Abstract:
A heavy vehicle door or ramp is opened and closed using an intuitive control system. The door includes a latch assembly, a lock assembly, and a power unit to assist in opening and closing the door. The door includes an interior joy stick handle and an exterior lever handle. From outside the vehicle, the door is opened and closed by pivoting the lever handle downwardly and upwardly, respectively. From the interior of the vehicle, the joy stick handle is pulled inwardly to close the door and push outwardly to open the door. Pivoting the joystick handle forwardly engages the blast locks, while pivoting the joystick handle rearwardly unlatches the latch assembly and disengages the blast locks. The power assist unit is actuated by pivotal movement of the outside door handle and lateral pivotal movement of the interior joystick handle. Perimeter bump strips offer safety functions to prevent injuries when remote function is active.

Description:
BACKGROUND OF THE INVENTION 
     Heavy duty armored vehicles, used for example, by the military, must be built to withstand forces far greater than encountered by conventional consumer cars and industrial trucks. The utilization of increasingly powerful explosive devices such as IED&#39;s, RPG&#39;s, and EFP&#39;s by hostile insurgent forces has compelled the defense industry to respond by deploying heavier armor on their tactical armored vehicles. While necessary to protect military personnel, heavier armor creates unique problems. The weight of heavily armored vehicle doors and ramps often exceeds 200 lbs., and in some instances, may exceed 1,000 lbs. To open and close such doors or ramps requires assistance from electric, pneumatic, or hydraulic powered units. Such power assisted doors and ramps are known in the industry. Prior art powered doors require separate mechanical and electrical systems, with separate control handles and/or switches for the door and locks, which result in non-integrated and complicated door functions. These complications unnecessarily lead to increased difficulties and time in opening and closing the heavy doors of these armored vehicles, particularly in emergency situations. 
     Accordingly, a primary objective of the present invention is the provision of an improved intuitive motion control system for heavy, power assisted vehicle doors, ramps, and hatches. 
     Another objective of the present invention is the provision of a mechatronic assembly which simplifies a soldier&#39;s ingress and egress from heavily armored vehicles that require power assisted opening and closing of doors. 
     Another objective of the present invention is the provision of an armored vehicle door having an intuitive joystick control system for locking, unlocking, latching, unlatching, opening and closing the door, ramp or hatch. 
     A further objective of the present invention is the provision of an improved method of operating a heavy duty vehicle door, ramp or hatch. 
     Still another objective of the present invention is the provision of an improved power assisted door with a safe and durable handle assembly for opening and closing the door from both inside and outside the vehicle. 
     Another objective of the present invention is the provision of an improved control system for operating an armored vehicle door or ramp in a minimal amount of time. 
     These and other objectives will become apparent from the following description of the invention. 
     SUMMARY OF THE INVENTION 
     The intuitive motion control system for operating a heavy armored vehicle door or ramp includes a power assist module that can simply, safely and quickly open and close the door with intuitive motions. The system connects the operation of the main latch, the combat or blast locks, and the power assist open/close unit to a single control point on the inside door handle, to the outside door handle, and to an exterior emergency egress override system for first responders. The simple functionality of the intuitive system reduces complexity for the soldiers and promotes safety and reliability in the field. 
     The control system includes a door module containing the linear actuator, integrated motion control system, backup power source, control sensors/valves, safety strips, and the mechanical hardware required to articulate the door, ramp or hatch between open and closed positions, as well as actuating the blast locks and door latch. The door includes an exterior handle and an interior joystick. The joystick motion coincides with the desired direction of door travel so as to be intuitive for the soldier&#39;s ingress and egress from the heavily armored vehicle. The system is designed to withstand the rigors of battle and rugged off-road abuse for easy door operation by a 5 th  percentile female soldier or a 95 th  percentile male soldier. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1A  is a schematic view of a heavy door having the control system of the present invention. 
         FIG. 1B  is a schematic side view of the heavy door of  FIG. 1A . 
         FIG. 1  is a perspective view of the intuitive control system for a heavy, power assisted door, ramp or hatch according to the present invention. 
         FIG. 2  is an inside elevation view of the mechatronic system. 
         FIG. 3  is an end elevation view of the mechatronic system. 
         FIG. 4  is a top plan view of the mechatronic system. 
         FIG. 5  is an exploded view of the mechatronic system components. 
         FIG. 6  is a partially exploded view of the mechanical control system for use with an electronic actuator or other device with electric inputs. 
         FIG. 7  is a partially exploded view of the system for use with a pneumatic actuator or other device with valve type inputs. 
         FIG. 8  is a perspective view of the joystick module of the system. 
         FIG. 9  is an exploded view of the joystick module. 
         FIG. 10  is a further partially exploded view of the joystick module. 
         FIG. 11  is an end elevation view of a portion of the joystick module. 
         FIG. 12  is another exploded view of the joystick shown in  FIG. 11 . 
         FIG. 13  is a front elevation view of the blast lock module for use with an electronic door actuator or other device with electric inputs. 
         FIG. 14  is a partially exploded view of the blast lock module of the blast lock module shown in  FIG. 13 . 
         FIG. 15  is another exploded view of the blast lock module of the blast lock module shown in  FIG. 13 . 
         FIG. 16  is a front elevation view of a blast lock module for use with a pneumatic door actuator or other device with valve type inputs. 
         FIG. 17  is a partially exploded view of the blast lock module shown in  FIG. 16 . 
         FIG. 18  is another exploded view of the blast lock module shown in  FIG. 16 . 
         FIG. 19  is a top elevation view of the latch module for use with an electronic door actuator or other device with electronic inputs 
         FIG. 20  is an exploded view of the latch module shown in  FIG. 19 . 
         FIG. 21  is an elevation view of a latch module for use with a pneumatic door actuator or other device with valve type inputs. 
         FIG. 22  is a partially exploded view of the latch module shown in  FIG. 21 . 
         FIG. 23  is a partially exploded perspective view of the latch module. 
         FIG. 24  is an top elevation view of the latch module shown in  FIG. 23 . 
         FIG. 25  is a front elevation view of the latch module shown in  FIG. 23 . 
         FIG. 26  is a side plan view of the latch module shown in  FIG. 23 . 
         FIG. 27  is a perspective view of the striker position assembly. 
         FIG. 28  is a front elevation view of the striker position assembly. 
         FIG. 29  is a top elevation view of the striker position assembly. 
         FIG. 30  is a side plan view of the striker. 
         FIGS. 31-33  show the interior handle in the neutral, close and open positions, respectively. 
         FIGS. 34-36  show the exterior handle in the neutral, open and close positions, respectively. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     As shown in  FIG. 1A , the intuitive control system  10  of the present invention is intended for use on a heavy door, ramp or hatch  12  of a vehicle, such as an armored military vehicle. The terms door, ramp and hatch are used synonymously in this description. As shown in  FIG. 1B , the door  12  has an interior side  14  and an exterior side  16 . As shown in  FIGS. 1A and 1B , a power assist unit  18  is mounted within the door  12 . The power assist unit  18  has opposite ends connected to the door  12  and the door frame, and is extensible through electric, hydraulic, or pneumatic means so as to move the door  12  between open and closed positions. The door  12  may include a latch assembly  20  which is operable between a latched position to retain the door in a closed position and an unlatched position to allow the door to open. The door  12  also includes a blast or combat lock assembly  22  moveable between locked and unlocked positions for additional door security. 
     A control handle module  30  is provided on the door  12  and operably connected to the power assist unit  18 , the latch assembly  20 , and the blast lock assembly  22 . The handle module  30  includes an interior assembly  32  and an exterior lever handle  34 . A mounting plate  36  supports various linkage components within the door that tie together the joystick module  32 , the outside handle lever  34 , the power assist unit  18 , the latch assembly  20 , and the blast block assembly  22 , as described below. 
     The mounting plate  36  supports the latch assembly  20  with screws  38  and supports the joystick assembly  32  with screws  40 . A linkage assembly  42  is bolted to the mounting plate  36 , as seen in  FIGS. 6 and 7 . 
     The components of the joystick module  32  are shown in  FIGS. 8-12 . The joystick module includes a handle  44  with a grip  46 . The handle  44  is mounted in a tubular support  48  via a pin  50 . The inner end of the support  48  has a geometric opening  54  adapted to matingly receive an outer end of a link  56 , as seen in  FIG. 12 . A shaft  58  extends into the opposite end of the link  56  and is retained by a rivet  60 . A snap ring  62  is received in a groove  64  on the shaft  58 . The link  56  is substantially tubular, with flattened top and bottom surfaces to which a washer  66  and a bearing  68  are mounted with a bolt  70 . 
     As best seen in  FIG. 9 , the shaft  58  of the joystick assembly  32  extends through a series of components, including a washer  72 , a bracket  74 , a bushing  76 , a link  78 , a pair of washers  80 , and a link cam  82 . The shaft  58  is not fixed to the components  72 - 80 . The end of the shaft  58  has a square or other geometric shape so as to be matingly received within a complementary square or geometric opening  84  in the link cam  82  such that rotation of the shaft  58  about its longitudinal axis will impart rotation to the link cam  82 . The link cam  82  has an upper leg  86  to be connected to blast lock assembly  22  and to bias the cam  82  and also includes a lower finger or hook  88 . A positive mechanical spring loaded detent may be provided. 
     The bracket  74  is mounted to a larger mounting bracket  90  via screws  92 . The bracket  90  also supports a sensor/valve plate  94  via screws  96 . A pair of spring plungers  98  extends through the sensor/valve plate  94  and is retained by nuts  100 , as best seen in  FIG. 10 . An upper cam  102  and a lower cam  104  are pivotally mounted onto the mounting bracket  90  with a bolt  106  and lock nut  108 . A pair of spacers  110  space the upper and lower cams  102 ,  104  from the mounting bracket  90 , with the bolt  106  extending through the spacers  110 . Appropriate washers  112  may also be provided on the bolt  106 . The upper and lower cams  102 ,  104  are pivotal about the bolt  106 , The cams  102 ,  104  transfer motion of the joystick assembly  42  through the bearings  68  to the sensor/valve mounted to plate  94 . 
     The linkage assembly  42  is best shown in  FIGS. 13-18 , and varies slightly depending upon the type of power assist unit  18  being used in the door  12 . The linkage  42  for an electrical power assist unit  18  is shown in  FIGS. 13-15 , while the linkage  42  for a pneumatic power assist unit  18  is shown in  FIGS. 16-18 . Common components for the linkage assembly  42  will use the same reference numerals throughout  FIGS. 13-18 . 
     The linkage assembly  42  includes a pair of triangular link plates  114  each of which is pivotally mounted on the end of a sleeve  116  of the exterior handle lever  34  via bushings  118 . A rod  120  has a first end secured between the plates  114  by a bolt  122  and nut  124 . The opposite end of the rod  120  is connected to the joystick module cam arm  86  as shown in  FIG. 10 . 
     The blast lock assembly  22  includes upper and lower blast plates  126 ,  128 . The upper blast plate  126  is connected to a mounting block  130 , and the lower blast plate  128  is connected to a lower mounting block  132 . The blocks  130 ,  132  are fixed to the door so that the plates  126 ,  128  are pivotal between locked and unlocked positions relative to the door frame. Rotation of the blast plates  126 ,  128  is controlled by link arms. More particularly, the upper blast plate  126  has a leg connected to the upper end  136  of an upper link arm  138  via a bolt  140 . The lower end  142  of the upper link arm  138  is connected between the link plates  114  with a bolt  144  and nut  146 . Similarly, the lower blast plate  128  has a leg  148  connected to the lower end of a link arm  152  via a bolt  154 . The upper end  154  of the lower link arm  152  is connected to a plate  158  via a bolt  160  and nut  162 . An intermediate link arm has a lower end  166  connected to the plate  158  by a bolt  160  and nut  162 , with the upper end  168  of the middle link arm  164  being connected between the link plates  114  via a bolt  144  and nut  146 . Thus, the ends of the rod  120 , upper link arm  138  and middle link arm  164  are connected to respective apexes or corners of the triangular link plates  114 . 
     The lower plate  158  has an opening through which a bushing  170  and shaft  172  extends, with a spacer  174  mounted on the bushing  170 . A trip lever rod  176  has one end fixed to the plate  158  by a bolt  160  and nut  162 . The opposite end of the trip lever rod  176  is connected to a trip lever  218  ( FIG. 19 ). 
     The linkage assembly  42  also includes a rod  180  having a clevis end connected to a guide bracket  182 , and an opposite end connected to a trip lever  216  as shown in  FIG. 19 . As best seen in  FIG. 15 , a bearing mount arm  184  is secured to the guide bracket  182  by a bolt  186 , lock nut  188 , and appropriate washers  190 . The bearing  192  resides between the guide plate  182  and the arm  184 . A shoulder bolt  194  with a spacer  196  is also mounted on the arm  184 . 
     A first spring  198  has one end connected between the link plates  114  by a pin  200 , with a C-clip  202  on the pin  200  to preclude the pin from being withdrawn from the plates  114 . The opposite end of the spring  198  is connected to a shoulder bolt  500  shown on  FIG. 10 . A second spring  204  has a first end connected to the bearing arm  184 , and a second end connected to the support bracket  36  hole or opening  501 , as shown in  FIG. 2 . 
     In the link assembly  42  used for the pneumatic power assist unit  18 , shown in  FIGS. 16-18 , the configuration of the guide bracket  182  is modified, as is the rod  180 . Also, another link arm  206  is used for the pneumatic power assist unit  18 , with one end of the link arm  206  being connected to guide bracket  182 , and the other end being connected to a valve or input directly on the power unit. 
     The latch assembly  20  is virtually the same for both the electronic and pneumatic power assist unit  18 .  FIGS. 19 and 20  show the latch assembly  22  for the electric power assist unit, while  FIGS. 21 and 22  show the latch assembly for the pneumatic power assist unit. Like parts in  FIGS. 19-22  are designated by the same reference numerals. 
     The latch assembly  22  includes a latch housing  210  having a conventional rotor  212  and a catch  213 . The latch housing  210  is mounted on a bracket  214  with fasteners, such as screws or bolts  215 . The bracket  214 , in turn, is mounted to the door  12  for cooperation with a striker bolt (not shown) on the door frame. First and second latch trip levers  216 ,  218  are connected to the housing  210  by a pin or rivet  220  for pivotal movement about the axis of the pin or rivet  220 . The use of two trip levers allow the internal trip lever to trip the latch even if the outside handle is locked. A striker position assembly  230  is mounted to the latch brackets  214  by screws  232 . A trip lever sensor bracket  234  is also connected to the bracket  214  by another set of screws  232 . The sensor bracket  234  is only used with an electric power assist unit  18 , and not with a pneumatic power assist unit. 
     The striker position assembly  230  is further shown in  FIGS. 27-30 . This assembly  230  includes an L-shaped mounting bracket  236  having an upright leg  238  secured to the latch assembly bracket  214  by the screws  232 , and a substantially horizontal leg  240  to which a position lever  242  is pivotally mounted via a pin  244 . A spring  246  on the pin  244  biases the position lever  242  to a neutral position. The bracket  234  also includes a leg  248  with an opening  250  therein. This assembly  230  when used with a sensor or valve indicates if the stricker bolt (not shown) is in the latch, allowing some functions and limiting others. 
     The lower blast mounting block  132  includes an outwardly extending emergency accessed shaft  260  which extends through the door  12  such that the geometric end  262  of the shaft  260  resides outside the exterior skin of the door  12 . The end  262  of the emergency access shaft  260  is adapted to matingly receive the geometric end  54  of the support  48  of the joystick assembly  32  from a similarly equipped vehicle in an emergency situation so that the blast lock assemblies  22  can be unlocked from outside the vehicle. 
     Operation of the Intuitive Door Control System 
     Entering a vehicle with the door intuitive control system  10  is as simple as rotating the exterior door handle  34  down from its neutral position. This action unlatches the door  12  and initiates the power unit  18  to open the door  12 . The exterior handle  34  must be held in the down position to maintain door opening motion. As a safety feature, the operator can simply let go of the handle  34  at any time to immediately stop the door movement. 
     Once inside the vehicle, closing the door  12  takes very little effort—the occupant simply pulls inwardly on the inside handle  44  of the interior joystick assembly  32  until the door  12  is fully closed and latched. At any time, the operator can stop the closing motion of the door  12  by stopping the pull effort on the handle  44  or letting go of the handle  44  altogether. If the door  12  has not reached its fully closed position when the handle  44  is released, the handle  44  may be pulled inwardly once again to continue closing the door  12 . The closing motion can also be quickly reversed by pushing outwardly on the handle  44  to re-open the door  12  to any position. 
     As a safety feature during the power assisted closing operation, if a part of the operator&#39;s body or a foreign object obstructs the path of the closing door  12 , safety contact strips  264  arranged around the perimeter of the door  12  will be activated to immediately stop the door  12  from closing further and actually reverse the motion to take any pinch pressure off the contact point. Once the obstruction is removed, the door  12  can continue to be closed by pulling inwardly on the joystick handle  44 . 
     Once the door  12  reaches it fully closed and latched position, to engage the blast combat locks  22 , the operator simply moves the handle  44  forwardly toward the hinge. The operator may now let go of the handle and it will remain in the forward position and the combat latches  22  will remain engaged. With safety in mind, when the handle  44  is in the forward, locked position, the joystick assembly  32  design prevents the handle  44  from being unintentionally pushed out, thereby prohibiting accidental door opening. Openings in support bracket  36  prevent bearings  68  from transferring motion to sensors/valves if unintentially operated. 
     To open the door  12  and exit the vehicle, in one simple motion, the operator pulls the handle  44  rearwardly away from the hinge from its forward, locked position through its vertical neutral position to the end of its rearward travel. This one action disengages the combat locks  22 , unlatches the automotive door latch  20  and actuates the power assist unit  18  so as to start the door  12  opening movement. The door  12  opening continues with operator pushing the handle outward until the desired open position is reached. The power actuator  18  is triggered when the handle  44  is pulled back to simultaneously disengage the blast locks  22 . This initial trigger is enough to move the door open just beyond the latch point if the handle  44  is released immediately. The handle  44  then springs back to the vertical position where it can be moved in and out to control the door movement. The operator can also keep the handle  44  in the rearward position and the door actuator  18  will continue to open the door  12 . 
     The size and the position of the handle  44  have been designed such that an occupant may open or close the door  12  even with both hands on a weapon or gear. It&#39;s possible to activate the open or closing operation with a forearm, elbow or shoulder pressed against the handle  44 . 
     At any time, an operator inside the vehicle can instantly stop the power assisted opening or closing function by pressing an emergency stop button  266 . After emergency stop activation, the door  12  can be opened or closed manually. Powered assist operation will be restored only after the emergency button has been reset by pulling it back out to its normal position. 
     Once outside the vehicle, the door  12  is easily closed by moving the exterior handle  34  upwardly. The handle  34  must be held in the up position to maintain power assisted closing. When released, the three-position handle  34  will spring back to the horizontal neutral position—immediately stopping the power assisted closing at the present position. Once again, this is intended as a safety feature to stop assisted motion if the operator lets go of the handle  34 . To restart the power assisted closing, the operator simply continues pulling up on the handle  34  until the door is fully closed and latched. 
     When closed from outside the vehicle, door  12  may be fully secured with a padlock to provide additional security. 
     As a security feature, when the door  12  is closed from inside the vehicle, and the combat locks  22  are engaged, the exterior handle won&#39;t open the door  12 . 
     In an emergency, the interior handle  44  of the door  12  may be removed from another similarly equipped armored vehicle and used as an emergency latch release rescue wrench to allow authorized personnel to disengage the combat locks  22  from the outside and open the door  12  on a vehicle that is damaged or whose personnel have been disabled. The rescue joystick  32  is placed over the emergency exterior access shaft  260 , with the end  54  of the joystick  32  matingly engaging the end  262  of the shaft  26 , and rotated to mechanically disengage the combat latches  22  and open the door  12 . The power assist unit  18  is operative during emergency opening of the door  12  from outside the vehicle, if power is available. 
     For a door with electric inputs, the electronic door control system includes an intelligent control, a plurality of switch inputs operatively connected to the intelligent control, the plurality of switch inputs associated with state of a plurality of mechanical components of the power assisted door, and motor drive operatively connected to the intelligent control for providing opening and closing of the power assisted door. The intelligent control is configured to monitor status of the plurality of switch inputs and control the motor drive at least partially based on the status of the plurality of switch inputs. 
     In regards to either electronic or valve type inputs, several switches as shown in  FIGS. 1-5  or valves may be used to determine the position or intended operation of a power assist system. The switches/valves are typically spring loaded plunger style mechanisms that indicate or control an either normally open or normally closed current. The input devices may be adjustable or offer several separate inputs to control speed or other functions. The use of contact, contact-less, or wireless inputs may be used where required to give the intended signals to a control module or valve bank to form the logic of a typical door assist system. 
     Flexible features within the system  10  allow the opening and closing speeds to be varied to match the need of the vehicle or mission. The speed can be profiled to slowly start, speed up in the middle of travel and slow down at the end of travel as another way to insure safe operation. 
     The centerpiece of the door  12  functionality of the system  10  is the joystick assembly  32 . Because the motion of the interior handle  44  intuitively leads to the motion of the hardware it controls, the system  10  is an intuitive motion control for assisting the powered opening and closing of the heavily armored doors and ramps used on today&#39;s military vehicles. 
     A remote toggle switch or other input device may be mounted off the door in a convenient location for the driver of a vehicle. This toggle switch may actuate an assist mechanism or separate power motion device to unlock the blast locks and initiate the open function of the door. The toggle switch can be configured to be held to cause motion or programmed to allow automatic operation. When pressed to the close position a remote toggle switch will close the door and engage the blast locks allowing the doors to be fully secure. 
     The intuitive door control system of the present invention can be further enhanced with an electronic control system, as described in co-pending application Ser. No. 12/713,029, entitled CONTROL SYSTEM FOR POWER-ASSISTED DOOR, filed on Feb. 25, 2010, and incorporated herein by reference. 
     The invention has been shown and described above with the preferred embodiments, and it is understood that many modifications, substitutions, and additions may be made which are within the intended spirit and scope of the invention. From the foregoing, it can be seen that the present invention accomplishes at least all of its stated objectives.