Patent Publication Number: US-2006005660-A1

Title: Hand lever with integrated controller

Description:
FIELD OF THE INVENTION  
      Generally, the invention relates to hand levers such as those that might be used for control of marine vessels. More particularly, the invention relates to such hand levers where a controller is integrated into the hand lever.  
     BACKGROUND OF THE INVENTION  
      Marine vessels typically include one or more hand levers via which an operator of the vessel can control the vessel&#39;s engine/transmission pairs (i.e., power trains). It is common for a separate hand lever to be provided for each power train, though a single hand lever may control more than one power train and separate hand levers may be provided for each of shift control and throttle control.  
      A marine vessel may have any number of helms, or control stations, from which an operator may control the vessel. Each helm typically has a steering mechanism, such as a steering wheel, for controlling the direction in which the vessel moves, and a control unit for controlling shift position and/or throttle.  FIG. 1  depicts a typical prior art single top mount control unit  10  for controlling a marine vessel. The control unit  10  includes a housing  12  and a hand lever  20 . The hand lever  20  controls the throttle of an associated engine (not shown) and the shift position of an associated transmission (not shown). The hand lever  20  may be rotationally coupled to the housing  12  via a rotational coupling mechanism  26 , and may include a hand lever knob  22  and a handle  24 .  
      The hand lever  20  can be moved through an operational range from reverse wide open throttle to forward wide open throttle. By moving the hand lever  20  along its operational range, an operator can control the shift position of the associated transmission and the throttle of the associated engine. The control unit  10  may include a shift status indicator  14  that indicates the current shift and throttle position of the hand lever  20 .  
      Such vessels also typically include electrically controlled horns. For this purpose, a horn controller is provided to enable the operator to sound the horn. Typically, such a horn controller includes a button mounted on the housing of the control unit or elsewhere at the helm.  
      In known systems, the horn button is located away from the hand lever, which causes the operator of the vessel to have to remove his hand from either the hand lever or the steering wheel in order to sound the horn. This is undesirable because, in situations where the operator needs to sound the horn, the operator usually wants to be able to steer the vessel and control its shift and throttle. Also, the operator typically has to take his eye off the “road” in order to locate the horn button to sound the horn. The time it takes for the operator to locate to the horn button may be amplified on vessels having more than one control station because the horn buttons may be in different locations at different stations and the operator may not remember immediately where the horn button is located at the station from which he is currently operating the vessel. Again, in a situation in which the operator needs to sound the horn, he probably does not want to take his eye off the “road.” Thus, systems in which the horn controller is located away from the hand lever may be dangerous.  
      Therefore, it would be advantageous to operators of such vessels if the operator could control the vessel&#39;s horn without having to remove a hand from either the hand lever or steering wheel and without having to take his eyes off the “road.” 
     SUMMARY OF THE INVENTION  
      The invention provides hand levers having integrated controllers. A hand lever according to the invention may include a housing and a horn controller that is adapted to be electrically connected to a horn. The horn controller, which may include a horn button, is coupled to the housing and is accessible from the exterior of the housing. The hand lever is adapted to control at least one of transmission shift position and engine throttle.  
      The horn controller may include electrically conductive wiring that adapts the horn controller to be electrically connected to the horn. Such wiring may extend through the interior of the housing. For example, the wiring may extend through a wire tunnel in the interior of the housing. The hand lever may include a hub shaft for rotationally coupling the hand lever to a hand lever support. In such an embodiment, the wiring may be coiled around the hub shaft.  
      The housing may have a distal end having an overall shape that enables the distal end to be received in the palm of a human hand. The horn controller may be coupled to the housing such that the horn controller is within reach of the thumb of the human hand while the distal end of the housing is received in the palm. Thus, a user of the hand lever may operate the horn without having to remove his hand from the hand lever.  
      Alternatively or additionally, a speed controller may be integrated into the hand lever. Such a speed controller may be electrically coupled to an electronic engine, for example, and may be used to provide speed or cruise control by controlling engine speed.  
      A control assembly according to the invention includes such a hand lever rotationally coupled to a control head. The control assembly may be a top mount control assembly or a side mount control assembly. In either top or side mount configuration, the hand lever may be mounted on either the port or starboard side of the control assembly. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
      The invention is further described in the detailed description that follows, by reference to the noted drawings by way of non-limiting illustrative embodiments of the invention, in which like reference numerals represent similar parts throughout the drawings.  
       FIG. 1  depicts a typical prior art single top mount control unit for controlling a marine vessel.  
       FIGS. 2A-2C  are front, side, and rear views, respectively, of an embodiment of a top mount control unit according to the invention.  
       FIGS. 3A-3C  are front, side, and rear views, respectively, of an embodiment of a side mount control unit according to the invention.  
       FIG. 4  is a partial exploded view of an embodiment of a hand lever according to the invention.  
       FIG. 5  is an exploded view of an embodiment of a hand lever according to the invention.  
       FIG. 6  depicts a wire tunnel within a handle hub as shown in  FIG. 6 .  
       FIG. 7  depicts an example wiring scheme for a hand lever according to the invention.  
       FIG. 8  depicts an example wiring scheme for an embodiment of a top mount control assembly according to the invention.  
       FIG. 9  depicts an example wiring scheme for an embodiment of a side mount control assembly according to the invention. 
    
    
     DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS  
       FIGS. 2A-2C  are front, side, and rear views, respectively, of an embodiment of a top mount control unit  200  according to the invention. As shown, the control unit  200  includes a control head  202 , and a hand lever  210  that is rotationally coupled to the control head  202 . The control head  202  may include a cover  204 . The cover  204  may include a cover insert  206 , which may be secured to the cover via one or more screws  208 . A tilt switch  209  is attached to cover  204 , and extends through an opening in the cover insert  206 .  
      The hand lever  210  may be used to control transmission shift position and engine throttle. According to the invention, the hand lever  210  includes a housing  212 , and an integrated horn controller  213  that is adapted to be electrically connected to a horn (not shown). The horn controller  213  is coupled to the housing  212  and is accessible from the exterior of the housing  212 . The hand lever  210  may include a handle portion  216  and a hub assembly  218 . The hub assembly  218 , and, thus, the hand lever  210 , is rotationally coupled to the control head  202 . For example, the hub assembly  218  may be coupled to a rotational mechanism (not shown) within the control head  202 .  
      In an example embodiment, the horn controller  213  includes a button  214  that the operator can push to sound the horn. The horn controller  213  is attached to the housing  212  of the handle portion  216  of the hand lever  210 . The hand lever  210  may also include an integrated trim switch  222 , and a handle cover  230 , which may be screwed into the handle portion  212  via one or more screws  232 . The handle cover  230  includes openings through which the trim switch  222  and horn controller  213  extend.  
      An interlock release plunger  224  may be provided to enable the operator to release the hand lever  210  from a locked position to enable rotational movement of the hand lever  210  relative to the control head  202 . The release plunger  224  may be coupled, via a cable and pawl system, for example, (not shown) to the rotational mechanism in the control head  202  such that, when the plunger  224  is pushed, the hand lever  210  is unlocked and rotational movement of the hand lever  210  is enabled. A detailed description of an example embodiment of such a cable and pawl system is provided in copending U.S. patent application Ser. No. ______ (Atty. Docket TELE-0030), filed on even date herewith, and entitled “System for controlling rotational movement of a hand lever.” The disclosure of U.S. patent application Ser. No. ______ (Atty. Docket TELE-0030) is incorporated herein by reference in its entirety.  
      In an example embodiment as shown, the distal end E of the housing  212  has an overall shape that enables the distal end E to be received in the palm of a human hand. The horn controller  213  is coupled to the housing  212  such that the horn controller  213  is within reach of the thumb while the distal end E is received in the palm. Though it should be understood that the horn controller  213  may be located anywhere on the hand lever  210  without departing from the scope of the invention, it should also be understood that it may be desirable to locate the horn controller  213  so as to enable an operator to push the horn button  214  with his thumb without having to remove his hand from the hand lever  210 . Thus, an operator may control the horn, shift, and throttle with one hand.  
      Further, though the embodiment depicted throughout this specification is a right handed embodiment (i.e., designed to be controlled using the right hand), it should be understood that a left handed embodiment may be provided. Also, though the embodiment shown depicts the hand lever attached to the left side of the control head, it should be understood that the hand lever could be attached to the right side of the control head or through the middle portion of the control head. Further, it should be understood that the specific configuration of the hand lever depicted in the figures was chosen for ornamental purposes and that other configurations could be used in alternative embodiments.  
       FIGS. 3A-3C  are front, side, and rear views, respectively, of an embodiment of a side mount control unit  300  according to the invention. As shown, the control unit  300  includes a side mount control head  302 . A hand lever  210 , such as described above in connection with  FIGS. 2A-2E , may be rotationally coupled to the control head  302 .  
      The side mount control head  302  may include a side mount bezel  304 . A trim switch  306  and an interrupt switch  308  extend through respective openings in the side mount bezel  304 . A pair of inserts  307 ,  309  may be secured to the bezel  304  via screws  311 ,  313 , for example. Each insert  307 ,  309  includes a respective opening through which the tilt switch  306  or interrupt switch  308 , respectively, extends.  
       FIG. 4  is a partial exploded view of an embodiment of a hand lever  210  according to the invention. As shown, an example embodiment of a horn controller  213  may include a horn button  214  and electrically conductive wiring  228  that adapts the horn controller  213  to be electrically connected to the horn (not shown). The wiring  228  may be low voltage wiring, for example, though it should be understood that any desired wiring may be used.  
      The horn controller  213  extends through respective openings in the housing  212  and handle cover  230 . In an example embodiment, the horn button  214  has a threaded portion  215  that extends through the openings and into the interior defined by the housing  212 . A nut and washer combination (not shown) may be used to tighten the horn button  214  against the housing  212 . Thus, the horn controller  213  may be attached to the housing  212  such that the horn controller  213  is accessible from the exterior of the housing  212 .  
       FIG. 5  is an exploded view of an embodiment of a hand lever  210  according to the invention. As shown, the hand lever  210  may include a handle portion  216  and a hub assembly  218 . The handle portion  216  of the hand lever  210  includes a handle grip  234 , which may be made of a rubber material and overmolded onto the handle housing  212 , which may be made of a plastic material.  
      The horn button  214  may be secured to the handle housing  212  via a nut  234 . The horn button may be a momentary switch, for example, and the nut may be a switch nut. The interlock plunger  224  and a compression pawl spring  236  are provided for unlocking the hand lever  210  to enable rotational movement of the hand lever  210 . The cover  230  may be secured to the handle portion  216  via a screw  232 . The trim switch  222  and horn controller  213  extend through respective openings in the cover  230 .  
      The hub assembly  218  may include a hub portion  240  having a stem  242 . The handle portion  216  is affixed to the stem  242  (and, thus, to the hub assembly  218 ) via screws  244 , which may be screwed into receiving holes  246  in the stem  242 . The stem  242  also includes a groove or wire tunnel  262  extending along a length thereof. The wire tunnel  262  serves as a conduit for the wiring  228  that extends through the interior of the housing  212 . The hub assembly  218  may also include a wiring shield  250  that shields wiring  228  that extends within the interior of the hub assembly  218 . The hub portion  240 , including the stem  242 , and the wiring shield  250  may be made of a zinc alloy.  
      The hub assembly  218  may also include an interlock latch  252  and compression pawl spring  254  that form part of a cable and pawl system for unlocking the rotational movement of the hand lever  210 . An interlock cable (not shown) is attached to the interlock plunger  224 , extends through the interior of the housing  212 , and is attached to the latch  252  in a receiving bore  253 . A hub cover  256 , which may be made of a zinc alloy, is secured to the hub portion  240  via a pair of screws  258 . Thus, the hub assembly  218  may be held together. Thrust washers  260  may be provided between the wiring shield  250 , latch  252 , and hub cover  256 .  
       FIG. 6  depicts the wire tunnel  262  as it extends into the interior of the hub portion  240 . The wire tunnel  262  curves at least partially around the hub shaft  264 . Wiring  228  may extend from the horn button  214  through the interior of the handle portion  216  into the wire tunnel  262 . The wiring  228  may then coil at least partially around the hub shaft  264 . The hub shaft  264  is adapted to rotationally couple the hand lever  210  to a hand lever support (such as one of the control heads described above). Coiling the wiring  228  around the hub shaft  264  is desirable because it accommodates the rotational movement of the hand lever  210 .  
       FIG. 7  depicts an example wiring scheme for a hand lever  210  according to the invention. As shown, the wiring  228  is coiled around the hub shaft  264  approximately 2½ times. The wiring  228  may be affixed to the hub portion  240  of the housing  212  using a tape, for example, at a fixation point  266 . The wiring  228  extends from the horn button  214  through the interior of the housing  212  through the wire tunnel  262  and around the hub shaft  264 . Wiring for the trim switch  222  may also be provided along this path. The wiring  228  extends through respective slots in the wiring shield  250 , interlock latch  252 , and hub cover  256 .  
       FIGS. 8 and 9  depict example wiring schemes for embodiments of top and side mount control assemblies, respectively. As shown, the wiring  228  extends out of the hand lever  210  and through the control head  202 ,  302 . The wiring  228  extends out of the control head  202 ,  302  and along a mechanism assembly  400 . The wiring  228  may be secured to the mechanism assembly  400  at one or more locations via cable ties  402 , which may be Ty-wrap cable ties, for example.  
      The wiring  228  may terminate in any fashion that enables the wiring  228  to be electrically connected to the horn. For example, if the wiring from the horn terminates in a connector, the wiring from the horn controller may terminate in a complementary connector. Alternatively, the wiring from the horn controller could terminate at one or more eyelets. Alternatively, the horn controller could be wired to a microprocessor for electronic control of a horn or any other device that may be controlled electronically.  
      It is also contemplated that the controller  213  could be a speed controller that may be integrated into the hand lever using the principles of the invention described above. Such a speed controller may be electrically coupled to an electronic engine, for example, and may be used to provide speed or cruise control by controlling engine speed. Pushing the button  214  as described above could thus enable or disable cruise control. For example, if the button is pushed a first time, cruise control could be enabled. If the button is pushed a second time, then cruise control could be disabled.  
      It is to be understood, therefore, that the foregoing illustrative embodiments have been provided merely for the purpose of explanation and are in no way to be construed as limiting of the invention. Further, although the invention has been described herein with reference to particular structure, materials and/or embodiments, the invention is not intended to be limited to the particulars disclosed herein. Rather, the invention extends to all functionally equivalent structures, methods and uses, such as are within the scope of the appended claims. Those skilled in the art, having the benefit of the teachings of this specification, may affect numerous modifications thereto and changes may be made without departing from the scope and spirit of the invention in its aspects.