Patent Description:
ABS (Antiblock Braking System) or anti-locking systems have been known for decades. These are driving safety systems, designed to prevent the locking of the vehicle wheels ensuring their driveability while braking. Such systems have evolved over the years to the extent that they have considerably reduced the number of road accidents and have become mandatory for all vehicles, in almost all countries worldwide.

Such systems basically comprise an electronic control unit, called ABS unit, capable of calculating the rotation speed of each vehicle wheel, by virtue of appropriate sensors and angle position transducers positioned on the wheels. In particular, the ABS comprises toothed phonic wheels rigidly connected to the vehicle wheels and a proximity sensor which detects the passage of the teeth of the wheels. The control unit counts the number of teeth which pass in front of the sensor in a predetermined unit of time and calculates the rotation speed of each individual wheel.

In the event of sudden braking, the wheels lock and thus the calculated speed will be zero. In these conditions, the control unit controls the hydraulic pump of the braking system in order to reduce the braking force and thus prevent the wheels from slipping if they are lock. In such a manner, the ABS reduces braking distances and maintains vehicle directionality, i.e. the possibility of controlling its direction.

Nowadays, in most cases, the ABS is integrated in, i.e. is supported by, auxiliary safety systems, such as EBD (Electronic Brakeforce Distribution), BAS (Brake Assistant System), ASR (Anti-Slip Regulation), ESP (Electronic Stability Program), or similar auxiliary systems, which require the presence of one or more dividing valves.

In motorcycles and motor vehicles, the ABS unit, i.e. the electronic control unit, is positioned in a remote location with respect to the dividing valve and, in presence of two dividing valves, the second dividing valve is positioned in a further location, remote with respect to the first two. In particular, the ABS unit is usually located under the seat, the front valve is located at the handlebar and the rear valve is located at the pedal brake, when present.

Such a configuration has a number of disadvantages, such as the need to use long connecting piping between the ABS unit, the valves and the brake calipers, between the valves and the pumps of the respective braking systems and possibly between the two valves.

The location of the ABS unit with respect to the valves and of the first valve with respect to the second one, in addition to the length of the piping, and therefore the excessive volumetric expansion, implies the need to use flexible piping. Such piping, due to its nature, may deform, especially at given critical points, to the extent of being crushed, thereby compromising the operation of the entire system. Furthermore, such piping has filling problems, i.e. the normal flow of fluids contained therein is prevented where the piping is crushed.

Moreover, flexible piping does not have a high degree of strength. Considering that the connection piping between ABS units and dividing valves takes on a high pressure of the fluids running through it, it can be understood that it constitutes a critical point of the structure, since its operation, and consequently that of the entire system, could be compromised.

Additionally, the current arrangement of the ABS unit and of the dividing valves, and the length of the aforesaid piping create considerable problems during assembly. At present, the assembly operator must firstly mount the ABS unit and the valves on the motorcycle or motor vehicle and then connect the numerous, long pieces of connecting piping. In the case of a simple braking system, for example, there are five of such pieces of piping and each one is intended to be connected at two ends to connect two components, so that at least ten connections must be made. Therefore, serious connection mistakes may be committed if the installer or assembly operative is not particularly trained for the purpose and/or is not particularly experienced.

Furthermore, even if completed without errors, such an assembly method is long and complex with obvious drawbacks from the point of view of productivity.

<CIT> discloses an example of a braking system provided with an anti-lock braking control module and a first brake master cylinder hydraulically coupled to the anti-lock braking control module.

<CIT> discloses another example of braking system provided with a brake control system that is received in a waterproof case and can be connected to hydraulic brakes through a plurality of brake pipes.

<CIT> discloses another example of braking system comprising a hydraulic brake device for braking of a front wheel and a rear wheel of a motorcycle.

<CIT> discloses an example of a motorcycle ABS hydraulic unit that performs antilock brake control.

The applicant of the present application has identified a need to develop an ABS to address the aforesaid problems.

In particular, it is an object the present invention to provide an ABS which is compact and avoids critical issues.

It is a further object of the present invention to create an ABS which achieves a simple and fast assembly process of the ABS unit, of the dividing valves and of the respective piping.

It is a further object of the present invention to make available an ABS which allows using piping which is resistant to mechanical deformation and to high internal fluid pressures.

These and other objects are achieved by means of a system the features of claim <NUM>.

Such a system is compact because the support comprises one or more valve housings, which are adjacent to the housing for the ABS unit. In other words, the ABS unit and the valves are positioned next to one another, in a single location and are no longer displaced, thus solving the above-mentioned problems. Indeed, such a configuration achieves a reduction in the length of the piping, with a consequent reduction in the overall dimensions and critical passages. Furthermore, the disclosed system allows reducing rigid connection piping, at least between the ABS unit and the dividing valves, thus avoiding the above-mentioned critical points. In particular, in addition to being more compact, the rigid piping also has improved resistance to mechanical deformation and is, therefore, are not subject to crushing. It is also highly resistant to operating pressures and therefore does not have the problem of hydraulic fluids.

Above all, a system with the disclosed characteristics results in a simple and fast installation process of the ABS, of the valves and of the respective piping.

Indeed, such a system allows pre-assembling various components (ABS units, dividing valves and some connecting piping), in a special station, outside the assembly line of the motorcycle or motor vehicle, with advantages in terms of time and simplicity of operation. In other words, such a system permits the installation on a workbench of ABS unit and valves on the support; connection piping between ABS unit and valves, connection piping between valves and braking system pumps at the valves, connecting piping between ABS unit and braking system calipers at the ABS unit and, if necessary, piping for connection between the valves, if there is more than one valve. In such a manner, it is sufficient to install a single piece, i.e. the support provided with the aforesaid components, in the assembly line of the vehicle and to connect the free ends of the aforesaid piping at the respective components (e.g. pumps and calipers, for a total of four connections for simple braking systems, i.e. two connections at the two pumps and two connections at the two calipers) to conclude the installation in line of the ABS. This allows avoiding the risk of pipe connection errors resulting in obvious advantages and reduces the degree of specialization and experience required of the installer, in addition to reducing the time and cost of the vehicle assembly line.

Furthermore, the system of the present invention allows simplifying maintenance operations, and therefore reducing the costs, because it is sufficient, in case of need, to dismantle a single piece, i.e. the support, and therefore to remove only one part of the fairing, instead of dismantling the various displaced components and therefore remove the entire fairing.

Preferably, the support is made in one piece, so as to be easily and cost-effectively manufactured by molding.

In an embodiment, there are two dividing valves and they are both positioned in the same housing seat, or they are each positioned in a corresponding housing seat, depending on the construction requirements.

According to preferred embodiments of the invention, the system further comprises at least a first connection tube between the ABS unit and said at least one dividing valve and said first tube is a rigid tube. This results in the above-mentioned advantages of compactness, mechanical strength and resistance to high pressures.

If there were two valves, the system would preferably comprise two first connection tubes, one for each dividing valve.

Advantageously, the system furthermore comprises at least two second connection tubes: a second connection tube between said at least one dividing valve and a first pump of a braking system and a further second connection tube between said at least one dividing valve and a second pump of the braking system.

If there were two dividing valves, the system would further comprise at least one third connection tube between the two dividing valves.

Alternatively, the two dividing valves are connected to each other by means of a branch on the second connection tube.

According to an embodiment, the system comprises a single dividing valve which is:.

the ABS unit being connectable to a brake caliper of a front wheel of a motorcycle or motor vehicle by means of a further tube and to a brake caliper of a rear wheel of a motorcycle or motor vehicle by means of a further tube.

According to a further embodiment, the system comprises a single dividing valve which is:.

the ABS unit is connectable to two brake calipers of the same front wheel of a motorcycle or motor vehicle by means of two respective further tubes and to a brake caliper of a rear wheel of a motorcycle or motor vehicle by means of a further tube.

According to a further embodiment, the system comprises:.

and the ABS unit is connectable to two brake calipers of two corresponding front wheels of a motorcycle or motor vehicle by means of two respective further tubes and to a brake caliper of a rear wheel of a motorcycle or motor vehicle by means of a further tube.

In a second aspect, the invention relates to a motorcycle or motor vehicle comprising a system with the aforesaid characteristics.

Preferably, said system is located at the front shield of the frame of the motorcycle or motor vehicle itself, even more preferably it is positioned below the handlebar. Such a position is particularly advantageous because it allows the connection piping between the valve and the pump of the front brake system, or the valves and the respective pumps of the front brake systems to be considerably reduced. In this context, when talking about the ABS, we are referring to an integrated ABS, i.e. to an ABS (comprising an ABS unit and respective piping) and at least one dividing valve.

When talking about the system, we are referring to the system of the present invention.

Further features and advantages of the invention will be more apparent from the examination of the following detailed description of some preferred, but not exclusive embodiments of the ABS, illustrated by way of non-limiting example, with reference to the accompanying drawings, in which:.

With reference to <FIG>, reference numeral <NUM> indicates an ABS according to the present invention as a whole.

The system <NUM> comprises an ABS unit <NUM> of known type and at least one dividing valve <NUM>, <NUM>' of known type. The system <NUM> of the present invention further comprises a support <NUM>, which is intended to support the ABS unit <NUM> and said at least one dividing valve <NUM>, <NUM>'. Therefore, such a support <NUM> comprises a housing compartment <NUM> for the ABS unit <NUM> and at least one housing seat <NUM> for said at least one dividing valve <NUM>, <NUM>'. The housing seat <NUM> is positioned so that it is adjacent to the housing compartment <NUM>. In other words, it may be located either by the side of the housing compartment <NUM> or to the front, rear, upper or lower thereof, provided that it is close to it so as to create a compact, space-saving system <NUM>.

In the embodiments shown in <FIG>, the system <NUM> is provided with a single housing seat <NUM>, which is located laterally to the housing compartment <NUM> and is adapted to accommodate two dividing valves <NUM>, <NUM>'. Such a housing seat <NUM> shares a wall <NUM> with the housing compartment <NUM> of the ABS unit <NUM>.

Alternatively, the system <NUM> may have a housing seat <NUM> for a first dividing valve <NUM> on one side of housing compartment <NUM> and a housing seat <NUM> for a second dividing valve <NUM>' at the opposite side of housing compartment <NUM>, so that, once the system <NUM> is assembled, the dividing valves <NUM>, <NUM>' are each arranged on one side of the ABS unit <NUM>.

Preferably, the support <NUM> is made of a single piece, i.e. is a monolithic structure, preferably made of composite or plastic material. The composite material should preferably comprise polyamide or the like.

Alternatively, the support <NUM> may be made of metal material, such as sheet metal or aluminum casting.

It is made by molding using methods and technologies of a known type.

According to alternative embodiments, the support <NUM> comprises two or more portions which are rigidly connected to one another. For example, housing compartment <NUM> and housing seat <NUM> could be manufactured separately, even with different materials, and connected together by means of special mechanical connection means, so as to form a compact structure.

According to the preferred embodiment, shown in <FIG>, there are two dividing valves <NUM>, <NUM>' and they are both positioned in the same housing seat <NUM>, but they could be each placed in a corresponding housing seat <NUM>, as mentioned above.

The number of dividing valves <NUM>, <NUM>' present in system <NUM>, depends on the motor vehicle or motorcycle in which the ABS is to be fitted, or on the type of braking system chosen for the motor vehicle or motorcycle. Normally, in presence of two brake pumps <NUM>, <NUM>, <NUM>, e.g. each at a relative brake lever <NUM>, <NUM> of the handlebar, or one at a brake lever <NUM>, <NUM> and one at the brake pedal <NUM>, the presence of a single dividing valve <NUM>, <NUM>' is expected. While when the braking system of a vehicle comprises three brake pumps <NUM>, <NUM>, <NUM>, e.g., one for each of the two brake levers <NUM>, <NUM> and one for the brake pedal <NUM>, the system <NUM> comprises two dividing valves <NUM>, <NUM>'. However, different cases could be provided.

<FIG> shows an example of a diagram of a brake system with which the system <NUM> of the present invention may be used. Such a brake system comprises an ABS unit <NUM>, a dividing valve <NUM>, a first pump <NUM> at a right brake lever <NUM> and a second pump <NUM> at a left brake lever <NUM>.

<FIG> shows a further example of a diagram of a braking system with which the system <NUM> according to the present invention can be used. Such a brake system comprises an ABS unit <NUM>, a dividing valve <NUM>, a first pump <NUM> at a right brake lever <NUM> and a second pump <NUM> at a brake pedal <NUM>.

<FIG> shows a further example of a diagram of a braking system with which the system <NUM> according to the present invention can be used. Such a brake system is provided with an ABS unit <NUM>, two dividing valves <NUM>, <NUM>', a first pump <NUM> at a right brake lever <NUM>, a second pump <NUM> at a left brake lever <NUM> and a third pump <NUM> at a brake pedal <NUM>.

These are just examples because the system <NUM> of the present invention can be used with basically all types of brake systems for motorcycles or motor vehicles available on the market.

The support <NUM> is fixed to the frame of the vehicle on which it is mounted by means of screws, or equivalent means, inserted in holes <NUM>.

The system <NUM>, according to preferred embodiments, further comprises at least a first connection tube <NUM>, <NUM>' between the ABS <NUM> unit and said at least one dividing valve <NUM>, <NUM>'. In particular, in the cases shown in <FIG> and <FIG>, the system <NUM> comprises only one first tube <NUM>, while in the embodiment shown in <FIG> and <FIG>, such first tubes <NUM>, <NUM>' are two, one for each dividing valve <NUM>, <NUM>'. In particular, a first tube <NUM> connects the first dividing valve <NUM> to the ABS unit <NUM> and a further first tube <NUM>' connects the second dividing valve <NUM>' to the ABS unit <NUM> itself. As shown above all in <FIG>, the first tubes <NUM>, <NUM>' are rigid tubes, preferably made of metal material, e.g. steel.

The system <NUM> further comprises at least two second connection tubes <NUM>, <NUM>' between at least one dividing valve <NUM>, <NUM>' and at least two brake system pumps <NUM>, <NUM>, <NUM>. In particular, in the case of the braking system shown in <FIG>, the system <NUM> comprises a second tube <NUM> connecting the dividing valve <NUM> to a first pump <NUM> of a braking system and a second tube <NUM>' connecting the dividing valve <NUM> itself to a second pump <NUM> of the braking system. The first pump <NUM> relates to the right brake lever <NUM>, while the second pump <NUM> relates to the left brake lever <NUM>.

Similarly, in the case of the braking system shown in <FIG>, the system <NUM> comprises a second connection tube <NUM> between the dividing valve <NUM> and a first pump <NUM> of a braking system and a further second connection tube <NUM>' between the dividing valve <NUM> itself and a second pump <NUM> of the braking system. However, while the second pump <NUM> in <FIG> is the pump of a left brake lever <NUM>, the second pump <NUM> in <FIG> is related to a brake pedal <NUM>.

In the case of the braking system shown in <FIG>, instead, the system <NUM> comprises a second tube <NUM> connecting the first dividing valve <NUM> to a first pump <NUM> of a braking system, a further second connection tube <NUM>' between said at least one dividing valve <NUM>' and a second pump <NUM> of a braking system and a further second connection tube <NUM>" between said at least one dividing valve <NUM>' and a second pump <NUM> of the braking system. In such a case, the first pump <NUM> relates to the right brake lever <NUM>, the second pump <NUM> to the left brake lever <NUM> and the third pump <NUM> to the brake pedal <NUM>.

In <FIG> and <FIG>, it is also worth noting that the system <NUM>, in such embodiments, further comprises at least one third connection tube <NUM> between the two dividing valves <NUM>, <NUM>'.

As shown in <FIG>, <FIG> and <FIG>, the ABS unit <NUM> is then connected to the brake calipers <NUM> by means of further tubes <NUM>. The latter are adapted to communicate with the ABS unit <NUM>, the information which allows the ABS <NUM> unit itself to operate.

In the example in <FIG>, there are two of such further tubes <NUM>, one for each brake caliper <NUM> which are arranged at a front wheel and at a lower wheel of the motorcycle or motor vehicle, respectively. Instead, there are three further tubes <NUM> in the example in <FIG>: two tubes are adapted to connect two brake calipers <NUM> of the same front wheel to the ABS unit <NUM> and one tube is adapted to connect a brake caliper <NUM> of the rear wheel to the ABS <NUM> unit itself.

Finally, there are three further tubes <NUM> in the example in <FIG>; two tubes are adapted to connect two brake calipers <NUM> of two corresponding front wheels with the ABS unit <NUM> and one tube is adapted to connect a brake caliper <NUM> of the rear wheel with the ABS unit <NUM> itself.

The present invention further relates to a motorcycle or motor vehicle comprising a system <NUM> as described above.

Advantageously, the system <NUM> is positioned at the handlebar of the motorcycle or motorbike itself. Preferably, the system <NUM> is located at the front shield of the frame, below the handlebar of the vehicle, so as to achieve short piping and the respective advantages mentioned above.

An assembly method of an ABS on a motorcycle or motor vehicle according to the present invention will now be described.

With a system <NUM> for ABS as described above, it is possible to pre-assemble such a system <NUM> and its piping, by implementing the following pre-steps off-line:.

In the embodiments shown in <FIG> and <FIG>, i.e. in presence of two dividing valves <NUM>, <NUM>', step b provides mounting a first dividing valve <NUM> and a second dividing valve <NUM>' in the housing seat <NUM>; step c provides connecting a first tube <NUM>' between the ABS unit <NUM> and a first dividing valve <NUM> and a further first tube <NUM>' between the ABS unit <NUM> and a second dividing valve <NUM>'; step d provides connecting a second connection tube <NUM> (intended to connect the first dividing valve <NUM> to the first pump <NUM> of the braking system) at said first valve <NUM> and a further second tube <NUM>' (intended to connect the second dividing valve <NUM>' to the second pump <NUM> of the braking system) at said second valve <NUM>'.

Furthermore, in such an embodiment, the method provides the implementation of a further step:
e. connecting at least one third connection tube <NUM> between the two dividing valves <NUM>, <NUM>', at both ends.

Claim 1:
A system (<NUM>) comprising an ABS unit (<NUM>) for the wheels of a vehicle, at least one dividing valve (<NUM>, <NUM>') and a support (<NUM>), comprising a housing compartment (<NUM>) for the ABS unit (<NUM>) and characterized by comprising at least one housing seat (<NUM>) for said at least one dividing valve (<NUM>), said at least one housing seat (<NUM>) being positioned to be adjacent to the housing compartment (<NUM>).