Patent Publication Number: US-2009229567-A1

Title: safety lockout device

Description:
BACKGROUND TO THE INVENTION 
     This invention relates to a safety lockout device for a lever throttle control of a motor vehicle. While the invention has particular application with four wheel all-terrain vehicles (“ATV”) it has application with other vehicles which have a lever operated throttle control adjacent a hand grip on the handle bar of the vehicle. An example of such other vehicle is the so-called “jet-ski”. 
     The ATV is a vehicle which is used in a wide range of applications though it is more commonly used in the farming industry because of its versatility. Unfortunately it is a vehicle which figures highly in statistics relating to injury or death though this is not necessarily a reflection of the vehicle being unsafe but rather the manner in which the vehicle is used by some operators. 
     The throttle control on an ATV is by way of a lever which is situated adjacent one of the hand grips on the handle bars of the ATV. Unfortunately, because of the positioning of the lever it can be accidentally operated by a rider of the ATV. For example, in the farming industry it is not uncommon for the ATV rider to lean forward (while standing on the ATV foot pegs/foot support surfaces) to, say, unlatch a gate or carry out some other farm related operation. In doing so it is possible for the upper leg or lower torso of the rider to push against the lever and hence move the lever forward. This can cause the ATV to move forward (or rearward if the ATV is in reverse gear) often at severe acceleration. This can directly lead to injury or, in extreme cases, death of the rider and/or a bystander. 
     There are other situations where accidental operation of the throttle lever can see the throttle lever move from its rest or idle position to a position where the ATV is caused to move often under severe acceleration. For example there are recorded instances of a young child sitting on the ATV (with engine going) playing with the controls and accidentally operating the throttle lever. Unfortunately in at least one instance this has resulted in death of the child. 
     Other vehicles with handle bars and a lever operated throttle have led to death or injury for similar reasons. One example is the so-called jet-ski where it is also too easy to knock or move the throttle lever such as to cause the machine to unexpectedly lurch forward/back and at somewhat high acceleration. 
     SUMMARY OF THE INVENTION 
     The object of the present invention is thus to provide a safety lockout device for the throttle control of a vehicle which has a lever type throttle control the device being operative to lock out use of the throttle when the throttle has been moved to an idle or rest position. 
     Broadly, in one aspect of the invention there is provided a safety lockout device for a lever throttle control of a vehicle, the device including a moveable stop adapted to fit within a housing of the lever operated throttle control, the stop having an engagement portion, a release coupled to the stop and accessible externally of the housing and biasing means to bias the stop into a lockout position whereby upon an arm of the throttle control, which is connected to the throttle lever, moving to an idle or rest position, the stop moves to a lockout position in which the engagement portion is engageable with the arm to restrict movement thereof until moved to a non-engageable position by the release. 
     In another aspect of the invention there is provided a lever operated throttle control device which includes a housing mountable on a handlebar of a vehicle, an externally accessible throttle lever, an internally mounted arm coupled to the throttle lever, a moveable stop within the housing the stop having an engagement portion engageable with the arm, an externally located release coupled to the stop and biasing means to bias the stop into engagement with the arm upon the arm moving to a rest or idle position but releasable from such engagement position by the operation of the release. 
     In the preferred form the moveable stop is a rocker or toggle with a pivot axle mountable with the housing. 
     A part of the stop distal from the axis of pivot forms the engagement portion. This distal part can be profiled to form a secure engagement with the arm. The profile can be a rebated part of the distal end so that surfaces of the rebated part engage with a face surface and edge of the arm. 
     The bias means can be a spring. In one preferred form the spring can be a coil spring engaged on the rocker/toggle axle with one leg coupled to the rocker/toggle and the second leg engaged with some fixed part of the housing. 
     The release can be a release pad, knob, button or the like coupled to or forming part of a pin, shaft or the like, which is slidingly engageable in a bore through a wall of the housing with an inner end thereof in contact with the rocker or toggle. 
     In one preferred form of the invention the moveable stop is coupled to a mounting element which is adapted for mounting between the housing and a housing cover. The mounting element can be of a form which substantially replicates a thick gasket fitted between the housing cover and the edge of the wall of the housing. 
     In one form a spring or resilient biasing element is carried by the housing cover and acts on the moveable stop. In another form a spring is carried by the mounting element and acts on the moveable stop. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       In the following more detailed description of the invention reference will be made to preferred embodiments of the lockout device incorporating the invention and reference will be made to the accompanying drawings in which:— 
         FIG. 1  is a perspective view of a lever throttle control, with top cover removed, showing the safety lockout device installed and in engagement in a lockout position with the throttle arm, 
         FIG. 2  is a further perspective view but looking from an opposite position to that of  FIG. 1 , 
         FIG. 3  is yet a further perspective view, 
         FIG. 4  is an elevation view, 
         FIG. 5  is the same view as  FIG. 1  but showing the throttle lever and arm moved to a full throttle position, 
         FIG. 6  is an illustration of the lever throttle control incorporating the invention when mounted on a handle bar of a vehicle, 
         FIG. 7  is a perspective view of a mounting element and moveable stop according to a second embodiment of the invention, 
         FIG. 8  is a plan view of the second embodiment, 
         FIG. 9  is an elevation view of the second embodiment, 
         FIG. 10  is a side elevation view of the second embodiment, and 
         FIG. 11  is an exploded view of the second embodiment. 
     
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS OF THE INVENTION 
     The drawings and following description are based on the device being used in a lever throttle control of an ATV more particularly a Honda® 4-wheel ATV. This is by way of example only. Other ATV, jet-ski type vehicles where a lever throttle control is mounted on a handlebar adjacent a hand grip also commonly use a housing to which the throttle lever is mounted and in which a safety lockout device of a type employing the present invention can be installed. 
     In the following it is assumed that the device will be retrofitted, however, it will be appreciated by those skilled in the art that the device can equally be fitted as original equipment in a throttle control. 
     Referring to  FIGS. 1 to 5  of the drawings there is shown a throttle control  10  in which the top cover  11   a  (see  FIG. 6 ) has been removed in order to show the internal part of the housing  11 . As is common with a throttle control  10  of this type the throttle control incorporates a housing  11  with a removable top cover. Projecting downwardly from the housing  11  is a spigot, turret or the like  12 . A circular cut-out portion  13  forms with a clamp member (not shown) the means of attachment of the housing  11  to the handlebar H of the vehicle. 
     Rotatably coupled via a shaft located in the spigot or turret  12  is the throttle lever  14 . The shaft is connected internally of the housing  11  with a throttle arm  15 . The distal end  17  of the arm  15  has a conventional coupling arrangement  17   a  whereby the end of a throttle cable can be engaged. The throttle cable enters into the housing  11  via an opening  18  in a wall of the housing  11 . 
     All of this is in accordance with known construction of lever operated throttle controls. 
     In accordance with the present invention a toggle or rocker  20  is coupled to or fixed to an axle  21 . According to the present embodiment of the invention, as shown, where the lockout device is intended for retro fitting, a hole is drilled (preferably using a jig suitable for the purpose) through the wall  19  of the housing  11 . The hole thus passes through an abutment  22  which forms a stop (limiting the position of the throttle arm  15  to full throttle) and through into a raised part  23  which forms part of the interior of the spigot  12 . The aligned openings in the stop  22  and raised portion  23  enable the axle  21  of the lockout device to be installed and rotatable. 
     In an alternative arrangement the shaft  21  is not rotatable but fits in an interference type fit in the aligned openings. In such an arrangement the rocker/toggle  20  rotates on the shaft  21 . It will be appreciated by those skilled in the art that the rocker/toggle  20  will be provided with suitable pivot journals which ensure free pivoting movement of the rocker/toggle  20  on the shaft  21 . 
     The rocker/toggle  20  has a first part  24  which projects from the axle  21  toward the throttle arm  15 . The distal end  25  of first part  24  is formed into a stop which is engageable with a part of the throttle arm  15 . 
     With the type of throttle control as shown in the drawings the arm  15  conveniently has a downwardly depending flange  26 . It is with this flange  26  that the distal end  25  of the rocker/toggle  20  engages. Therefore, as more clearly shown in  FIG. 3 , the end  25  can, in one form, be rebated such that a vertical surface thereof can engage with the flange  26  while a substantially horizontal surface thereof engages under the edge of the flange  26 . 
     This is one way of achieving a positive engagement between the rocker/toggle  20  and the arm  15 . It will be appreciated by those skilled in the art there will be other ways in which this positive engagement can be achieved. 
     It will also be appreciated that in  FIG. 3  the rebated end  25  is shown as being slightly away from its full contact with the flange  26 . This is to illustrate the rebated portion but, as is evident from  FIG. 1  the rebated portion fits against and under the flange  26 . 
     To the other side of the axle  21  the rocker/toggle  20  has a second part  27  which is coupled with, attached to or formed as part of a pin, shaft or the like  28 . This pin  28  is engaged in a bore (not shown) which is drilled through the wall of the housing  11 . 
     In the case of the throttle control as illustrated a spigot  29  is formed as part of the housing wall but, if this were not present, it is anticipated that such a spigot  29  would be provided as part of the lockout device. The spigot  29  would thus have a threaded portion engageable through the opening in the wall of the housing  11  into which would be engaged a locknut  30  positioned on the external side of the wall. In this way a significant length of bearing surface can be provided to ensure stable attachment of the shaft  28  so as to not only provide correct location of the shaft  28  but ensure smooth sliding movement thereof. 
     The exposed or distal end  31  of the pin  28  can be of a reduced diameter but, as shown, it projects beyond the nut  30  or if such a nut is not present, beyond the outer surface of the housing. To this distal end  31  can be attached a knob, button pressure pad  36  or the like (e.g. as shown in  FIG. 6 ). 
     As shown in  FIG. 3  (but omitted from the other Figures) there is a coil spring  32  engaged on the shaft  21 . One end  33  of the coil spring  32  engages with the rocker/toggle  20  while the other end  34  engages with a fixed part e.g. floor  35  of the housing  10 . The coil spring  32  thus applies a biasing effect which causes the distal end  25  of the rocker/toggle  20  to move into an engagement or stop position as will hereinafter become apparent. 
     With the lockout device in the position as shown in  FIGS. 1 ,  2  and  3  the distal end  25  of the rocker/toggle  20  engages with the flange  26 . This therefore prevents movement of the throttle arm  15  and hence the throttle lever  14 . The knob or pressure pad which is attached to the distal end  31  of the pin  28  is positioned so as to be immediately adjacent the hand grip G (see  FIG. 6 ) on the handle bar H of the vehicle. Thus when the vehicle operator wishes to operate the throttle lever  14  he/she simply applies a pressure to the knob, pad  36 , etc., or the like which causes the pin  28  to move inwardly thereby rotating the rocker/toggle  20  such that the profiled stop end  25  moves downwardly and clear of the flange  26 . 
     The throttle arm  15  is thus able to slide over the first part  24  of the rocker/toggle  20  so that the throttle lever  14  can be operated normally.  FIG. 5  shows, for example, the lever arm  15  moved to the full throttle position where the arm  15  is in contact with the stop  22 . However, upon the lever  14  being moved back to the idle or rest position the flange  26  clears the distal end  25  of the rocker/toggle  20  so that under the bias of the spring  32  the rocker/toggle  20  reverts to its normal position where the profiled distal end  25  engages with the flange  26  to thereby once again prevent the throttle lever  14  from being operated. 
     The lockout device therefore provides an automatic lockout of the throttle upon the throttle being moved to the idle/rest position. Consequently, if in use of the vehicle the operator moves the vehicle to a stop position and then stands up to, say, carry out an operation such as opening of a gate, any accidental contact with the throttle lever  14  will not cause the throttle lever  14  to move because of the lockout effect of the safety device. However, upon completing the operation and wishing to once again move the vehicle the operator simply applies pressure to the knob, pad or the like  36  and then operates the throttle lever  14  as normal. 
     The safety lockout device also means that if a young child is playing with the controls of the ATV (with the motor running) it is unlikely that that child would know how to operate the lockout device or to be able to operate the lockout device and simultaneously move the throttle lever  14 . As a consequence the safety device provides a means of preventing a young child from accidentally operating the throttle. 
     As illustrated and described herein the lockout device can be retro fitted. Equally it can be manufactured into a form which is part of the throttle control as manufactured. 
     As will be appreciate by those skilled in the art the invention is open to modification into forms in which the inventive concept can equally be incorporated. One such modification is to provide the lock out device in a form which is more easily retro fitted to a throttle control  10 . Such a modified form of the invention is shown according to a second embodiment in  FIGS. 7-11  of the accompanying drawings. This second embodiment is intended for retro fitting to the housing  11  of a throttle control  10  of the type shown in  FIGS. 1-6 . 
     According to this embodiment of the invention there is provided a mounting element  37  which, as is apparent from  FIGS. 7 and 8 , is shaped to substantially conform with the shape of the edge profile of the wall of throttle housing  11  onto which the housing cover  11   a  is fitted. The mounting element  37 , therefore, essentially takes on the form of a somewhat thick gasket which is mounted between the edge of the housing  11  and the housing cover  11   a . To this end, openings  38  are formed in the mounting element  37  for reception of the screws S which normally mount the cover  11   a  to the housing  11 . 
     In the preferred form of the invention the mounting element  37  is formed of a metal material though equally it could be moulded from a suitable plastic material. The thickness of the mounting element  37  is sufficient to provide a stable pivot mounting of the toggle or rocker  20 . 
     As is apparent from  FIGS. 7-11  the toggle or rocker  20  is substantially of the form shown in the first embodiment. It therefore has a shaped distal end  25  which is formed in such a manner as to be engageable with a part of the throttle arm  15 . The rocker/toggle  20  is also pivotally mounted by an axle  21  which in this form of the invention can be a cap screw  39  engaged through one part  40  of the mounting element  37  and threaded and locked into a second part  41  of the mounting element  37 . As shown in  FIG. 11  a sleeve  42  is preferably located in an opening  43  in the rocker/toggle  20  and the cap screw  39  engages therethrough. In this way a free movement of rocker/toggle  20  is achieved. 
     The rocker/toggle  20  also includes a knob, button or more particularly a pressure pad  36 . Thus when the mounting element  37  is sandwiched between the housing  11  and cover  11   a  the pressure pad  36  is located externally of the housing  11 . 
     A biasing means is incorporated, as with the first embodiment, so as to bias the rocker/toggle  20  into the position where it will engage with the throttle arm  15  so as to prevent the throttle lever  14  from moving away from substantially the idle position. Thus, as with the first embodiment, the user of the vehicle will apply a pressure to the pressure pad  36  so as to cause the rocker/toggle  20  to pivot upwardly (in the direction of arrow A of  FIG. 10 ) so that the distal end  25  clears away from the throttle arm  15  to thereby enable the throttle lever  14  to be moved. 
     As illustrated more clearly in  FIGS. 7 and 10  the pressure pad  36  is preferably profiled with an outwardly inclined lower portion  44  so as to provide a better contact area for a user to apply a pressure to the pressure pad  36  to cause the appropriate upward pivoting A movement of the rocker/toggle  20 . 
     In a retro fit situation the cover  11   a  of the throttle housing  11  would simply be removed by removing the three screws S (see  FIG. 6 ) whereupon the cover  11   a  can be taken off and the mounting element  37  placed in position on the edge of the wall of the housing  11 . The cover  11   a  can then be replaced and screwed back into position by screws S. 
     If desired gaskets or seals (not) shown can be included either side of the mounting element  37 , these will provide a seal between the mounting element  37  and the cover  11   a  and edge of the housing wall respectively. 
     When the biasing means is a spring it can be in the form of a coil spring which is engaged between some part of the mounting element  37  and rocker/toggle  20 . It is thus incorporated as part of the whole assembly thus, no further installation work needs to be carried out. It is simply a matter of putting the whole assembly in place and reinstalling the cover. Therefore, the operation is simple, straight forward and quick. 
     In an alternative arrangement, however, a spring biasing element could be applied to the inside surface of the cover  11   a  and come in contact with some part of the upper edge of the rocker/toggle  20  so as to apply a downward biasing effect. This biasing means could be in the form of say a resilient body of material adhered to the underside of the cover  11   a  or some form of leaf spring adhered or otherwise mounted to the underside of the cover  11   a . It will be apparent to those skilled in the art that as with the first embodiment different means of applying a biasing effect to the rocker/toggle  20  can be employed. 
     As shown in  FIG. 11  a compression spring  45  can at one end be engaged with the rocker/toggle  20  and the other end will contact the underside of the cover  11   a.    
     It will be appreciated by those skilled in the art that other modified forms of the lock out device incorporating the inventive concept can be employed. For example in an original equipment situation the cover  11   a  could be formed in such a manner as to provide a place for the pivot mounting of the rocker/toggle  20  so that it becomes an integrally mounted part of the cover  11   a . Thus in a manufacturing operation the lock out device would be incorporated with the cover  11   a  such that the cover  11   a  can simply be mounted onto the throttle housing  11  whereby the rocker/toggle  20  will automatically engage with the throttle arm  15  in the required manner. 
     The safety lockout device is open to yet further modifications as will be appreciated by those skilled in the art. For example the positioning of the rocker/toggle and its associated shaft as well as the means by which it engages with the throttle arm can be altered depending on the internal construction of the throttle control. Such modified forms of the lockout device according to the present invention fall within the scope of the invention. 
     Another modification can reside in the biasing means where it will be apparent to those skilled in the art that alternative means of biasing can be employed. For example, a spring element can be replaced by simply having the rocker  20  counterweighed. This can be achieved in one form of the invention by having the end of the rocker inboard of the pivot axis of shaft  21 /cap screw  39  sufficiently heavy or weighed such that it will always tend to drop down into the lockout position i.e. engage with the throttle arm  15 .