Abstract:
A foldable control lever for use with a riding mower comprising a main lever tube having a lower end, an upright section and a grip portion. An upper weldment is affixed to the lower end of the main lever tube. The upper weldment comprises a support flange and a plurality of outwardly projecting ears. A lower weldment connected to the mower drive unit is adapted to receive the lower end of the main lever tube. The lower weldment comprises a receiver flange having a plurality of notches spaced about the circumference of the flange. The notches are configured so as to engage the outwardly projecting ears of the upper weldment. When the outwardly projecting ears are engaged with the notches, the main lever tube is prevented from rotating relative to the lower weldment. When the outwardly projecting ears are not engaged with the notches, the main lever tube can be rotated downward and on to the top of the mower.

Description:
FIELD OF THE INVENTION 
     This invention relates generally to the field of riding mowers and, in particular, to a control lever that can be folded or collapsed to permit improved entry to or exit from the operator&#39;s seat of a riding mower. 
     BACKGROUND OF THE INVENTION 
     Riding lawn mowers are used to cut grass and the like and are manufactured in various designs and configurations. Certain elements, however, are common to most riding lawn mowers. For example, a riding lawn mower typically includes a frame supported by three or more wheels. A mower deck comprising one or more rotating cutting blades is normally suspended beneath the frame and in close proximity to the ground. Rotation of the cutting blades is usually provided by a power plant such as a gasoline engine. The power plant also provides the driving force for the wheels. 
     An operator controls the various mechanical operations of the riding lawn mower. In many riding lawn mower designs, the operator is seated on top of the mower. From this position, the operator can control the speed and direction of the mower, as well as the operation of the mower deck. 
     One particular design for a riding lawn mower is disclosed in U.S. Pat. No. 5,496,226, which is hereby incorporated by reference. As set forth therein, the riding lawn mower comprises a pair of hand levers that engage a transmission assembly. Fore and aft movement of the hand levers alters the rotational speed of the drive wheels, thereby changing the direction of the riding mower. In other words, the riding mower is steered by manipulation of the hand levers. 
     The hand levers of this design are positioned so that they can be easily grasped and manipulated by the operator from the seated riding position. In particular, the hand levers are each “C”-shaped and extend from a connection point beneath and along each side of the operator&#39;s seat. The middle portion of the hand levers extend upwards on either side of the operator&#39;s legs. The upper portion of the hand levers extend horizontally towards each other (through a 90 degrees bend) and in front of the operator&#39;s upper body (i.e., above the operator&#39;s lap). This configuration allows the operator to easily and comfortably grasp and manipulate the hand levers from the seated position on top of the riding mower. 
     The configuration for the hand levers of the above-described design has a number of disadvantages. For example, the hand levers can impede entry to or exit from the operator&#39;s seat. To gain entry to the operator&#39;s seat, the operator ordinarily has to swing one of the hand levers to the outwardly from the side of the mower. Alternatively, the operator may push one of the hand levers to the rear while pulling the other hand lever towards the front. Either procedure spreads the hand levers apart so that operator can maneuver between the ends of the hand levers and sit down on the operator&#39;s seat. These procedures, however, may be difficult to perform and may fail to provide sufficient clearance for many operators. 
     One attempt to solve this problem is to allow the hand levers to swing outwardly towards the sides of the mower. Swinging the hand levers to side of the mower, however, may still not provide sufficient access to the mower for some operators. This is because the hand levers will remain adjacent to the side of the operator&#39;s seat. The position of the hand levers may consequently inhibit the ability of some operators, particularly elderly or handicapped operators, to gain entry to the operator&#39;s seat. 
     Accordingly, it would be desirable to provide a control lever arrangement that overcomes the disadvantages and limitations described above. 
     BRIEF SUMMARY OF THE INVENTION 
     The foldable control lever of the present invention comprises a main lever tube having a lower end, an upright section and a grip portion. The upright section connects the grip portion to the lower portion. An upper weldment is affixed to the lower end of the main lever tube. The upper weldment comprises a support flange and a plurality of outwardly projecting ears. 
     The foldable control lever is supported by a lower weldment adapted to receive the lower end of the main lever tube. The lower weldment is connected to the transmission assembly and transmits the movement of the control lever to the drive unit of the mower. The lower weldment comprises a receiver flange having a plurality of notches spaced about the circumference of the flange. The notches are configured so as to engage the outwardly projecting ears of the upper weldment. When the outwardly projecting ears are engaged with said notches, the main lever tube is prevented from rotating relative to the lower weldment. This allows the control lever to be used to operate the drive unit. When the outwardly projecting ears are not engaged with the notches, the main lever tube can be rotated downward and on to the top of the mower. This allows the control lever to be folded out of the way of the operator, thereby providing increased access to the operator&#39;s seat. 
     The preferred embodiment of the invention includes features in addition to those listed above. Moreover, the advantages over the current art discussed above are directly applicable to the preferred embodiment, but are not exclusive. The other features and advantages of the present invention will be further understood and appreciated when considered in relation to the detailed description of the preferred embodiment. 
    
    
     BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS 
     FIG. 1 is a perspective view of a riding mower incorporating foldable control levers of the present invention. 
     FIG. 2 is an exploded view of a foldable control lever of the present invention. 
     FIG. 3 is a partial perspective view of the riding mower of FIG. 1 showing the foldable control lever of the present invention in the folded or collapsed position. 
     FIG. 4 is a front view of the lower portion of the foldable control lever of the present invention showing the foldable control lever in the operating position. 
     FIG. 5 is a right-side view of the lower portion of the foldable control lever of the present invention taken along line  5 — 5  of FIG.  4 . 
     FIG. 6 is a front view of the lower portion of the foldable control lever of the present invention showing the foldable control lever in the folded or collapsed position. 
     FIG. 7 is a detailed view of the end of the lower weldment of the foldable control lever of the present invention. 
     FIG. 8 is a detailed view of the end of the upper weldment of the foldable control lever of the present invention. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     While the present invention will find application in all types of riding machinery, the preferred embodiment of the invention is described in conjunction with the riding lawn mower  10  of FIG.  1 . The riding lawn mower  10  comprises a frame  12  supported on two pairs of wheels  14 ,  16 , a mower deck  18  suspended from the frame, a seat  20  for the operator, and an engine  22 . The mower also comprises a pair of control levers  24  for operating a transmission drive  26  connected between the engine  22  and each of the rear pair of wheels  16 . 
     The mower deck  18  includes a pair of cutting blades (not shown) rotatably supported beneath the upper surface of the mower deck  18 . The engine  22  of the mower  10  provides the rotational force to the cutting blades through a belt and pulley arrangement (not shown). A clutch mechanism is also provided between the engine and the cutting blades. The clutch mechanism (not shown) allows the cutting blades to be disengaged from the engine  22 . The design and function of mower cutting blades is well known to those skilled in the art. 
     The two front wheels  14  are pivotally mounted to the forward end of the frame  12 . The pivotal connection allows the axis of each of the front wheels  14  to rotate (i.e., turn) 360 degrees relative to the frame  12 . The two rear wheels  16  are connected to the engine  22  by a transmission drive  26 . No steering wheel is provided since the direction of the mower  10  is controlled by altering the rotational speed of the rear wheels  16 . In other words, the mower  10  is turned towards one side or the other by slowing the speed of one of the rear wheels  16  relative to the other. 
     The rotational speed of the rear wheels  16  is controlled by the transmission drive  26  of the mower  10 . The transmission drive  26  includes a variable speed friction unit mounted beneath the operator&#39;s seat  20  and forward of the engine  22 . The friction unit provides a means for independently controlling the rotational speed of each rear wheel  16 . Altering the rotational speed of one of the rear wheels  16  relative to the other causes the mower  10  to change direction. For example, reducing the speed of the left rear wheel  16  relative to the right rear wheel  16  will cause the mower  10  to turn towards the left. The design and function of the transmission drive  26  of the preferred embodiment is set forth in detail in U.S. Pat. No. 5,496,226, which is hereby incorporated by reference. Other aspects of the design and function of the mower  10  of the preferred embodiment are also disclosed in the above-referenced patent. 
     The operation of the transmission drive  26  is controlled by the control levers  24 . As best seen in FIG. 1, each control lever  24  comprises a generally “C”-shaped round stock or tubular member  28 . The lower end  30  of each control lever is connected to an input member  32  on the transmission drive (see FIG.  5 ). Movement of the input member  32  controls the operation of the transmission drive  26 . For example, an upward movement of the input member  32  on the left side of the mower reduces the rotational speed of the left rear wheel  16  (relative to the rotational speed of the right rear wheel  16 ). As will be described in detail below, upward movement of the input member  32  is accomplished by pulling the control arm  24  towards the rear of the mower  10 . 
     As best seen in FIG. 2, each control arm  24  comprises a main lever tube  34  supported by a lower weldment  36 . The main lever tube  34  is generally “C”-shaped and comprises a lower leg  38 , an upright section  40 , and a grip portion  42 . The lower leg  38  is connected to the lower weldment  36  at a location below the operator&#39;s seat  20  and extends upwardly and outwardly towards the side of the mower  10  (see FIG.  1 ). The upright section  40  extends upwards along the side of the mower  10  (i.e., outside the operator&#39;s legs). The grip portion  42  generally extends horizontally from the upper end of the upright section  40  and terminates near the centerline of the mower  10 . 
     As best seen in FIG. 1, the operating position of the grip portion  42  is in above and forward of the operator&#39;s seat  20 . This places the grip portion  42  of each control arm  24  in front of the operator&#39;s upper body and above the operator&#39;s lap. An end cap  44  is placed over the end of the grip portion  42  to prevent rain or the like from entering the grip portion  42  of the main lever tube  34  and to protect the operator from any sharp edges or burrs that may exist on the end of the main lever tube  34 . The main lever tube  34  of the preferred embodiment is manufactured from a tubular metal that has been bent to form the preferred shape. 
     As best seen in FIG. 2, the lower leg  38  of the main lever tube  34  terminates with a threaded section  46 . As will be discussed in greater detail below in connection with the description of the lower weldment  36 , the threaded section  46  engages a retaining nut  48 . An upper weldment  50  is affixed to the lower leg  38  inwardly from the threaded section  46 . The upper weldment  50  comprises a collar  52 , a support flange  54 , and a pair of locking ears  56 . The collar  52  is affixed to the lower leg  38  of the main lever tube  34  by one or more welds (not shown). As best seen in FIGS. 4-6 and  8 , the support flange  54  extends perpendicularly from one end of the collar  52 . In particular, the exterior face  58  of the support flange  54  is aligned with the lower end (the left end in FIGS. 4 and 6) of the collar  52  to form a single plane. The locking ears  56  are located on opposite sides of the collar  52  and project past the exterior face  58  of the support flange  54 . The ends of the locking ears  56  are inward from the outer diameter or circumference of the support flange  54 . The locking ears  56  also project past the interior face  60  of the support flange  54  and are secured to the exterior surface of the collar  52 . As best seen in FIG. 8, the flange includes notches  62  through which the locking ears  56  project. These notches  62  secure the locking ears  56  against lateral movement. In the preferred embodiment shown, the collar  52 , the support flange  54 , and the pair of locking ears  56  are each manufactured from separate metal components and welded together to form the upper weldment  50 . In the alternative, these components could be machined or cast as a single monolithic element. 
     The lower leg  38  of the main lever tube  34  is supported by the lower weldment  36 . As best seen in FIGS.  2  and  4 - 6 , the lower weldment  36  comprises a sleeve  64  welded to a mounting tube  66 . The mounting tube  66  includes a mounting flange  68  that is connected to the input member  32  of the transmission drive  26 . The connection between the mounting flange  68  and the input member  32  may be made pivotal. A pivotal connection would permit the lower weldment  36  to rotate relative to the input member  32 , thereby allowing the control lever  24  to be swung outwardly towards the side of the mower  10  (as shown with respect to the right control lever  24  in FIG.  1 ). 
     As best seen in FIGS. 4-6, the sleeve  64  is welded to the mounting tube  66  at a generally perpendicular angle. The size and shape of the sleeve  64  is designed to fit over the lower leg  38  of the main lever tube  34 . In the preferred embodiment shown, inside diameter of the sleeve  64  is slightly larger than the outside diameter of the lower leg  38 . This allows the sleeve  64  to freely rotate and/or translate on the lower leg  38 . A receiver flange  70  is connected to one end of the sleeve  64 . As best seen in FIG. 6, the exterior face  72  of the receiver flange  70  is aligned with the upper end (the right end in FIG. 6) of the sleeve  64  to form a single plane. In the preferred embodiment shown, the receiver flange  70  has a diameter that equals the diameter of the support flange  54  of the upper weldment  50 . As best seen in FIG. 7, the receiver flange  70  comprises a pair of notches  74  on opposite sides that are configured so as to engage the locking ears  56  of the upper weldment  50 . In the preferred embodiment shown, the various components of the lower weldment  36  are manufactured separately and welded together. In the alternative, these components could be machined or cast as a single monolithic element. 
     As best seen in FIGS. 4-6, the control arm  24  is connected to the input member  32  of the transmission drive  26  by the insertion of the lower leg  38  through the sleeve  64  of the lower weldment  36 . The lower leg  38  extends past the lower end of the sleeve  64 . A retaining nut  48  engages the threaded portion  46  of the lower leg  38 . A spring  76  is positioned over the lower leg  38  between the retaining nut  48  and the lower end of the sleeve  64 . A flat washer  78  is positioned at each end of the spring  76  so as to confine the spring  76  between the retaining nut  48  and the lower end of the sleeve  64 . The spring  76  biases the upper weldment  50  against the lower weldment  36 . 
     FIG. 4 shows the control arm  24  in the engaged position. In this position, the locking ears  56  of the upper weldment  50  are engaged with the notches  74  on the receiver flange  70  and the exterior face  58  of the support flange  54  is pressed against the exterior face  72  of the receiver flange  70 . These components are held in this position by the spring  76 , which biases the upper weldment  50  against the lower weldment  36 . The engagement of the locking ears  56  in the notches  74  on the receiver flange  70  prevents the upper weldment  50  from rotating relative to the lower weldment  36 . This results in a rigid connection between the control arm  24  and the input member  32 , thereby enabling the control arm  24  to be used to operate the transmission drive  26 . In other words, pulling back on the control arm  24  will cause upward movement in the input member  32  and, consequently, a reduction in the rotational speed of the rear wheel  16 . 
     FIGS. 3 and 6 shows the control arm  24  in the disengaged position. Applying an outward force on the main lever tube  34  sufficient to compress the spring  76  disengages the control arm  24 . As the spring  76  is compressed, the lower leg  38  slides through the sleeve  64  thereby allowing the upper weldment  50  to separate from the lower weldment  36 . The upper weldment  50  is moved a distance sufficient to disengage the locking ears  56  from the notches  74  on the receiver flange  70 . With the locking ears  56  disengaged, the upper weldment  50  can be rotated relative to the lower weldment  36 . This permits the main lever tube  34  of the control arm  24  to be folded or collapsed forward onto the frame  12  of the mower  10  (as shown in FIG.  3 ). 
     It should be noted that the outward force on the main lever tube  34  may be released once the locking ears  56  have been brought out of alignment with the notches  74  on the receiver flange  70 . This is because the ends of the locking ears  56  will not inhibit the rotation of the upper weldment  50  while biased against the exterior face  72  of the receiver flange  70 . 
     When the control arm  24  is in the folded or collapsed position, the operator can easily gain access to the operator&#39;s seat  20  on the mower  10 . Once the operator is positioned on the operator&#39;s seat  20 , then the control arm  24  can be returned to the engaged position. This is accomplished by rotating the main lever tube  34  to the upright position so as to align the locking ears  56  with the notches  74  on the receiver flange  70 . When locking ears  56  are aligned with the notches  74 , the spring  76  will push the locking ears  56  into notches  74 . 
     The preferred embodiment utilizes a pair of locking ears  56  positioned on opposite sides of the upper weldment  50 . The upper weldment  50  could, however, comprise any number of locking ears  56 . For example, a single locking ear  56  could be used instead of the pair shown. In addition, the preferred embodiment utilizes a pair of notches  74  on the receiver flange  70  that coincide with the pair of locking ears  56  on the upper weldment  50 . The receiver flange  70  could, however, include additional notches  74  so as to provide multiple locking positions. This would permit the control arm  24  to be locked in a variety of positions depending on the size of the operator. 
     It should be appreciated that the apparatus of the present invention is capable of being incorporated in the form of a variety of embodiments, only a few of which have been illustrated and described above. The invention may be embodied in other forms without departing from its spirit or essential characteristics. For example, the arrangement of locking ears  56  and the notches  74  could be reversed (i.e., the locking ears  56  could be located on the lower weldment  36 ), or different types of mechanical devices could be used to connect the upper weldment  50  to the lower weldment  36 . The described embodiments are therefore considered in all respects only as illustrative and not restrictive, and the scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All modifications that come within the meaning and range of equivalency of the claims are to be embraced within their scope.