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The variable combined brake system (VCBS) is a mechanism for motorcycles to simultaneously activate the front and rear brake systems by using one brake lever or pedal. The purpose is to reduce the risk of rollover accidents due to misuse of the front brake when panic braking. Due to its ability in a wide variation range of braking force distribution (BFD) ratios between the front and rear wheels, the VCBS can simultaneously achieve high braking effort and driving comfort performances, provided that the BFD ratio is designed appropriately. This paper aimed to develop the design method for the VCBS. A mathematical model of the VCBS mechanism is derived, and a parameter matching design method that applies adaptive control theory is proposed. A prototype of VCBS is designed and built based on the proposed method. The straight-line braking test results show that the motorcycle equipped with the VCBS prototype effectively obtained a high braking performance in deceleration. The obtained maximum deceleration is an average of 6.37 m/s2 (0.65 g) under an average handbrake lever force of 154.29 N. For front brake failure, maximum deceleration is obtained at an average of 3.38 m/s2 (0.34 g), which is higher than the homologation requirement of 2.9 m/s2.

A Design Method for a Variable Combined Brake System for Motorcycles Applying the Adaptive Control Method