylinder is formed, the reservoir joint portion 3 is formed by processing a rectangular metal member with a cutting machine so as to have a predetermined external dimension, and also with a receiving hole 3a and a through hole by a drill or the like. The hole 3b is formed. Accordingly, it is possible to improve the dimensional accuracy of the inner diameter of the accommodation hole 3a and to reduce the fitting error between the outer peripheral surface of the cylinder part 2 and the inner peripheral surface of the accommodation hole 3a as much as possible, compared with the case of molding by casting. Can do.
[0030]
By the way, the other site | part (in this embodiment the lever holder 6) which comprises a lever holder assembly is shape | molded by high pressure casting. In other words, a molten metal melt is poured into a mold or the like, and the cavity shape of the mold is cooled and solidified while being transferred, and the lever holder 6 having a complicated shape including the clamping part 6a, the support part 6b, and the fitting part 6c. To get. In this way, when other parts are molded by high pressure casting, shape formation is performed well, but as described above, nests are likely to occur, but such parts are the parts where the master cylinder is formed. On the other hand, since the oil is not kept liquid-tight, the dimensional accuracy is not necessarily strict, and there is very little problem because a high pressure is not applied during use.
[0031]
As described above, the part 1 in which the master cylinder is formed in the lever holder assembly is separated from the other part, the part 1 in which the master cylinder is formed is formed by cutting, and the other part is formed by high pressure casting. Therefore, the lever holder assembly can be formed taking advantage of the advantages of high-pressure casting and cutting, and the lead time in manufacturing the lever holder assembly can be reduced.
[0032]
The part 1 where the separately manufactured master cylinder is formed and the other part are assembled as follows. That is, as shown in FIG. 6, the reservoir joint portion 3 is fitted into the fitting portion 6c of the lever holder 6, and the accommodation hole 3a of the reservoir joint portion 3 and the through hole 6d of the lever holder are communicated. Then, as shown in FIG. 7, the cylinder part 2 including the return spring 8 and the piston 4 is inserted from one opening of the through hole 6d, and the cylinder part 2 is disposed across the through hole 6d and the accommodation hole 3a. Insert to do.
[0033]
After the assembly, as shown in FIG. 8, the ends of the stays ST1 and ST2 are each fixed with a bolt or the like, and the reservoir tank T is fixed to the other end to support the reservoir tank T and extend from the reservoir tank T. The tip ta of the provided tube t2 is inserted into the opening of the communication hole 3b and attached. Then, the handle bar H is clamped by the clamping unit 6a to fix the entire lever holder assembly to the handle bar H, while the tip of the tube t1 extended from the brake mechanism of the vehicle is connected to the opening 2b of the cylinder unit 2.
[0034]
Through the above steps, the lever holder assembly according to the present embodiment is attached to the handlebar of the two-wheeled vehicle, but the present invention is not limited to this, and the part 1 where the master cylinder is formed is integrated. It is good. For example, as shown in FIG. 9, an integral master cylinder portion 1 ′ is used as a portion where the master cylinder is formed, and a horizontal hole 1′a is formed in the master cylinder portion 1 ′. A hole 1'b communicating with 1'a is formed.
[0035]
And what inserted return spring 8 and piston 4 in hole 1'a is attached to the lever holder which should be fixed to handlebar H of a two-wheeled vehicle, and the tip of the tube extended from a reservoir tank is opened to hole 1'b. Install and configure. Like the reservoir joint portion 3 in the previous embodiment, the master cylinder portion 1 ′ is formed by processing a rectangular metal member with a cutting machine to have a predetermined external dimension, and by using a drill or the like, the hole 1′a And 1'b are formed.
[0036]
Therefore, compared with what is shape | molded by casting, an operation man-hour is not increased so much and a dimensional accuracy can be improved. Moreover, since dimensional accuracy can be improved, the oil which should be filled inside can be kept liquid-tight. Furthermore, it is possible to obtain a master cylinder portion 1 ′ that can withstand high pressure while improving yield without producing nests as compared with manufacturing by high pressure casting or the like.
[0037]
The lever holder to which the master cylinder portion 1 'is attached is formed by high-pressure casting as in the previous embodiment, and the lever holder assembly is formed by taking advantage of the advantages of high-pressure casting and cutting. The lead time in manufacturing the lever holder assembly can be reduced.
[0038]
In this embodiment, the part where the master cylinder is formed is obtained by cutting and the other part is obtained by high-pressure casting. The part where the master cylinder is formed is molded by low-pressure casting. Other parts may be formed by high pressure casting. In this case, after low-pressure casting, the part where the master cylinder is formed must be shaped by separate machining, but the work man-hours should be reduced compared to the conventional machining of complex shapes as a whole. And lead time as a whole is reduced. Therefore, the lead time can be reduced by forming by utilizing the advantages of high pressure casting and low pressure casting.
[0039]
In this embodiment, the reservoir tank is separated from the lever holder. However, the reservoir tank may be built when the lever holder is formed, and a lever holder assembly in which these are integrated. In this case, the reservoir tank is included in another part of the part where the master cylinder is formed, and is integrally formed by high pressure casting.
[0040]
The lever holder assembly according to the present embodiment is attached to the right end of the handlebar of the two-wheeled vehicle to support the brake lever, but is attached to the left end of the handlebar to support the clutch lever. It can also be applied to things. In this case, the formed master cylinder is filled with oil for operating the clutch mechanism of the vehicle in response to the swing operation of the clutch lever.
[0041]
Of course, the lever holder assembly according to the present invention is not limited to being applied to a two-wheeled vehicle, and can be applied to a lever holder assembly of another vehicle having a handlebar (such as a snow vehicle or ATV).
[0042]
【The invention's effect】
According to the first aspect of the present invention, the part where the master cylinder is formed and the other part are separated, the part where the master cylinder is formed is molded by low pressure casting or cutting, and the other part is high pressure. Since it was formed by casting, the lever holder assembly can be formed taking advantage of the advantages of high pressure casting and low pressure casting, and the lead time in manufacturing the lever holder assembly can be reduced.
[0043]
In addition, when the part where the master cylinder is formed is formed by low pressure casting, a separate cutting process is required to obtain a desired dimension after that, but compared to the conventional process of cutting the entire complex shape. The work man-hour can be reduced, and the lead time as a whole is reduced.
[0044]
Further , the portion where the master cylinder is formed is composed of a cylinder portion formed in a cylindrical shape for accommodating oil, and a reservoir joint portion for connecting the reservoir tank and the inside of the cylinder portion while accommodating the cylinder portion. Even when the design of the lever holder assembly is changed depending on the vehicle type, the cylinder portion can be used in common.
[0045]
According to the invention of claim 2 , since the cylinder part is cut into a substantially cylindrical shape by a lathe, the cylinder part can be formed with higher accuracy without taking much man-hours. it can. That is, according to the lathe process, it is possible to easily perform strict dimensioning, and it does not take much work time to cut into a substantially cylindrical shape.
[0046]
According to the invention of claim 3 , since the reservoir joint portion is formed of a substantially rectangular member having a fitting hole for fitting the cylinder portion therein, the overall shape becomes simple, and the reservoir joint portion Since the processing of the part can be facilitated, the lead time can be further reduced.
[Brief description of the drawings]
1 is a plan view showing a lever holder assembly according to an embodiment of the present invention. FIG. 2 is a right side view of the same. FIG. 3 is a sectional view taken along line III-III in FIG. FIG. 5 is a perspective view showing a cylinder portion and a reservoir joint portion in the lever holder assembly according to the embodiment of the present invention. FIG. 6 is a perspective view showing the cylinder portion and the reservoir joint portion in the lever holder assembly according to the embodiment of the present invention. FIG. 7 is a schematic diagram showing a state before the reservoir joint portion is fitted into the lever holder in order to show the manufacturing process. FIG. 7 shows the lever holder and the reservoir joint portion in order to show the manufacturing process of the lever holder assembly according to the embodiment of the present invention. FIG. 8 is a schematic diagram showing a state before the cylinder portion is fitted into the handlebar. FIG. 8 is a perspective view of attaching the lever holder assembly according to the embodiment of the present invention to the handlebar of the motorcycle. Perspective view of a portion of the master cylinder is formed in the lever holder ASSY according to another embodiment of the schematic diagram Fig. 9 present invention showing a state before EXPLANATION OF REFERENCE NUMERALS
1, 1 '... part where the master cylinder is formed 2 ... cylinder part (part where the master cylinder is formed)
3 ... Reservoir joint (the part where the master cylinder is formed)
4 ... piston 5 ... working end 6 ... lever holder 7 ... switch 8 ... return spring R ... brake lever H ... handle bar G ... throttle grip T ... reservoir tank

Claims (3)

It is attached to the tip of the handlebar in a vehicle having a handlebar and supports the brake lever or the clutch lever so as to be swingable, and contains oil that is pressurized according to the swinging operation of the brake lever or the clutch lever. In the lever holder assembly in which the master cylinder for
The part where the master cylinder is formed and another part are separated, the part where the master cylinder is formed is molded by low pressure casting or cutting, the other part is molded by high pressure casting , and
The part where the master cylinder is formed is
A cylinder part formed in a cylindrical shape to accommodate oil;
A reservoir joint part for connecting the reservoir tank and the inside of the cylinder part while accommodating the cylinder part;
Lever holder ASSY, characterized in that it consists of. The cylinder portion, the lever holder ASSY according to claim 1, characterized in that the cutting in a substantially cylindrical shape in a lathe. The reservoir joint, the lever holder ASSY according to claim 1 or claim 2, wherein in that it consists substantially rectangular member insertion hole is formed for fitting the cylinder portion therein.

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