ATV with ratcheting four wheel drive actuator

A system for and method of shifting a drive configuration of an all-terrain vehicle (ATV) is provided. The system includes a shifter assembly, a gear case, and a linkage assembly extending therebetween. The shifter assembly includes a trigger lever for receiving a mechanical user input, thereby moving the shifter assembly between a locked configuration and an unlocked configuration. The linkage assembly translates the user input to the gear case, thereby causing the gear case to shift between an engaged configuration and a disengaged configuration, respectively. A linkage biasing member provides mechanical flexibility between the shifter assembly and the gear case, facilitating shifting on the fly. The trigger lever is operated by toggling it from a rest position to a deployed position. Upon user release, the trigger lever is automatically returned to its rest position for future engagement by the user.

FIELD OF THE INVENTION

The present invention relates generally to motorized vehicles having variable drive configurations. More specifically, the present invention is concerned with an all-terrain vehicle (an “ATV”) having a ratcheting shifter assembly for mechanically shifting the ATV between a two-wheel drive configuration and a four-wheel drive configuration.

BACKGROUND

Existing ATVs having variable drive configurations utilize an electronic actuator to shift the ATV from a two-wheel drive configuration to a four-wheel drive configuration. The actuator is controlled by an electronic switch, thereby enabling a user to change the drive configuration of the ATV by operating the switch. Unfortunately, the necessary components for such electrical systems are expensive and sometimes inadequate and/or unreliable in some ATV operating conditions. Furthermore, existing configurations make it difficult for a user to shift the ATV while riding. Consequently, it would be beneficial for an ATV to have a shifting system, such as a mechanical shifting system, that is less expensive and easier to use than existing shifting systems. It would also be beneficial for the shifting system to be adequate and reliable in all ATV operating conditions.

SUMMARY

In some examples, an ATV comprises a shifter assembly in mechanical communication with a gear case, thereby facilitating mechanical shifting of the gear case between a first/disengaged configuration and a second/engaged configuration. By shifting the gear case between its disengaged and engaged configurations, the ATV is shifted between two or more drive configurations, such as a two-wheel drive configuration and a four-wheel drive configuration. In some embodiments, the shifter assembly includes one or more feature for indicating the drive configuration of the ATV.

The shifter assembly includes a mechanical user interface, such as a trigger lever, for receiving a mechanical input from a user of the ATV. A linkage assembly extends between the shifter assembly and the gear case for translating the user input to the gear case. In this way, the user is able to control the configuration of the gear case, thereby controlling the drive configuration of the ATV.

In some embodiments, the shifter assembly is secured to a handlebar of the ATV in close proximity to a handgrip of the ATV such that a user can quickly and easily operate the trigger lever with an index finger and/or a thumb. For instance, in some embodiments the trigger lever includes a click or toggle feature for allowing a user to quickly and easily move the trigger lever from a first/rest configuration to a second/deployed configuration. In some embodiments, the trigger lever is biased towards the rest configuration such that movement of the trigger lever from its deployed configuration back to its rest configuration is accomplished simply by releasing the lever. In this way, the trigger lever is automatically returned to its rest configuration for future engagement by the user.

In some embodiments, the shifter assembly includes a ratcheting assembly/mechanism for mechanically moving the shifter assembly between locked and unlocked configurations, thereby mechanically setting the ATV in one or more drive configurations. In some embodiments, movement of the trigger lever from its rest configuration to its deployed configuration causes the ratcheting assembly to move from its locked configuration to its unlocked configuration, or vice versa. In some embodiments, moving the trigger lever from its deployed position to its rest position has no effect on the configuration of the ratcheting assembly.

In some embodiments, the linkage assembly includes a linkage biasing member, such as a spring, so as to provide mechanical flexibility between the shifter assembly and the gear case. In this way, internal components of the gear case, such as splines on a shift collar, are provided time to align upon actuation.

In some embodiments, the gear case is biased towards its disengaged configuration such that moving the shifter assembly from its locked configuration to its unlocked configuration causes the gear case to move towards its disengaged configuration. In some embodiments, any biasing force associated with the linkage biasing member is overcome by an opposed biasing force associated with the gear case when the shifter assembly is in its unlocked configuration. Conversely, the biasing force associated with the linkage biasing member overcomes the biasing force associated with the gear case when the shifter assembly is in its locked configuration. In this way, the configuration of the shifter assembly controls the configuration of the gear case, thereby controlling the drive configuration of the ATV.

The foregoing and other objects are intended to be illustrative and are not meant in a limiting sense. Many possible embodiments may be made and will be readily evident upon a study of the following specification and accompanying drawings comprising a part thereof. Various features and subcombinations may be employed without reference to other features and subcombinations. Other objects and advantages will become apparent from the following description taken in connection with the accompanying drawings, wherein is set forth by way of illustration and example, one or more embodiments of the invention(s) and various features thereof.

DETAILED DESCRIPTION

One or more embodiments are disclosed herein; however, it is to be understood that the one or more embodiments are merely exemplary of the principles of the invention(s), which may be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the teachings herein in any appropriately detailed structure.

FIG. 1shows an embodiment of a four-wheel all-terrain vehicle (“ATV”)10having a shifter assembly100for shifting the ATV between a two-wheel drive configuration (a “first configuration”) and a four-wheel drive configuration (a “second configuration”). It will be appreciated that other embodiments include a different number of wheels or other drive mechanisms and/or different variable drive configurations. In each embodiment, the ATV is configured to shift between first and second drive configurations, wherein power is directed to a first number of wheels when the ATV is in the first drive configuration and a second number of wheels when the ATV is in the second drive configuration. In some embodiments, the second number of wheels is greater than the first number of wheels. In other embodiments, the first number of wheels is greater than the second number of wheels.

FIG. 2shows an embodiment of the shifter assembly100secured to a handlebar30of the ATV and a portion of a linkage assembly500extending from the shifter assembly100. The shifter assembly100includes a mechanical user interface, such as a trigger lever210, so as to provide a user of the ATV the ability to shift the ATV between first and second configurations. In some embodiments, the shifter assembly is positioned in close proximity to a handgrip32of the ATV (e.g., within 4 inches) so as to facilitate safe and easy operation of the trigger lever210by a user while the user is operating the ATV. In some embodiments, the trigger lever210is positioned relative to the handgrip32such that the user can operate the trigger lever210with an index finger of the hand while the hand is still gripping the handgrip, thereby allowing the user to maintain a constant grip on the handgrip while mechanically shifting drive configurations of the ATV.

In some embodiments, the shifter assembly100is configured to shift the ATV from a first drive configuration to a second drive configuration by moving the trigger lever210from a first position to a second position. In some embodiments, the shifter assembly100is similarly configured to shift the ATV from its second drive configuration to its first drive configuration by moving the trigger lever210from its first position to its second position. In some embodiments, the shifter assembly100includes a trigger biasing member250for biasing the trigger lever210towards its first position, thereby automatically reconfiguring the shifter assembly100for mechanically shifting the ATV from the second drive configuration to the first drive configuration following shifting the ATV from the first drive configuration to the second drive configuration, or vice versa. In some embodiments, the shifter assembly includes a position indicator330for indicating the configuration of the ATV. In some embodiments, the shifter assembly100further includes indicia corresponding with one or more position of the position indicator330, such indicia providing an indication of the configuration of the ATV based on the position of the position indicator330.

In some embodiments, the shifter assembly includes a housing110having a bottom portion112and a top portion114secured together to form an interior area115that is at least partially enclosed, thereby serving aesthetic, safety, protective, and/or functional purposes. In some embodiments, as shown inFIG. 2, the housing110defines an aperture116through which the position indicator330is visible. In some such embodiments, a lens cover118is positioned over at least part of the aperture116. It will be appreciated that other embodiments, not shown, the position indicator330extends from the housing110and/or is positioned outside of the housing110.

Still referring toFIG. 2, some embodiments further include a throttle lever22of a throttle assembly20positioned at or near the trigger lever210such that a user can operate the throttle lever22with the same hand used to operate the trigger lever210. In this way, the user can control the speed and the drive configuration of the ATV with a single hand. In some embodiments, the throttle lever is positioned relative to the handgrip32such that the user can operate the throttle lever22with a thumb of the hand gripping the handgrip, thereby allowing the user to maintain a constant grip on the handgrip while operating the throttle lever. It will be appreciated that in other embodiments the trigger lever will be positioned so as to accommodate operation by the user's thumb, by one or more of the user's fingers, and/or by a palm of the user. It will further be appreciated that in other embodiments the throttle lever will be positioned so as to accommodate operation by one or more of the user's fingers and/or by the palm of the user's hand.

Referring toFIG. 3, the shifter assembly100includes a trigger assembly200and a cam300. The trigger assembly200is moveable from a rest configuration towards an advanced configuration by moving the trigger lever210from a first position towards a second position. Similarly, the linkage assembly500is movable between a first configuration and a second configuration by moving the cam300between a first position and a second position, respectively. In some embodiments, the position indicator330extends from the cam300such that the position indicator330provides an indication of the position of the cam300and/or a position of the linkage assembly. In some embodiments, the trigger lever210and/or the cam300is configured to rotate about a primary axis of the shifter assembly100such that movement of the trigger lever210and/or cam300between respective first and second positions is accomplished by rotating about the primary axis. In some embodiments, the primary axis is defined by a primary pin102of the shifter assembly.

In some embodiments, at least part of the trigger assembly200and the cam300are positioned at least partially within an interior area115of a housing110of the shifter assembly100, with the trigger lever210extending from the housing for selective engagement by a user of the ATV. In some embodiments, a primary pin102extends into the interior area115of the housing110so as to provide support about which the trigger lever210and cam300are configured to rotate.

Still referring toFIG. 3, the shifter assembly100further includes a ratchet assembly400. The ratchet assembly400includes a ratchet gear410for selective engagement with the trigger assembly200and/or the cam300. In some embodiments, the ratchet gear410includes a first portion412for selective engagement with the trigger assembly200and a second portion414for selective engagement with the cam300. The ratchet assembly400is moveable between a locked configuration and an unlocked configuration. In some embodiments, moving the ratchet assembly400between locked and unlocked configurations causes the shifter assembly100to move between respective locked and unlocked configurations. In the unlocked configuration, the ratchet assembly400is configured to allow the cam300to move freely between its first and second positions. In the locked configuration, the ratchet assembly is configured to retain the cam300in its second position. In some embodiments, the ratchet gear410is configured to rotate about an auxiliary axis of the shifter assembly100such that rotation of the ratchet gear410causes the ratchet assembly400to move between its locked and unlocked configurations. In some embodiments, the auxiliary axis is parallel with the primary axis.

The trigger assembly200includes one or more features for selectively engaging with the cam300. In some embodiments, an engagement pin240extends from the trigger lever towards the cam. Referring toFIGS. 7A and 7B, some embodiments of the shifter assembly100are configured such that the engagement pin240of the trigger assembly200is positioned adjacent to an engagement lip310of the cam300when the cam300and the trigger lever210are in their respective first positions, thereby causing the trigger assembly200to be engaged with the cam300. It will be appreciated that in other embodiments, depending on the relative travel of the trigger lever210and the cam300, the engagement pin240is displaced from the engagement lip310when the cam300and the trigger lever210are in their respective first positions. In some such embodiments, the engagement pin240of the trigger assembly200is configured to engage with the engagement lip310of the cam300as the trigger lever is moved towards its second position. When engaged with the engagement lip310of the cam300, the engagement pin240of the trigger assembly200urges the cam300towards its second position as the trigger lever210moves towards its second position.

Some embodiments of the trigger assembly200include an advancement mechanism220for advancing the ratchet assembly400between locked and unlocked configurations. In some embodiments, the advancement mechanism220includes an advancement pawl222that is configured to urge the ratchet assembly400towards its locked configuration as the trigger lever210and the cam300move towards their respective second positions. In this way, the ratchet assembly400advances from its unlocked configuration to its locked configuration, thereby engaging with a locking lip320of the cam300so as to secure the cam300in its second position. In some embodiments, the advancement mechanism220is configured to urge the ratchet assembly400towards its unlocked configuration, thereby disengaging the ratchet assembly400from the locking lip320of the cam300so as to allow the cam300to move away from its second position.

In some embodiments, the advancement mechanism220includes an advancement pawl222for selective engagement with the ratchet gear410of the ratchet assembly400. As the trigger lever210moves towards its second position, the advancement pawl222causes the ratchet gear410to rotate in a first direction, thereby causing the ratchet assembly to advance from its unlocked configuration to its locked configuration and/or from its locked configuration to its unlocked configuration. In some embodiments, the advancement mechanism220includes an advancement biasing member224for biasing the advancement pawl222into engagement with one or more tooth of the ratchet gear410while the trigger lever210moves from its first position to its second position. In some embodiments, the advancement pawl222disengages from the ratchet gear410as the trigger lever210moves from its second position to its first position. In this way, the advancement mechanism is capable of rotating the ratchet gear410in the first direction but not a second direction.

In some embodiments, the ratchet assembly400further includes a stop mechanism420for preventing the ratchet gear410from rotating in the second direction. In some embodiments, the stop mechanism includes a stop pawl422that is configured to selectively engage with the ratchet gear410as the trigger lever210when the ratchet assembly400is in its locked or unlocked configuration. In this way, the stop mechanism420selectively restricts the ratchet assembly400from moving between its locked and unlocked configurations. In some embodiments, the stop mechanism420includes a stop biasing member424for biasing the stop pawl422into engagement with one or more tooth of the ratchet gear410when the ratchet assembly400is in its locked or unlocked configuration, thereby preventing the ratchet gear410from rotating in the second direction. In some embodiments, the stop pawl422disengages from the ratchet gear410as the ratchet gear410rotates in the first direction. In this way, the advancement mechanism is capable of preventing the ratchet gear410from rotating in the second direction without preventing rotation in the first direction.

Referring toFIGS. 4B and 5B, the cam300defines a receptacle350for receiving a first end512of an inner wire510of the linkage assembly500, thereby coupling the linkage assembly to the cam. In some embodiments, a first end522of an external sheath520of the linkage assembly500is secured relative to the shifter assembly100such that movement of the cam300between its first and second positions causes the inner wire510of the linkage assembly500to move relative to the external sheath520of the linkage assembly500, thereby moving the linkage assembly500between first and second configurations. In some embodiments, the cam300further defines a raceway352extending from the receptacle350such that as the cam300moves towards its second position, a portion of the inner wire510of the linkage assembly is received by the raceway352of the cam300, thereby controlling the amount of travel of the inner wire510relative to the external sheath520.

Referring toFIGS. 9 through 12, the linkage assembly500extends towards a gear case600of the ATV, such as a front gear case. In some embodiments, a linkage bracket550extends from the gear case600and/or is otherwise secured relative to the gear case. The linkage bracket550is configured to receive a second end524of the external sheath520of the linkage assembly500, thereby securing the second end524of the external sheath520relative to the gear case600. In this way, a constant distance is established between the gear case600and the second end524of the external sheath520such that a second end514of the inner wire510is caused to travel relative to the gear case600as the linkage assembly500is moved between its first and second configurations, thereby causing the gear case600to move between respective first/disengaged and second/engaged configurations. Each first and second configuration of the gear case600and the linkage assembly500is associated with a respective first or second drive configuration of the ATV.

In some embodiments, the gear case600is biased towards its disengaged configuration. In some such embodiments, such as the embodiment shown inFIGS. 11 and 12, the gear case600includes a disengagement biasing member602for biasing the gear case towards its disengagement configuration, thereby biasing the ATV towards its first drive configuration. In some embodiments, moving the linkage assembly500from its first configuration to its second configuration overcomes a biasing force associated with the disengagement biasing member, causing the gear case600to move towards its engaged configuration, thereby causing the ATV to move towards its second drive configuration.

In some embodiments, as shown inFIG. 10, the ATV includes a linkage biasing member560for biasing the gear case towards its engaged configuration, thereby biasing the ATV towards its second drive configuration. In some embodiments, moving the linkage assembly from its first configuration to its second configuration causes a biasing force associated with the linkage biasing member560to overcome the biasing force associated with the disengagement biasing member602, thereby causing the gear case to move towards its engaged configuration. Conversely, moving the linkage assembly from its second configuration to its first configuration allows the biasing force associated with the disengagement biasing member to overcome the biasing force associated with the linage biasing member, thereby allowing the gear case to move towards its disengaged configuration.

In some embodiments, the disengagement biasing member is an internal biasing member positioned at least partially within an interior area of the gear case. In some embodiments, the linkage biasing member is an external biasing member positioned at least partially outside of an interior area of the gear case.

In some embodiments, the linkage biasing member560extends between the gear case600and the second end514of the inner wire510of the linkage assembly500. In some embodiments, the biasing member is coupled, directly or indirectly, to a rod610or other feature of the gear case600such that the biasing force associated with the linkage biasing member excerpts a translational force on the rod610. In some embodiments, the rod610is coupled to a carriage assembly604or other feature of the gear case600, such feature being configured to selectively engage with a drive gear606or other feature of the ATV10. In some embodiments, the carriage assembly604includes a shift collar608that is configured to mesh with the drive gear606when the carriage assembly604is in an engaged configuration, thereby creating a mechanical link between a power source of the ATV and one or more wheel of the ATV, the creation of such mechanical link causing the ATV to move from its first drive configuration to its second drive configuration. In some embodiments, moving the carriage assembly604away from its engaged configuration towards a disengaged configuration breaks the mechanical link between the power source of the ATV and the one or more wheel of the ATV, thereby causing the ATV to move from its second drive configuration to its first drive configuration. In some embodiments, the disengagement biasing member602of the gear case600is configured to bias the carriage assembly604towards its disengaged configuration, thereby biasing the ATV towards its first drive configuration.

In some embodiments, a method of shifting an ATV10from a first drive configuration to a second drive configuration is carried out by moving a trigger lever210of a shifter assembly100from a first position to a second position. During at least part of such travel, the trigger lever210is engaged with a cam300of the shifter assembly100such that the cam300is similarly moved from a first position to a second position. A first end512of an inner wire510of a linkage assembly500is secured to the cam300such that movement of the cam300between its first and second positions causes the linkage assembly500to move between corresponding first and second configurations, thereby moving a second end of the linkage assembly500relative to a gear case600of the ATV so as to facilitate moving the gear case600between corresponding first and second configurations associated with corresponding first and second drive configurations of the ATV. In some embodiments, the method further includes moving the trigger lever210away from its second position while retaining the cam300in its second position, thereby disengaging the trigger lever210from the cam300while retaining the ATV10in its second drive configuration. In some embodiments, the method further includes engaging the cam300with a ratchet assembly400of the shifter assembly100so as to retain the cam300in its second position after the trigger lever210becomes disengaged from the cam300. In some embodiments, the method further includes disengaging the cam300from the ratchet assembly400and moving the cam300from its second position to its first position, thereby causing the ATV to move from its second drive configuration to its first drive configuration. In some embodiments, the method further includes moving the trigger lever210from its first position to its second position so as to cause the cam300to become disengaged from the ratchet assembly400.

In some embodiments, the shifter assembly100engages with one or more differential lock such that operation of the trigger lever210of the trigger assembly200of the shifter assembly100moves the differential lock between a locked and an unlocked configuration. In some embodiments, a first trigger lever of the shifter assembly100is configured to operate the differential lock and a second trigger lever is configured to change the ATV from a first drive configuration to a second drive configuration. In some embodiments, a first shifter assembly is configured to operate the differential lock and a second shifter assembly is configured to change the ATV from a first drive configuration to a second drive configuration.

Although the foregoing detailed description of the present invention has been described by reference to an exemplary embodiment, and the best mode contemplated for carrying out the present invention has been shown and described, it will be understood that certain changes, modification or variations may be made in embodying the above invention, and in the construction thereof, other than those specifically set forth herein, may be achieved by those skilled in the art without departing from the spirit and scope of the invention, and that such changes, modification or variations are to be considered as being within the overall scope of the present invention. Therefore, it is contemplated to cover the present invention and any and all changes, modifications, variations, or equivalents that fall within the true spirit and scope of the underlying principles disclosed and claimed herein. Consequently, the scope of the present invention is intended to be limited only by the attached claims, all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.

Having now described the features, discoveries and principles of the invention, the manner in which the invention is constructed and used, the characteristics of the construction, and advantageous, new and useful results obtained; the new and useful structures, devices, elements, arrangements, parts and combinations, are set forth in the appended claims.