INTERLOCKING BELLCRANK DEVICE AND ASSOCIATED SYSTEMS AND METHODS

An apparatus, system, and method according to which a bellcrank is used to transfer an output of a lever to a component requiring actuation. For example, a bellcrank that includes two interlocking portions transfers an output of a linear motion around a fixed axis via a rotational motion then to a transverse motion in order to pressurize brake fluid in a master cylinder of a vehicle.

FIELD OF THE INVENTION

The field of the invention is technologies associated with a bellcrank device, and in particular, an interlocking and interchangeable bellcrank device for transferring an output of a linear motion around a fixed axis via a rotational motion then to a transverse motion to pressurize brake fluid in a master cylinder.

BACKGROUND

The background description includes information that may be useful in understanding the present inventive subject matter. It is not an admission that any of the information provided herein is prior art or applicant admitted prior art, or relevant to the presently claimed inventive subject matter, or that any publication specifically or implicitly referenced is prior art or applicant admitted prior art.

A master cylinder is a component of a braking system of a vehicle that drives pressure generated by the brake pedal to the braking mechanism at the vehicle's wheels. In conventional systems, when a driver presses on the brake pedal a pushrod is pressed into a primary piston of the master cylinder, via a linear motion, in order to compress the brake fluid. As the primary piston is pushed, hydraulic pressure builds inside both the cylinder and the brake lines coupled to the cylinder. This pressure causes the secondary piston to compress the brake fluid, and consequentially, to engage the braking mechanism.

Because conventional master cylinders operate using only linear motion (i.e., driver pushes brake pedal and pushrod is inserted into a primary piston of the master cylinder), these conventional systems require a significant amount of space between the bulkhead and firewall of the vehicle to fit the master cylinder. In a non-cabover design, the master cylinder protrudes into the engine bay, which is in front of the firewall, so there is usually plenty of room to fit the master cylinders.

Low-speed vehicles (LSVs), which typically include four-wheel electric vehicles, have a top speed of about 25 to 35 miles per hour (about 40 to 56 kilometers per hour). These vehicles may be designed with a cabover design, which renders less space for components between the bulkhead and the firewall. Therefore, a conventional master cylinder is unable to be installed in a LSV in its traditional manner.

Therefore, there remains a need to develop a device to transform the motion transversely such that the master cylinder could be installed to fit in a vehicle with less space between the bulkhead and firewall and/or a vehicle with a cabover design such as an LSV. Additionally, there remains a need to develop a device that allows for various configurations depending on the required transverse motion.

SUMMARY

In one example embodiment, a bellcrank system is provided. The bellcrank system includes a bellcrank that include a first portion including a first top surface, a first bottom surface, and a first wing. The first top surface opposes the first bottom surface. The first wing is disposed between the first top surface and the first bottom surface. The first wing extends laterally past the first top surface and the first bottom surface. The bellcrank also includes a second portion that includes a second top surface, a second bottom surface, and a second wing. The second portion is disposed directly below the first portion such that the second top surface is configured to interlock with the first bottom surface. The second wing is disposed between the second top surface and the second bottom surface. The second wing extends laterally past the second top surface and the second bottom surface.

In another example embodiment, a method for actuation is provided. A first arm is moved along a first direction, and the first arm is coupled to a first portion of a bellcrank. A second arm is moved along a second direction. The second direction is perpendicular to the first direction. The second arm is coupled to a second portion of the bellcrank; and the second portion of the bellcrank is disposed directly below the first portion.

In one example embodiment, a vehicle is provided. The vehicle includes a brake pedal and a master cylinder. The master cylinder includes a bellcrank. The bellcrank includes: a first portion including a first top surface, a first bottom surface, and a first wing. The first top surface opposes the first bottom surface. The first wing is disposed between the first top surface and the first bottom surface. The first wing extends laterally past the first top surface and the first bottom surface. The bellcrank also include a second portion that includes a second top surface, a second bottom surface, and a second wing. The second portion is disposed directly below the first portion such that the second top surface is configured to interlock with the first bottom surface. The second wing is disposed between the second top surface and the second bottom surface. The second wing extends laterally past the second top surface and the second bottom surface. The master cylinder also includes a tank that includes a plunger and brake fluid. The plunger is coupled to a first side of an arm. A second side of the arm is coupled to the second wing. The vehicle also includes brake lines configured to carry brake fluid to a plurality of wheels.

DETAILED DESCRIPTION

The example embodiments described below recognize that it may be desirable to have an interlocking bellcrank device that has various configurations depending on the required transverse motion. Additionally, the example embodiments describe below recognize, an example use of the interlocking bellcrank device—use in a master cylinder of a vehicle. For example, the use of the interlocking bellcrank device is space efficient. This allows for the master cylinder to be installed at a ninety-degree angle to fit in a vehicle with less space between the bulkhead and firewall and/or a vehicle with a cabover design such as a low-speed vehicle (LSV).

Referring toFIG.1, in an embodiment, low-speed vehicle (LSV) is generally referred to by reference number100and includes one or more module configurations105permitting LSV100to change its target purpose. The LSV100also includes a battery pack110, bus/power115, and a controller120operationally coupled to the battery pack110. The LSV100includes axles125to which one or more controllable motors130, braking system135, and controllable wheels140are each operationally coupled to. The controllable wheels140are mechanically coupled with at least one controllable motor130, which in turn is electrically coupled with battery pack110. The LSV includes a set of sensors145, as represented by the small circles inFIG.1, which are operationally coupled to and/or in communication with the controller120.

In some embodiments, module configurations105may be considered to change the nature of LSV100, which in turn can change which operational profiles are of most relevance, possibly based on the attributes of LSV100. For example, in a flatbed configuration LSV100could be operating as a ground keeping vehicle. In which case, LSV100may be permitted to operate in natural terrains, lawns, fairways, forest, or other natural terrains for example. However, in a cargo configuration, LSV100could be operating in a delivery capacity. In which case, the corresponding operational profiles may permit LSV100to operate at higher speeds, but only on paved surfaces. Further, the various module configurations105, as well as any loading/unloading of the LSV100(e.g., loading/unloading groundskeeping equipment, boxes, packages, etc.), may also change the center of gravity of the LSV100, which in turn can change the operational profile.

In some embodiments, LSV100operates as a battery-powered electric vehicle. LSV100comprises at least one battery as represented by the battery pack110. Battery pack110may comprise one or more rechargeable batteries (e.g., Li-ion, Li-polymer, Li-S, etc.). Further, in some embodiments, battery pack110may comprise one or more swappable batteries to facilitate getting the LSV100back in operation after a battery has drained. In some embodiments, the battery pack110is located near the rear of the vehicle. In other embodiments, the battery pack is located at least in part between the axles125.

In some embodiments, the Bus/Power115interconnect the battery pack110, the controller120, the braking system135, the motors130, and/or the wheels140.

In some embodiments, the controller120may control the brake response for the electric motor-generator, for example while in the second mode of operation, to achieve between about 60-70% energy regeneration by the regenerative braking force. In some embodiments, the controller120is referred to as a vehicular controller.

In one or more embodiments, the axles125includes a front axle and a back axle.

In some embodiments, LSV100presents various configurations of the controllable motors130for discussion purposes. In some examples, the motors130themselves may comprise an electric motor-generator that provides a motive rotational force in a first mode of operation, and charges (e.g., supplying electric energy to) the battery pack110by regenerative braking in a second mode of operation. In one or more embodiments, each of the controllable wheels140could have a dedicated motor130(e.g., such as an electric hub motor disposed within the wheels140) in a manner that permits each wheel140to operate individually, but also collectively under instructions of the controller120. Still, in other embodiments, a single motor130could couple to more than one wheel140. For example, a single motor130could couple to the axle125of the LSV supporting two or more wheels where motor130causes wheels140to rotate via a drive train. In a further example, a single motor130could couple to two or more axles (such as axles125) of the LSV, each of the two or more axles supporting two or more wheels, and where the motor130causes the wheels140to rotate via a drive train. Thus, it should be appreciated that the controllable wheels140rotate in response to engagement of one or more of motors130.

In one or more embodiments, the braking system135may include a frictional, electromagnetic, and/or hydraulic braking system. In some embodiments, the braking system135includes one or more of a brake pedal, a master cylinder, brake fluid, brake lines, disc brakes, drum brakes, a brake light, a pressure switch, a pedal position sensor, and the like. In some embodiments, the braking system135may include a friction braking system such as an electrohydraulic or electromechanical braking system, an eddy current braking system, or other type of supplemental braking system that is coupled with the controller120and to one or more of the wheels140, and which may be used separately from or in conjunction with the regenerative braking of the electric motor-generator(s). LSV100further comprises one or more controllers120, which provide instructions to motors130or wheels140as well as governs other systems and/or operational parameters of LSV100.

In some embodiments, the set of sensors145are located in a different configuration on LSV100than Shown inFIG.1. In other embodiments, LSV100includes a different number of the set of sensors145from the set of sensors145shown inFIG.1. While the set of sensors145are illustrated disposed on or about LSV100, the inventive subject matter is not so restricted. Rather, the set of sensors145could be deployed remotely. Further sensor data could be obtained from any local or remote source (e.g., weather prediction, news events, etc.). The set of sensors145may include at least one location sensor; a GPS unit, for example. Still other types of location sensors could comprise image-based sensors, IMUs, wireless triangulation units, cellular network location units, or other types of location sensors. In other examples, the set of sensors145may include other sensors such as accelerometers, gyroscopes, piezoelectric sensors, cameras, LIDAR, radar, sound detectors, electromagnetic field sensors, wheel speed sensors, steering angle sensors, load sensors, displacement transducers, strain gauges (e.g., on the vehicle's suspension), or other types of sensors. In some embodiments, a set of sensors145are located on a portion of the braking system135. In some embodiments, the set of sensors145includes a pedal position sensor, a pedal position range sensor, a pressure switch, a pressure sensor, and the like.

Referring toFIG.2A, in an embodiment,FIG.2Aillustrates a front side of a braking system, the braking system is generally referred to by reference numeral200. The braking system200includes: a brake pedal205that is operationally coupled to a lever210, the lever210is operationally coupled to a first arm215and the first arm215is operationally coupled to an interlocking bellcrank220. The interlocking bellcrank220includes a first portion of the interlocking bellcrank225, and the first portion225includes a wing of the first portion230. In particular, the first arm215is coupled to the wing of the first portion230. The interlocking bellcrank220also includes a second portion of the interlocking bellcrank235, and the second portion235includes a wing of the second portion240. The wing of the second portion240is coupled to a second arm245. The second arm245may extend within at least a portion of a tank250.

Referring toFIG.2B, with continuing reference toFIG.2A, in an embodiment,FIG.2Billustrates a back side of the braking system200and includes several components of the braking system ofFIG.2A, which components are given the same reference numerals. The braking system200further includes a coupling device255that couples the lever210with the first arm215. The braking system200may also include a pressure switch260and a pedal position sensor265coupled to a housing270of the braking system200.

With continuing reference toFIGS.2A and2B, in some embodiments, the braking system200is the braking system135ofFIG.1. In some embodiments, the braking system200includes and/or is the master cylinder. In one or more embodiments, the braking system200is referred to as a bellcrank system. In some embodiments, a portion of the braking system200, described herein, may be installed at a ninety-degree angle to fit in a vehicle with less space between the bulkhead and firewall and/or a vehicle with a cabover design such as a low-speed vehicle (LSV). In other embodiments, the interlocking bellcrank220allows for the master cylinder and/or a portion of the braking system200to be installed any configuration from 0 to 360 degrees.

In some embodiments, the brake pedal205is directly coupled to the lever210.

In one or more embodiments, the lever210is coupled to the first arm215via the coupling device255. In some embodiments, the coupling device255provides an axis of rotation or fulcrum for the lever210. In some embodiments, the lever210includes a through hole and the first arm215is coupled via a bolt through the through hole. In some embodiments, the lever is coupled to the housing270via a bolt (representing the fulcrum of the lever210) to move the lever210about. In some embodiments, the coupling device255may include a first bolt that extends transversely through a width of the lever210, a second bolt that extends transversely through a width of the first arm215, and a joint that extends from the first bolt to the second bolt such that the lever210is coupled to the first arm215. In some embodiments, the coupling device255couples a first end portion of the lever210to a first end portion of the first arm215.

In some embodiments, the first end portion of the first arm215extends over the first end portion of the lever210and a second, opposing end portion of the first arm215extends toward the brake pedal205and is coupled to the wing portion of the first portion230. In some embodiments, the first arm215is composed of metal, plastic, or the like. In some embodiments, the second end portion of the first arm215is coupled to the wing portion of the first portion230via a bolt. In other embodiments, an alternative coupling device is used such as a clip, hook, or the like. In some embodiments, the first arm215is integrally formed and/or permanently coupled to the wing portion of the first portion230.

In one or more embodiments, the interlocking bellcrank220includes the first portion225disposed over the second portion235. In some embodiments, the interlocking bellcrank220includes a pin, rod, screw, or the like that extends down a central lumen or through-hole of the first portion225and the second portion235. In some embodiments, the interlocking bellcrank220also includes a nut, washer, or the like to couple the pin, rod, screw, or the like to the housing270. In some embodiments, the interlocking bellcrank220includes a pin, rod, screw, or the like that extends from a first side of the housing270through the first portion225and the second portion235to a second side of the housing270. In some embodiments, the rod, pin, or screw is fastened and/or coupled to the housing270. In some embodiments, the interlocking bellcrank220is sized to extend the entire height of the housing270. In other embodiments, the interlocking bellcrank220does not extend the full height of the housing270. In yet other embodiments, the first portion225and the second portion235do not extend the full height of the housing270; however, the rod, pin, screw, or the like inserted into the first portion225and the second portion235extends at least the full height of the housing270. In some embodiments, the interlocking bellcrank220includes a pin, rod, screw or the like and an axis of rotation about the pin, rod, screw, or the like.

In some embodiments, the first portion225is in direct contact with the second portion235. In some embodiments, the first portion225has a first set of cutouts, keyshafts, or indentations that form a keyway, and the second portion235has a second set of cutouts, keyshafts, or indentations that form another keyway. In some embodiments, the keyways are the keyways described herein. In some embodiments, the second portion235interlocks with the first portion225using these keyways. In some embodiments, the first portion225is the same size (height, weight, and/or width) as the size of the second portion235. In other embodiments, the first portion225differs in size from the size of the second portion235. In some embodiments, a top surface of the first portion225is in contact with the housing270. In one or more embodiments, a bottom surface of the first portion225is in contact with a top surface of the second portion235. In some embodiments, a bottom surface of the second portion235is in contact with the housing270. In one or more embodiments, the top surface of the first portion225opposes the bottom surface of the first portion225. In one or more embodiments, the top surface of the first portion225opposes the bottom surface of the second portion235. In some embodiments, the top surface of the second portion235opposes the bottom surface of the second portion235. In some embodiments, the first portion225and the second portion235both have a through-hole. In some embodiments, the through-hole of the first portion225is aligned with the through-hole of the second portion235.

In some embodiments, the wing of the first portion230is integrally formed into the first portion225. In other embodiments, the wing of the first portion230is a separate component from the first portion225. In some embodiments, the wing of the first portion230has a first edge. In some embodiments, the first edge is rounded. In some embodiments, the wing of the first portion230includes a through-hole near the first edge. In some embodiments, the first arm215is coupled to wing of the first portion230by a bolt, screw, or the like extending from the first arm215through the through-hole and secured via a nut. In other embodiments, other coupling means, such as a hook extending from the arm through the through-hole, are used to couple the first arm215to the wing of the first portion230.

In some embodiments, the wing of the second portion235is integrally formed into the first portion225. In other embodiments, the wing of the second portion235is a separate component from the first portion225. In some embodiments, the wing of the second portion235has a first edge. In some embodiments, the first edge is rounded. In some embodiments, the wing of the second portion235includes a through-hole near the first edge. In some embodiments, the second arm245is coupled to wing of the second portion235by a bolt, screw, or the like extending from the second arm245through the through-hole and secured via a nut. In other embodiments, other coupling means, such as a hook extending from the arm through the through-hole, are used to couple the second arm245to the wing of the second portion235. In other embodiments, the second arm245is permanently coupled to and/or integrally formed with the wing of the second portion235.

In one or more embodiments, the second arm245is operationally coupled to the wing of the second portion235and a plunger (not shown) in the tank250. The second arm245, in some embodiments, is directly coupled to the plunger in the tank250. The second arm245may be made of plastic, metal, or a similar material.

In some embodiments, the tank250is in communication with the second arm245. The tank250contains brake fluid. In some embodiments, the tank250may include a sensor such as sensor145that indicates when there is a shortage of brake fluid. The tank250, in some embodiments, may be a cylindrical tank as shown, but it also may be another shape. The tank250includes a plunger. The plunger may be a horizontally moving plunger to which the second arm245is coupled. In other embodiments, a vertically moving plunger is used. The tank250may be in communication with brake lines to distribute the brake fluid.

In one or more embodiments, the pressure switch260is used to sense when the brake pedal205is depressed, in order to turn on the brake lights (not shown). The pressure switch260is mounted to, or near, the braking system200. In some embodiments, the pressure switch260may be located near the lever210or the first arm215. The pressure switch260may be coupled to the bellcrank220. In other embodiments, the pressure switch260is coupled to the brake pedal205. In yet other embodiments, the pressure switch260is mounted to the housing270. In some embodiments, the pressure switch260is a strain gauge.

In one or more embodiments, the pedal position sensor265is used to measure a threshold or range. The pedal position sensor265may help to optimize regenerative braking for a vehicle such as LSV100. For example, the pedal position sensor265may provide data to an inverter such as the range of the brake pedal stroke. The pedal position sensor265may be located on the housing270. The pedal position sensor265may be located near the end of the lever210that is opposite the brake pedal205.

In one or more embodiments, the housing270encases the interlocking bellcrank220and at least a portion of first arm215and second arm245. In some embodiments, the housing270encases four sides (a top, bottom, left, and right), such as shown inFIGS.2A and2B. In other embodiments, the housing270encases all sides. In yet another embodiment, the housing270encases all sides except the back side to leave room for movement of the first arm215and/or the lever210. In some embodiments, the second arm245may stop when it hits a first side of the housing270, and/or may extend past an opposing second side of the housing270. In one or more embodiments, the housing270includes one or more stoppers to stop movement of the first arm215and/or the second arm245. The stoppers may include a bolt or nail extending within a housing. The housing270may include a plurality of bolts to hold the housing270together. In some embodiments, the housing270may be a rectangular shape. The housing270may extend, in one or more embodiments, to include a housing of the tank250. The housing270, in some embodiments, may include a portion that couples to the tank250. In one or more embodiments, the housing270fully encases the second arm245

In operation, the brake pedal205is depressed by a foot of a driver of a vehicle (such as LSV100). By depressing the brake pedal (applying a force), the lever210attached to the brake pedal205moves about the fulcrum of the lever210becoming substantially perpendicular to the housing270. As the lever210moves backward toward a firewall (or front) of the vehicle, the first arm215which is coupled on a first side to the lever210moves forward (away from the firewall of the vehicle). The first arm215is coupled on a second side to a wing of the first portion230of the interlocking bellcrank220. Therefore, as the first side of the first arm215moves forward, the second side of the first arm215rotates the wing of the first portion230clockwise about an axis of rotation. The first portion225of the interlocking bellcrank220is in direct contact with the second portion235; therefore, as the first portion225is rotated about a fixed axis, the second portion235is also rotated. The second portion235includes a wing of the second portion240to which the second arm245is coupled. Therefore, as the wing of the second portion240rotates along the axis of rotation, the coupled second arm245moves transversely. The second arm245is operationally coupled to a horizontally moving plunger in the tank250which pressurized brake fluid in the tank250. Therefore, the braking system200transfers output of a linear motion around a fixed axis via a rotational motion then to a transverse motion in order to pressurize brake fluid.

In some embodiments, the second portion235is rotated clockwise. In other embodiments, the second portion235is rotated counterclockwise. In one or more embodiments, the wing of the first portion230rotates counter-clockwise about an axis of rotation and/or the wing of the second portion240rotates counter-clockwise about an axis of rotation. In some embodiments, a vertical axis is defined by a through-hole that extends down a center of the first portion225and a center of the second portion235. In some embodiments, the vertical axis is the axis of rotation. In other embodiments, the axis of rotation is along the longitudinal axis or lateral axis. In some embodiments, the second arm245moves transversely left to right. In other embodiments, the second arm245moves transversely right to left. In some embodiments, the second arm245moves in the same direction as wing of the second portion240. In some embodiments, the interlocking bellcrank220may apportion any transverse motion, such as 90 degrees to the right. In other embodiments, the interlocking bellcrank220may apportion any transverse motion such as 90 degrees to the left. In other embodiments, other angles (between 0 and 360 degrees) are used to change activation.

Referring toFIG.3, in an embodiment,FIG.3illustrates a front side of an interlocking bellcrank, the front side of the interlocking bellcrank is generally referred to by the reference numeral300and the interlocking bellcrank is generally referred to by reference numeral305. The interlocking bellcrank305includes a first portion310and a second portion315, disposed directly beneath the first portion310. The first portion310includes a first cut-out portion320, a first extended portion325, and a second extended portion330. The first portion310also includes a wing335defined between a first edge340and a second edge345. The second portion315includes a first cut-out portion350, a second cut-out portion355, and a first extended portion360.

Referring toFIG.4, in an embodiment,FIG.4illustrates a back view of the interlocking bellcrank305, generally referred to by the reference numeral400and includes several components ofFIG.3, which components are given the same reference numerals. The interlocking bellcrank305includes the first portion310and the second portion315, disposed directly beneath the first portion310. The first portion310includes a second cut-out portion405, the first extended portion325, and the second extended portion330. The first portion310also includes the wing335defined between the first edge340and the second edge345. The second portion315includes the first cut-out portion350, the second cut-out portion355, and a second extended portion410. The second portion315also includes a wing415defined between a first edge420and a second edge425.

Referring toFIG.5, in an embodiment,FIG.5illustrates a right view of the interlocking bellcrank305, generally referred to by the reference numeral500and includes several components ofFIGS.3and4, which components are given the same reference numerals. The interlocking bellcrank305includes the first portion310and the second portion315, disposed directly beneath the first portion310. The first portion310includes the first cut-out portion320, the second cut-out portion405, and the first extended portion325. The first portion310also includes the wing335defined between the first edge340and the second edge345. The second portion315includes the second cut-out portion355, the first extended portion360, and the second extended portion410. The second portion315also includes the wing415defined between the first edge420and the second edge425.

Referring toFIG.6, in an embodiment,FIG.6illustrates a left view of the interlocking bellcrank305, generally referred to by the reference numeral600and includes several components ofFIGS.3-5, which components are given the same reference numerals. The interlocking bellcrank305includes the first portion310and the second portion315, disposed directly beneath the first portion310. The first portion310includes the first cut-out portion320, the second cut-out portion405, and the second extended portion330. The second portion315includes the first cut-out portion350, the first extended portion360, and the second extended portion410. The second portion315also includes the wing415defined between the first edge420and the second edge425.

Referring toFIG.7, in an embodiment,FIG.7illustrates a top view of the interlocking bellcrank305, generally referred to by the reference numeral700and includes several components ofFIGS.3-6, which components are given the same reference numerals. The interlocking bellcrank305includes the first portion310and the second portion315, disposed directly beneath the first portion310. The first portion310includes the wing335. The wing335is defined in part by the first edge340. The second portion315includes the wing415defined in part by the first edge420. The first portion310includes a top surface705. The top surface705is a circular surface. The top surface705includes a through-hole710extending down the length of the first portion310. The wing335of the first portion310includes a through-hole715near the first edge340. The wing415of the second portion315includes a through-hole720near the first edge420.

Referring toFIG.8, in an embodiment,FIG.8illustrates a bottom view of the interlocking bellcrank305, generally referred to by the reference numeral800and includes several components ofFIGS.3-7, which components are given the same reference numerals. The interlocking bellcrank305includes the first portion310and the second portion315. The first portion310includes the wing335. The wing335is defined in part by the first edge340. The second portion315includes the wing415defined in part by the first edge420. The second portion315includes a bottom surface805. The bottom surface805is a circular surface. The bottom surface805includes a through-hole810extending down the length of the second portion315. The wing335of the first portion310includes a through-hole715near the first edge340. The wing415of the second portion315includes a through-hole720near the first edge420.

Referring toFIG.9, in an embodiment,FIG.9illustrates a top perspective view of the interlocking bellcrank305, generally referred to by the reference numeral900and includes several components ofFIGS.3-8, which components are given the same reference numerals. The interlocking bellcrank305includes the first portion310and the second portion315, disposed directly beneath the first portion310. The first portion310includes the wing335. The wing335is defined in part by the first edge340and the second edge345. The second portion315includes the wing415defined in part by the first edge420and the second edge425. The first portion310includes the top surface705. The top surface705includes the through-hole710extending down the length of the first portion310. The wing335of the first portion310includes the through-hole715near the first edge340. The wing415of the second portion315includes the through-hole720near the first edge420.

Referring toFIG.10, in an embodiment,FIG.10illustrates a bottom perspective view of the interlocking bellcrank305, generally referred to by the reference numeral1000and includes several components ofFIGS.3-9, which components are given the same reference numerals. The interlocking bellcrank305includes the first portion310and the second portion315. The first portion310includes the wing335. The wing335is defined in part by the first edge340. The second portion315includes the wing415defined in part by the first edge420. The second portion315includes the bottom surface805. The bottom surface805includes the through-hole810extending down the length of the second portion315through the length of the first portion310. The wing335of the first portion310includes the through-hole715near the first edge340. The wing415of the second portion315includes the through-hole720near the first edge420.

Referring toFIG.11, in an embodiment,FIG.11illustrates a top perspective, exploded view of the interlocking bellcrank305, generally referred to by the reference numeral1100and includes several components ofFIGS.3-10, which components are given the same reference numerals. The interlocking bellcrank305includes the first portion310and the second portion315, disposed directly beneath the first portion310. The first portion310includes the first extended portion325, the second cut-out portion405, and the second extended portion330. The first portion310includes the wing335. The wing335is defined in part by the first edge340and the second edge345. The second portion315includes the first cut-out portion350, the second cut-out portion355, the first extended portion360, and the second extended portion410. The second portion315includes the wing415defined in part by the first edge420and the second edge425. The first portion310includes the top surface705. The top surface705includes the through-hole710extending down the length of the first portion310. The second portion315includes the through-hole810extending down the length of the second portion315. The wing335of the first portion310includes the through-hole715near the first edge340. The wing415of the second portion315includes the through-hole720near the first edge420.

Referring toFIG.12, in an embodiment,FIG.12illustrates a bottom perspective, exploded view of the interlocking bellcrank305, generally referred to by the reference numeral1200and includes several components ofFIGS.3-11, which components are given the same reference numerals. The interlocking bellcrank305includes the first portion310and the second portion315. The first portion310includes the first extended portion325, the second extended portion330, the first cut-out portion320, and the second cut-out portion405. The first portion310includes the wing335. The wing335is defined in part by the first edge340. The second portion315includes the first cut-out portion350, the second cut-out portion355, and the second extended portion410. The second portion315includes the wing415defined in part by the first edge420. The second portion315includes the bottom surface805. The bottom surface805includes the through-hole810extending down the length of the second portion315through the length of the first portion310. The wing335of the first portion310includes the through-hole715near the first edge340. The wing415of the second portion315includes the through-hole720near the first edge420.

In some embodiments, the first portion310includes a plurality of extended portions. In some embodiments, the first portion310includes only one extended portion. In some embodiments, the first portion310includes greater than two extended portions. In some embodiments, the first portion310includes a plurality of cut-out portions. In some embodiments, the first portion310includes only one cut-out portion. In some embodiments, the first portion310has a number greater than 2 for number of cut-outs. In some embodiments, the size and shape of the plurality of cut-outs and/or the plurality of extended portions of the first portion310differs. In some embodiments, the plurality of cut-out portions are referred to as a plurality of indentations or keyseats. In some embodiments, the plurality of extended portions and the plurality of cut-outs are referred to as keyways. In some embodiments, a length of the plurality of extended portions extends past a length of the plurality of cut-outs.

In some embodiments, the second portion315includes a plurality of extended portions. In some embodiments, the second portion315includes only one extended portion. In some embodiments, the second portion315includes greater than two extended portions. In some embodiments, the second portion315includes a plurality of cut-out portions. In some embodiments, the second portion315includes only one cut-out portion. In some embodiments, the second portion315has a number greater than 2 for number of cut-outs. In some embodiments, the size and shape of the plurality of cut-outs and/or the plurality of extended portions of the second portion315. In some embodiments, the plurality of cut-outs are referred to as a plurality of indentations or keyseats. In some embodiments, the plurality of extended portions and the plurality of cut-outs are referred to as keyways. In some embodiments, a length of the plurality of extended portions extends past a length of the plurality of cut-outs. In some embodiments, the plurality of extended portions of the second portion315interlock with the cut-out portions of the first portion310, and the plurality of cut-out portions of the second portion315interlock with the extended portions of the first portion310.

In some embodiments, the first extended portion325is disposed within the second cut-out portion355. In other embodiments, the first extended portion325is disposed instead within the first cut-out portion350. In some embodiments, the second extended portion330is disposed within the first cut-out portion350. In other embodiments, the second extended portion330is disposed within the second cut-out portion355. In some embodiments, the first extended portion325is separated by 180 degrees from the second extended portion330. In one or more embodiments, the first extended portion325is the same size as the second extended portion330. In some embodiments, the first extended portion325is a different size as the second extended portion330. In one or more embodiments, the first extended portion325is directly across from the second extended portion330.

In some embodiments, the first cut-out portion320is separated by 180 degrees from the second cut-out portion405. In some embodiments, the first cut-out portion320is separated by less than 180 degrees from the second cut-out portion405. In one or more embodiments, the first cut-out portion320is the same size as the second cut-out portion405. In some embodiments, the first cut-out portion320is a different size than the size of the second cut-out portion405. In one or more embodiments, the first cut-out portion320is directly across from the second cut-out portion405.

In some embodiments, the first extended portion360is disposed within the first cut-out portion320. In other embodiments, the first extended portion360is disposed instead within the second cut-out portion405. In some embodiments, the second extended portion410is disposed within the first cut-out portion320. In other embodiments, the second extended portion410is disposed within the second cut-out portion405. In some embodiments, the first extended portion360is separated by 180 degrees from the second extended portion410. In one or more embodiments, the first extended portion360is the same size as the second extended portion410. In some embodiments, the first extended portion360is a different size as the second extended portion410. In one or more embodiments, the first extended portion360is directly across from the second extended portion410.

In some embodiments, the first cut-out portion350is separated by 180 degrees from the second cut-out portion355. In some embodiments, the first cut-out portion350is separated by less than 180 degrees from the second cut-out portion355. In one or more embodiments, the first cut-out portion350is the same size as the second cut-out portion355. In some embodiments, the first cut-out portion350is a different size than the size of the second cut-out portion355. In one or more embodiments, the first cut-out portion350is directly across from the second cut-out portion355.

The wing335, in one or more embodiments, has a sharp edge340. In some embodiments, the wing355is integrally formed with the first portion310. In other embodiments, the wing335is a separate component that is coupled to the first portion310.

The wing415, in one or more embodiments, has a sharp edge420. In some embodiments, the wing415is integrally formed with the second portion315. In other embodiments, the wing415is a separate component that is coupled to the second portion315.

In some embodiments, the top surface705mirrors the bottom surface805. In some embodiments, the top surface705differs in shape, smoothness, or size from the bottom surface805. In some embodiments, the top surface705and/or the bottom surface is rectangular.

In some embodiments, the through-hole710is aligned with the through-hole810such that a pin, screw, rod, or the like may pass through the entire length of the interlocking bellcrank305. In some embodiments, the through-hole710is the same as the through-hole810. In some embodiments, the through-hole710is the same size as the through-hole810. In some embodiments, the through-hole715is the same size as the through-hole720. In other embodiments, the through-hole715and/or the through-hole720is omitted. In some embodiments, a screw, pin, rod, or the like may be inserted into the through-hole715and/or720to couple the wing335and the wing415, respectively, to an arm, lever, or the like. In some embodiments, a clamp or other similar device is used to couple the wing335and/or the wing415to an arm, lever, or the like.

With reference toFIG.13, a method1300for changing the direction of actuation of a bellcrank system by transforming the bellcrank system from a first configuration to a second configuration, according to one or more embodiments. The method1300illustrates the advantages of the invention by providing various configurations depending on the required transverse motion. Method1300is illustrated as a set of operations or blocks1305through1325. Not all of the illustrated blocks1305through1325may be performed in all embodiments of method1300. One or more blocks that are not expressly illustrated inFIG.13may be included before, after, in between, or as part of the blocks1305through1325. In one or more embodiments, the blocks in method1300are performed for a vehicle such as vehicle100, or any of the other embodiments described herein.

The method1300includes: providing an interlocking bellcrank having a first configuration at a block1305; receiving a transverse motion requirement at a block1310; determining a second configuration of the bellcrank based on the transverse motion requirement at a block1315; configuring the bellcrank according to the second configuration at a block1320; and providing the bellcrank having the second configuration for achieving the transverse motion requirement at a block1325.

In some embodiments, at the block1305, the interlocking bellcrank has a first transverse motion requirement. In some embodiments, the interlocking bellcrank has a first angle of actuation or first direction of actuation (such as a right-hand push). In some embodiments, the interlocking bellcrank may be any bellcrank device described herein.

In some embodiments, at the block1310, a user determines that a different transverse motion is needed. In some embodiments, at the block1310, a transverse motion requirement of the first configuration is made and compared to the received transverse motion requirement. If different, then a second configuration of the bellcrank is needed. In one or more embodiments, receiving a transverse motion requirement is receiving a change in the angle of actuation and/or the direction of actuation.

In one or more embodiments, the block1320includes rotating a first portion of the bellcrank and inserting the rotated first portion into a second portion. In other embodiments, at the block1320, the second portion is rotated and inserted into the non-rotated first portion. In some embodiments, the block1320includes unfastening a first arm attached to a first wing of a first portion of an interlocking bellcrank device and a second arm attached to a first wing of a second portion of the interlocking bellcrank; removing a pin that extends between the first portion and the second portion of the interlocking bellcrank; separating the first portion from the second portion; rotating the first portion 180 degrees so that a keyway of the first portion is over a different portion of a keyway of the second portion; sliding the rotated keyway of the first portion into the keyway of the second portion to interlock the bellcrank; and/or inserting a pin and refastening the first and second arms to the first wing of the first portion and the first wing of the second portion, respectively. In some embodiments, the block1320includes unfastening the first arm and unfastening the second arm. In some embodiments, the second arm is unfastened prior to unfastening the first arm. In some embodiments, the first arm and/or the second arm is unfastened by removing a nut, washer, a hook, and/or bolt that extends from the first arm and/or the second arm through a through-hole of the first wing of the first portion and the first wing of the second portion, respectively. In other embodiments, the first arm and/or second arm is clamped on to the first wing of the first portion and/or the first wing of the second portion, respectively. In some embodiments, the pin is instead a rod, nail, or screw. In one or more embodiments, at the block1320, the second portion is separated from the first portion. In other embodiments, at the block1320, the first portion is pulled apart from the second portion. In some embodiments, at the block1320, the second portion is instead rotated 180 degrees to change the orientation. In some embodiments, the first portion is instead rotated less than 180 degrees such as 90 degrees.

In one or more embodiments, at the block1320or the block1325, the rotated keyway of the second portion is inserted into the keyway of the first portion. In some embodiments, the rotated keyway of the first portion is inserted into a rotated keyway of the second portion.

In some embodiments, at the block1325the bellcrank is interlocked and ready to perform actuation. In some embodiments, at the block1325, the interlocking bellcrank in the second configuration performs a right-hand push, whereas in the first configuration, the interlocking bellcrank performed a left-handed push. In other embodiments, at the block1325, the interlocking bellcrank in the second configuration performs a left-hand push, whereas in the first configuration, the interlocking bellcrank performed a right-handed push. In some embodiments, the angle of the push differs between the first configuration and the second configuration. In other embodiments, the direction of the push or actuation differs between the first configuration and the second configuration.

In some embodiments, at the block1325, the interlocking bellcrank may have a second transverse motion requirement, different from the first. In some embodiments, the transverse motion requirement is the transverse motion requirement of block1310. In some embodiments, the interlocking bellcrank has a second angle of actuation or second direction of actuation (such as a left-hand push) that is different from the first angle of actuation and/or second direction of actuation. In some embodiments, after block1325, the first and second arms are fastened prior to inserting the pin. In some embodiments, the second arm is fastened to the first wing of the second portion first. In other embodiments, the first arm is fastened to the first wing of the first portion first. In yet another embodiment, the pin is inserted through a through-hole of the first portion and a through-hole of the second portion. In some embodiments, the pin is additionally secured to a housing via a nut. In some embodiments, the first arm and/or the second arm is fastened to the first wing of the first portion and to the first wing of the second portion, respectively, using a bolt, screw, hook, clamp, nut, and the like.

In one or more embodiments, additional configurations are provided based on the received transverse motion requirement.

With reference toFIG.14, a method1400for activating brakes in a vehicle, according to one or more embodiments. Method1400is illustrated as a set of operations or blocks1405through1425. Not all of the illustrated blocks1405through1425may be performed in all embodiments of method1400. One or more blocks that are not expressly illustrated inFIG.14may be included before, after, in between, or as part of the blocks1400through1405. In some embodiments, one or more of the blocks1405through1425may be implemented, at least in part, by a controller (such as controller120) which may include a processor, such as processor, in the form of executable code stored on non-transitory, tangible, machine-readable media that when run by one or more processors may cause the one or more processors to perform one or more of the processes. In one or more embodiments, the blocks in method1400are performed within a vehicle, such as LSV100, or any of the other embodiments described herein.

The method1400includes: pressing a brake pedal at a block1405, moving a first arm, which is operationally coupled to the brake pedal and a first portion of an interlocking bellcrank, forward in response to the brake pedal being pressed at block1410; moving the second arm, which is operationally coupled to a second portion of the interlocking bellcrank and a plunger, transversely in response to the brake pedal being pressed at a block1415; applying a force on a horizontally-moving plunger to pressurize brake fluid due to the second arm moving transversely at a block1420; and activating the brakes at a block1425.

In some embodiments, the method1400provides for transferring an output of a linear motion around a fixed axis via a rotational motion then to a transverse motion to pressurize brake fluid in a master cylinder, which is beneficial in vehicles such as LSV100that has a cabover design and/or limited space between a bulkhead and a firewall.

In some embodiments, a driver of vehicle100presses the brake pedal with his/her foot at the block1405. In one or more embodiments, the brake pedal is pressed in a first direction.

In one or more embodiments, the block1410occurs simultaneously to the block1405. In one or more embodiments, the first arm moves in a second direction, opposing the first direction in response to the brake pedal being pressed at the block1410. In some embodiments, the first arm is coupled to a lever that is coupled to the brake pedal as described herein.

In some embodiments, an additional block is added after the block1410that rotates the first portion about a vertical axis of the interlocking bellcrank in response to the brake pedal being pressed. In some embodiments, an additional block is added that occurs simultaneously to the block1410that rotates the first portion of the interlocking bellcrank in response to the first arm moving forward. In some embodiments, only a partial rotation is completed.

In one or more embodiments, the second arm moves transversely right to left at the block1415. In other embodiments, the second arm moves left to right, transversely, at the block1415. In some embodiments, the block1415occurs simultaneously to the block1405and/or the block1410.

In some embodiments, the block1420occurs simultaneously to the block1405, block1410, and/or block1415. In some embodiments, the plunger moves along the same direction as the second arm at the block1420. In some embodiments, the plunger is located within a brake fluid tank as described herein. In some embodiments, another arm couples the plunger to the second arm and the plunger is instead a vertically moving plunger. The vertical extending plunger moves up to pressurize the fluid tank, in some embodiments.

In some embodiments, an additional block is added after the block1415or block1420that moves the second portion about a vertical axis of the interlocking bellcrank in response to the brake pedal being pressed. In some embodiments, an additional block is added that occurs prior to and/or simultaneously to the block1415that moves the second portion of the interlocking bellcrank which in response moves the second arm transversely.

In some embodiments, activating the brakes1425includes moving brake fluid through the brake lines. In other embodiments, the brakes are implemented to slow rotation of one or more wheels (such as wheels140).

In several example embodiments, the elements and teachings of the various illustrative example embodiments may be combined in whole or in part in some or all of the illustrative example embodiments. In addition, one or more of the elements and teachings of the various illustrative example embodiments may be omitted, at least in part, and/or combined, at least in part, with one or more of the other elements and teachings of the various illustrative embodiments.

In several example embodiments, while different blocks, processes, and procedures are described as appearing as distinct acts, one or more of the blocks, one or more of the processes, and/or one or more of the procedures may also be performed in different orders, simultaneously, and/or sequentially. In several example embodiments, the blocks, processes and/or procedures may be merged into one or more blocks, processes, and/or procedures.

The phrase “at least one of A and B” should be understood to mean “A; B; or both A and B.” The phrase “one or more of the following: A, B, and C” should be understood to mean “A; B; C; A and B; B and C; A and C; or all three of A, B, and C.” The phrase “one or more of A, B, and C” should be understood to mean “A; B; C; A and B; B and C; A and C; or all three of A, B, and C.”

Although several example embodiments have been described in detail above, the embodiments described are examples only and are not limiting, and those skilled in the art will readily appreciate that many other modifications, changes, and/or substitutions are possible in the example embodiments without materially departing from the novel teachings and advantages of the present disclosure. Accordingly, all such modifications, changes, and/or substitutions are intended to be included within the scope of this disclosure as defined in the following claims. In the claims, any means-plus-function clauses are intended to cover the structures described herein as performing the recited function and not only structural equivalents, but also equivalent structures. Moreover, it is the express intention of the applicant not to invoke 35 U.S.C. § 112(f) for any limitations of any of the claims herein, except for those in which the claim expressly uses the word “means” together with an associated function.