Patent ID: 12208658

DETAILED DESCRIPTION

Some embodiments, illustrating its features, will now be discussed in detail. The words “comprising,” “having,” “containing,” and “including,” and other forms thereof, are intended to be equivalent in meaning and be open-ended in that an item or items following any one of these words is not meant to be an exhaustive listing of such item or items, or meant to be limited to only the listed item or items. It must also be noted that as used herein and in the appended claims, the singular forms “a,” “an,” and “the” include plural references unless the context clearly dictates otherwise. Although any methods and systems similar or equivalent to those described herein can be used in the practice or testing of embodiments, the preferred methods, and systems are now described. The disclosed embodiments are merely exemplary.

The present invention is described hereinafter by various embodiments with reference to the accompanying drawing, wherein reference numerals used in the accompanying drawing correspond to the like elements throughout the description. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiment set forth herein. Rather, the embodiment is provided so that this disclosure will be thorough and complete and will fully convey the scope of the invention to those skilled in the art. In the following detailed description, numeric values and ranges are provided for various aspects of the implementations described. These values and ranges are to be treated as examples only and are not intended to limit the scope of the claims. In addition, several materials are identified as suitable for various facets of the implementations. These materials are to be treated as exemplary and are not intended to limit the scope of the invention.

The various features and embodiments of the present invention will now be described in conjunction with the accompanying figures, namelyFIGS.1-18, andFIGS.19A-19B, which should be regarded as merely illustrative without restricting the scope and ambit of the present invention. Although the control arm200of the present invention is explained with respect to its uses in measuring or adjusting a camber angle in a preferred embodiment. It should be understood that the proposed control arm200should not be considered as limited to its uses with respect to the measurement and adjustment of the camber angle, rather can be used to measure and adjust the other suspension angles in vehicles, for example, toe angle and caster angle.

One of the embodiments of the present invention as shown inFIGS.1-7provides a novel control arm200configured to allow a user to recall a particular suspension angle without using traditional alignment equipment, a metal square or camber gauges. The embodiment as illustrated inFIGS.1-7specifically includes a bracket100configured on the adjustable control arm200. The bracket100ensures adjustment of the particular suspension angle (Eg. camber angle) manually without affecting the distance between the ride height sensor assembly of the vehicle and a ball point or ball115located on the bracket100operationally connected to the height sensor assembly for facilitating the height adjustment of the vehicle's air suspension system. The bracket100is easy to manufacture and assemble. The bracket100is lightweight and removable as required. For the purpose of this invention, it has been assumed that people skilled in the art are well aware of the use of the height sensor assembly in vehicles using air suspension systems. Likewise, the parts such as the subframe assembly of the vehicles are not described and shown herein to keep the description concise. The control arm200, the bracket100, and associated components thereof will now be described with respect toFIGS.1-7.

Referring toFIGS.1-7, the control arm200includes an arm body202, a rod end201, a first bushing203, a second bushing204, a control arm length adjusting mechanism205comprising at least an adjuster206, and the bracket100.

The rod end201embodies the first bushing203at an end201aand comprises a first set of threading201cpresent on a shaft201bextending from the end201a. The threading201cis conventional spiral threading. The end201ais referred to as a sub-frame assembly end201afor the purpose of this application. The sub-frame assembly end201aof the control arm200is connected inside the vehicle or to the sub-frame assembly of the vehicle through the bushing203. The threading201cpresent on the shaft201bof the rod end201rotatably engages within a second set of threading206a′ (or internal threading) of an adjuster206of the control arm length adjusting mechanism205. The adjuster206also includes external threading or a third set of threading206a. In other words, the adjuster206includes two sets of threading, threading206aconfigured externally and threading206a′ configured internally. The adjuster206also includes a first end206band a second end206c. The first end206bof the adjuster206comprises a plurality of slits or cutouts206dpartially extending along the length of the adjuster206. In an example, there are four such slits or cutouts206din the adjuster206. The first end206bof the adjuster206comprises a hex head or an eccentric bolt206efor a user to adjust or rotate the adjuster206of the control arm angle adjusting mechanism205in order to adjust the particular suspension angle or length of the control arm200. When the rod end201is engaged within the adjuster206using threads201cand206a′, the adjuster206is further secured using a first clamping means205a(that passes over the slits206d) and corresponding fastener205b. The clamping means205asqueezes the adjuster206further around the threads201cof the rod end201. The arm body202further comprises a second clamping means202d. In operation, the clamping means205aand202dare first loosened in order to adjust the adjuster206in other words adjust the control arm length and when the control arm200is adjusted to the required length, the clamping means205aand202dare retightened to retain the length of the control arm200.

The arm body202of the control arm200comprises a first end202a, and a second end202b. The first end202ais referred to as a wheel assembly end202afor the purpose of this application. The wheel assembly end202of the control arm200is connected to a knuckle of the wheel assembly through the bushing204. The arm body202is configured to receive the adjuster206at its end202b. The arm body202internally includes a cavity with a fourth set of threads202c. The threads202care formed such as to operationally engage the threads206aof the adjuster206.

During the assembly, the adjuster206engages the internal threads202cpresent within the arm body202. Likewise, the threading201cof the rod end201engaged the threading206a′ of the adjuster206. The control arm200includes cylindrical foam206fthat engages to the end206cof the adjuster206within the arm body202for weather sealing. The control arm200further includes an arm gasket206gthat engages the adjuster206lengthwise and the arm body202for proper sealing of the control arm200. The clamping means205a,202dare manipulated (loosened or tightened) in order to adjust the adjuster206of the control arm length adjusting mechanism205. The adjuster206allows the user to adjust the length of the control arm200. Upon adjusting the length of the control arm200, the particular suspension angle of the wheel gets adjusted. When the adjuster206rotates so that it enters into the arm body202, the length of the control arm200gets decreased. Likewise, when the adjuster206is rotated so that it comes out of the arm body202, the length of the control arm200gets increased. The proposed invention provides an easy way to recall preset suspension angles without using any alignment measuring instruments prevalent in the prior art and adjust the same.

As seen, the control arm200of the proposed invention is provided with a scale207. As seen, the scale is marked on one of the side surfaces of the arm body202. The scale207is marked using paint or using a known metal removing process or using a laser beam of high intensity or any other known process. In an exemplary non-limiting embodiment of the present invention, the scale207has positive and negative integers each marked on either side of ‘0’. In an example as shown, the scale207may range from (+15) mm-0-(−15) mm. (0) on the scale represents the manufacturers default arm length. The positive integers represent the control arm getting longer and the negative integers represent the control arm getting shorter.

The control arm200of the proposed invention is provided with the bracket100according to an embodiment of the present invention as illustrated inFIGS.1-7. The bracket100is removably and rotatably mounted to the sub-frame assembly end201aof the control arm200(FIG.6). The bracket100is formed by performing any combination of operations comprising forging, casting, welding, pressing, injection molding or machining. The bracket100is made from a lightweight metal, a metal alloy or polymer. The bracket100may be provided with a plurality of slots for weight reduction and for material-saving.

Referring now toFIGS.4and5, the bracket100is comprised of a pair of rings101,102, a connecting segment103, and a pair of side segments104,105. The rings101, and102are configured to sit over the outer sleeve of bushings203. The rings101,102have a gap therebetween for receiving outer sleeve of the bushing203configured at the end201aof the control arm200. Each ring101,102has a hole106,107respectively through which a portion of the bushing203would come out. Each of the rings101,102has a ring end profile108,109that connect the rings101,102with the connecting segment103respectively. Each ring end108,109has a hole110,111respectively. The holes110,111are provided for receiving a fastener210therein. The fastener210may include a pin, a nut-bolt assembly, a screw, or the like. The fastener210helps in tightening the bracket100to the sub-frame assembly end201aof the control arm200. The ring end profiles108,109are extended out from the connecting segment103. The extension from the connecting segment103to the ring end portions108, and109decides the gap length between rings101,102. Initially, the gap length between the rings101,102is set less than the diameter of the outer sleeve of the bushing203(bushing at the sub-frame assembly end). When the rings101,102are mounted around each side of the bushing203, the rings101,102oppose the deformation against each other and hold the outer sleeve of the bushing203tightly therebetween.

The bracket100is rotatable about the sub-frame assembly end bushing203of the control arm200as shown inFIG.6. The connecting segment103limits the rotation of the bracket100. The connecting segment103is supported by a top surface208of the control arm200(particularly the top surface of the arm body202). The connecting segment103has a first side segment104and a second side segment105. Each of the side segments104and105are extended from two side edges of the connecting segment103. Each side segment104,105is provided with a slot113and112respectively. The slots112,113provide limited freedom of motion to the bracket100in direction of control arm200. The slots112,113are configured in a rectangular, circular, elliptical, or any other known geometrical shape. The control arm200or arm body202is further provided with a hole for receiving a fastener209that passes through the slots112,113. Upon fastening the fastener209, a free end of the bracket100gets tightened with the control arm200with a slidable clearance therebetween.

At least one of the side segments104,105is provided with a pointer114(depending upon on which side of the arm body202the scale207is located). The control arm200is provided with the scale207marked thereon for measuring the particular suspension angle using the pointer114. Initially, the pointer114is set by the manufacturer as per the initial length of the arm. The pointer114changes position if the control arm length is changed using the adjuster206. The pointer114moves towards positive-integers representing a longer arm if the control arm200is moved in the positive direction using the adjustment mechanism205. The pointer114moves towards the negative integers representing a shorter arm if the control arm200is moved in the negative direction using the adjustment mechanism205.

In an embodiment as shown inFIG.4, at least one of the side segments104,105is provided with a ball-point or ball joint115. The ball-point115is an extended protrusion extending from the side surface of the side segment104as seen inFIG.4. The ball-point115of the bracket100is operationally connected to the height sensor assembly of the vehicle for facilitating the height adjustment of the vehicle and to maintain a level setting for all four corners of the vehicle. To maintain accuracy and calibration of the ride height sensor assembly, it is necessary to maintain the same distance between the sub frame assembly of the vehicle and the ball point115of the bracket. When the length of the control arm200is adjusted using the adjuster206, the bracket100maintains the preset ball-point/joint position accordingly so that the ride height sensor is not affected from the change in control arm length. Due to the positioning of the ball point/joint115, the distance between the sub frame assembly and the ball-point115is always maintained constant even if the particular suspension angle gets adjusted by rotating the adjuster.

In one more embodiment of the present invention, not shown, the bracket is provided with a ring, a connecting segment, and a side segment. The side segment has a pointer that points to an integer on the scale207representing control arm length and particular suspension angle of the wheel as marked on the control arm scale.

For coupling the bracket100to the control arm200, the rings101,102of the bracket100are configured around the outer sleeve of the bushing203, and fastened using the fasteners210through the holes of the ring ends108,109as best shown inFIG.6. At next step, the connecting segment103is rotated until the slots112,113of the side segments105and,104respectively get overlap with the holes110, and111on the side surfaces of the control arm200. At the next step, after the control arms are installed in the vehicle, the length of the control arm200is adjusted by rotating the adjuster206in the required direction, until the required particular suspension angle is achieved by using traditional alignment equipment. The user has the ability to set multiple alignment settings by recording the scale positions in each alignment setting. These settings can then be recalled or reset at a later time without traditional alignment equipment by referring to the noted scale settings. This is matched on the scale207using the pointer114to get the wheel position with the required particular suspension angle. Next, the free end of the bracket100is fitted with the control arm200using the fastener209by passing through slots112,113, and the hole of the control arm200such that the bracket100is slidable therein. For measuring the particular suspension angle, the user needs to look at the integer pointed by the pointer114.

For removing the bracket100, the user needs to remove the fasteners209,210that hold the bracket100over the control arm200. At the next step the connecting segment103is rotated against the control arm200. At the final step, the rings101,102are removed from the bushing203.

In some other embodiment, the bracket100may be designed without the ball point115for use with vehicles that don't make use of the height sensor assembly as shown inFIG.5, but can still make use of the alignment scale functionality.

Although the bracket100is shown here to be designed in some form, it should be understood that the bracket may be customized in many different forms to make it suitable for the adjustable control arm200or control arms available in the market. One such bracket design may just include only one side of the bracket100and would fit onto the bushing end203of the control arm200at just one side of the arm200.

The above-described embodiment of the present invention has the advantage of providing the bracket100that allows the user to recall the particular suspension angle without using metal square or camber gauges. The bracket100adjusts the suspension angle manually without affecting the distance between the height sensor assembly and/or the subframe assembly of the vehicle and the ballpoint115of the bracket100is operationally connected to the height sensor assembly for maintaining proper calibration of the height sensor. Basically, the ball point115remains located at a fixed location with respect to the ride height sensor, while the arm body202makes a movement in a forward or backward direction when the control arm's200length is adjusted by the user using the hex head206e.

Referring now toFIGS.8-18andFIGS.19A-19B, a second embodiment of the control arm200is shown without the bracket100. The mechanics of the bracket100particularly the ball point115that connects to the height sensor assembly of the vehicle is made part of the arm body202and yet the control arm200is made to remain adjustable in nature without compromising the accuracy of the particular suspension angle measurement and adjustment. Further, in contrast to the embodiment described inFIGS.1-7, the adjuster206in this embodiment is customized such that it eliminates use of multiple clamping means. Additionally, the adjuster202in this embodiment is customized such that when the adjuster206is adjusted or rotated, it is just the adjuster206that makes linear backward and forward movement based on positive or negative movement which is in contrast to the control arm200embodiment described inFIGS.1-7in which when the user manipulates the adjuster206, the adjuster206as well as the rod end201both makes a linear movement, which all will be described in the description to follow.

Most of the components of the alternative embodiment of the control arm200represented inFIGS.8-18,19A-19Bare identical to the components and their functionality shown and described with respect toFIGS.1-7, therefore, the applicant would omit to describe the like components (having like reference numbers) and their function from the description of the alternative embodiment. For example, the control arm200ofFIGS.8-11also includes an arm body202, a rod end201, a first bushing203, a second bushing204, and a control arm length adjusting mechanism205comprising at least an adjuster206. However, the use of bracket100comprising a ball point115is eliminated from this particular embodiment. Rather, in this embodiment, a new ball115, a scale207, and an adjuster206design proposition are shown embodied in the control arm200.

The applicant will herein try to highlight the features embodied in the embodiment illustrated inFIGS.8-18,19A-19Bapart from the embodiment described above.

The rod end201of the control arm200ofFIGS.8-18,19A-19B, particularly the threading201con the shaft201bare made circular (FIGS.16A and16C) in nature in contrast to the spiral threading in the embodiment described inFIGS.1-7. The circular threading201cprovided at the rod end201of this embodiment restricts the motion of the rod end201back and forth with the adjuster206, as was the case in the embodiment inFIGS.1-7. This feature of rod end201threading being circular allows just the adjuster and connected slider assembly303to move. To complement to the circular threading201cof the rod end201, the internal threading206a′ of the adjuster is suitably configured with increasing depth for the threading from the end206bto the end206cas seen inFIG.17C. This allows the adjuster206to expand to receive the rod end while the rod end201is totally engaged within the adjuster206.

The control arm200ofFIGS.8-18,19A-19Bshows a rubber boot206hconfigured around the adjuster600rather than leaving the adjuster206exposed to the external environment as shown inFIGS.1-7. Particularly, the rubber boot206his hollow and flexible and configured to prevent the water from getting into the control arm200. Along with the increase and decrease in the length of the control arm200, the rubber boot206halso expands and contracts.

Additionally, the control arm200shown inFIGS.8-9just makes use of one clamping element202din contrast to the uses of the clamping elements202dand205aas shown and described with respect toFIGS.1-7.

Further, as best seen inFIGS.14A-14B, the adjuster206in this embodiment comprises a groove206iformed all around the circumference of the adjuster206in proximity to the second end206c. Also, unlike, the plurality of slits or cutouts206dthat extend partially along the length starting at the first end206bof the adjuster206, the slits or cutouts206dare shown to extend along the entire length of the adjuster206from the first end206bto the second end206c. In an example, the number of slits206dis shown to be four, however, one should understand that any other number of slits may be made for the invention to function.

Further, as an essence of this embodiment and to eliminate the use of bracket100, the control arm200includes a slider assembly300that operationally engages within the groove206iof the adjuster206as best seen inFIGS.14A-14B. As seen inFIG.10, the slider assembly300includes a ball cover or face plate302, a ball115, a ball plate303, a ball plate gasket304, a Teflon (PTFE) layer305for the ball plate303to attach on it. All of these components are assembled together as a single unit, and aligned and housed within a cutout opening202econfigured on the arm body202and secured therein using a set of screws306that passes through holes202g. The ball115is fixedly mounted on the ball plate303as seen inFIG.14B. The ball plate303of the slider assembly300includes a protrusion303aextending away from the plate303and oriented at an angle. In another embodiment, a portion of the ball plate303may be cut partially at its extreme end and the cut end may be bent at an angle to form the plate303as illustrated in the accompanying figures. The plate303and the extending protrusion303amay be made as one unit using a single metal sheet or may be configured as two pieces and welded together. This angled protrusion303ais received within the groove206iof the adjuster206by passing through another cutout opening202flocated within the cutout opening202e. The angled protrusion303aof the ball plate303is limited to movement along the length of the cutout opening202f. When the adjuster206is manipulated by a user to vary the particular suspension angle, along with the movement of adjuster206, the slider assembly also moves backward or forward and the movement or sliding of the slider assembly is limited to the length of slots302a304aformed on the face plate302and the ball plate gasket304. The ball115on the ball plate303slides or moves within the slots302a304adepending upon the positive or negative movement of the adjuster206.

Additionally, in the embodiment shown inFIGS.8-18and19A-19B, the scale207instead of being a simple marking on the side surface of the control arm200is assembled together with the arm body202and is operationally coupled to the adjuster206just like the slider assembly300. The scale207according to this embodiment and shown inFIGS.14A-14B,15A-15b, and18includes a housing401, a rack402, a needle404, a pointer shaft410, a pinion407, a lower cover408, a top cover406, o rings405,411, bottom gasket409, fasteners412, and a dial plate403. All of the components of the scale207are assembled together as single unit and fastened onto the arm body202using fasteners412. When all the components are assembled together to form the scale, teeth407aof the pinion407engage with the teeth402bof the rack402. Further, a protrusion402aextending from the rack402engages within the groove206iof the adjuster206. In operation, when the adjuster206is rotated to move back and forth, the rack402makes a linear movement, the pinion407engaged with the rack402rotates rotating the pointer shaft410and in turn the needle404connected thereto. The needle's404reading is read against the markings on the dial plate403to know the control arm length and corresponding particular suspension angle or to adjust the adjuster. The scale207as seen is an analog scale just like mechanical analog watches or clocks. In an exemplary non-limiting embodiment of the present invention, the scale207has positive and negative integers each marked on either side of ‘0’. In an example as shown, the scale207may range from (+15) mm-0-(−15) mm. Initially, the particular suspension angle (For example, camber angle) is pre-set by the manufacturer preferably to ‘0’. The positive integers represent lengthening the arm beyond the factory length and negative integers represent shortening the arm beyond factory length. The zero represents the equal length to the factory control arm length.

In another embodiment, it may be possible to read/sense the need404positions on the dial plate403(using appropriate position or other similar proximity sensors) and transfer (using some communication module such as Bluetooth, WiFi etc) the sensed data remotely to a computer or handheld device for display.

In yet another embodiment, it may be possible, the control arm200may be embodied with electronic circuitry having at least one or more sensors, a laser emitter, a communication module (Such as Bluetooth, WiFi), one or more processors/microcontrollers and so on. The laser emitter may be embedded into the arm and adapted to emit the laser towards the rod end and/or the adjuster and the reflected laser beam may be analyzed to determine the suspension angle or distance moved or length of the arm or adjuster or determine the position of the adjuster by position sensor/proximity sensor and the same may be displayed remotely on handheld devices such as smartphone or computers.

It should be understood according to the preceding description of the present invention that the same is susceptible to changes, modifications and adaptations and that the said changes, modifications and adaptations fall within scope of the appended claims