DESC:FORM 2
The Patent Act 1970
(39 of 1970)
&
The Patent Rules, 2005

COMPLETE SPECIFICATION
(See Section 10 and Rule 13)

TITLE OF THE INVENTION
“SPLIT TYPE BRAKING SYSTEM FOR A VEHICLE”

Endurance Technologies Limited
E-92, M.I.D.C. Industrial Area, Waluj,
Aurangabad – 431136, Maharashtra, India

The following specification particularly describes and ascertains the nature of this invention and the manner in which it is to be performed
Field of Invention

[001] The present invention is related to a braking system for a vehicle. More particularly, the present invention is related to a split-type braking system for a modular vehicle i.e. a two-wheeler (scooter) convertible into three wheeler and vice-versa depending on the user requirement addressing the braking solution for modular mobility.

Background of the Invention

[002] Two-wheeled vehicles are typically utilized for personal needs and the delivery of goods like food and parcels in the developing countries. These two-wheeled vehicles do not serve the same purpose as that of the three-wheeled vehicles in terms of number of passenger and the transportation of goods. There may be situations for the vehicle owners wherein the user might require to use the two wheeled vehicle and in other situation the user might require the use of the three wheeled vehicle depending on the number of passengers and/or the goods to be transported. Therefore, these situations require to maintain two types of vehicles at user’s end to address the situational requirement viz. the two wheeler and the three wheeler as well.

[003] To overcome this hefty requirement of maintaining two types of vehicles, the researchers have developed a modular vehicle that can be easily and quickly convertible from a two-wheeled vehicle to a three-wheeled vehicle and vice versa according to the requirement of the user. In this, a latching mechanism facilitates the detachable coupling of a body frame of the two-wheeled vehicle to a body frame of the three-wheeled vehicle to convert the two-wheeled vehicle to a three-wheeled vehicle and vice versa according to the requirement of the user. In the two-wheeled mode, the user may use it for personal work, food delivery, transportation of two riders, etc. In case of three-wheeled mode, the user may use as a passenger vehicle for carrying more number of passengers and/ or a goods carrier for the transportation of goods at distant places.

[004] Conversion of the vehicle from two wheeled vehicle mode to three wheeled vehicle mode requires incorporation of the technical challenges such as a common braking system for both modes. Currently, a brake lever on the left side of the handlebar is used to control the two-wheeled vehicle's rear wheel, while the brake lever on the right side of the handlebar is used to control the two-wheeled vehicle's front wheel. Similar braking systems are used for the modular vehicle that convertible from a two-wheeled vehicle to a three-wheeled vehicle and vice versa. The above-mentioned braking system is effective in only when the vehicle is in two-wheeled condition, but not effective in three-wheeled condition because such a vehicle is used for transporting goods and passengers.

[005] Therefore, there is a long pending unmet need to provide an intelligent solution that will ensure effective braking in both cases whether the vehicle is in two-wheeled mode or three-wheeled mode.

Objectives of the Present Invention

[006] The main objective of the invention is to provide a split-type braking system for a modular vehicle i.e. a two-wheeler (scooter) convertible into three wheeler and vice-versa.

[007] Another objective of the present invention is to provide a split type braking system operable in a single loop imparting an effective braking performance when the two-wheeled vehicle is converted to three-wheeled mode.

[008] Another objective of the present invention is to provide a split type braking system having a uniquely designed actuator assembly configured to prevent the repetition of brake bleeding operation when the vehicle is converted into three wheeled mode.

[009] Still, the objective of the present invention is to provide a split type braking system with an actuator assembly that significantly aids in reducing the brake actuation effort by the user.

[0010] Still, the objective of the present invention is to provide a split type braking system having a coupling unit which connects the actuator assembly with a master cylinder assembly making a single loop and easy to operate braking system for a modular (convertible) vehicle.

[0011] Yet the objective of the present invention is to provide a split type braking system having a coupling unit which is very simple to engage and disengage the actuator assembly with a master cylinder assembly during conversion of a two-wheeled vehicle into a three-wheeled vehicle and vice versa.

[0012] Yet the objective of the present invention is to provide a cost effective solution and simpler design of a split type braking system for a modular vehicle i.e. a two-wheeler (scooter) convertible into three wheeler and vice-versa.
Brief Description of the Drawings

[0013] This invention is illustrated in the accompanying drawings, throughout which like reference letters / numerals indicate corresponding parts in the various figures. The embodiment/s herein and advantages thereof will be better understood from the following description when read with reference to the following drawings, wherein

[0014] Figure 1 presents the layout of a split type braking system in engaged condition for a modular vehicle (i.e. when the two-wheeled vehicle is converted to three-wheeled vehicle) in accordance with the present invention.

[0015] Figure 2 presents the layout of a split type braking system in disengaged condition for a modular vehicle i.e. when said modular vehicle is working as a two-wheeled vehicle as per the present invention.

[0016] Figures 3 and 4 present the sectional view of the actuator assembly in non-working and working condition, respectively in accordance with the present invention.

[0017] Figure 5 presents an isometric view of the actuator assembly in accordance with the present invention.

[0018] Figures 06 and 07 present the views of the actuator assembly and master cylinder assembly in disengaged and engaged condition, respectively in accordance with the present invention.

Detailed Description of the Present Invention

[0019] The invention will now be described in detail with reference to the accompanying drawings which must not be viewed as restricting the scope and ambit of the invention. Referring to Figs. 1 and 2, a split-type braking system (1000) for a modular vehicle i.e. a two-wheeler (scooter) convertible into three wheeler and vice-versa is disclosed. The modular vehicles are convertible from a two-wheeled vehicle to a three-wheeled vehicle and vice versa. A latching mechanism or any suitable coupling mechanism (not shown) facilitates detachable coupling of a body frame of the two-wheeled vehicle to a body frame of the three-wheeled vehicle so as to convert the two-wheeled vehicle to a three-wheeled vehicle and vice versa according to the requirement of the user.

[0020] Referring to Figs. 1 and 2, the split type braking system (1000) of the modular vehicle comprises of two braking assemblies (500A and 500B). The braking assembly (500A) is assembled on the two-wheeled vehicle and comprises of a rear brake lever (100) on the left side of the handlebar, a front brake lever (200) on the right side of the handlebar, a first master cylinder assembly (100M), a second master cylinder assembly (200M), a third master cylinder assembly (215), a front brake caliper (205), a plurality of hydraulic lines (110), a rear wheel brake (115) and a front wheel brake (210).

[0021] The rear brake lever (100) is in communication with the first master cylinder assembly (100M) mounted on the handle bar along with the rear brake lever and the said first master cylinder assembly (100M) is in hydraulic communication with the rear wheel brake (115) through the hydraulic line (110). The front brake lever (200) is in communication with the second master cylinder assembly (200M) mounted on the handlebar along with the front brake lever and the said second master cylinder assembly (200M) is hydraulically connected to the front brake caliper (205). Further, the brake caliper assembly (205) is configured to apply brake force on a brake disc (210) of the front wheel of the vehicle.

[0022] The brake caliper assembly (205) is configured to have two inputs ports (205a and 205b). The input port (205a) of the brake caliper assembly (205) is in hydraulic communication with the front brake lever (200) via hydraulic line (110) and is configured to have one working piston. The input port (205b) of the caliper assembly (205) is in communication with the third master cylinder assembly (215) and is configured to have two working pistons which is used to exert more braking force with consistent and uniform brake force distribution.

[0023] When the front brake lever (200) is actuated, the input port (205a) of the caliper assembly (205) comes into the action to apply braking force to the brake disc (210) of the front wheel brake. In this condition of two-wheel mode of the modular vehicle, the input port (205b) of the caliper assembly (205) which is in communication with the third master cylinder assembly (215) remains inactive (idle). The third master cylinder assembly (215) is configured to have a mechanical input/pushrod (215a) and a hydraulic output (215b). The said mechanical input (215a) is detachably coupled with the braking assembly (500B) when the two-wheeled vehicle is converted into the three-wheeled vehicle. The hydraulic output (215b) of the said third master cylinder assembly (215) is in communication with input port (205b) of the caliper assembly (205) via hydraulic line (110). Further, the third master cylinder assembly (215) has a hydraulic reservoir, which is connected to a cylinder of the master cylinder assembly (215) via an inlet valve and supplies brake fluid into the third master cylinder assembly (215). The said third master cylinder assembly (215) is non-functional when the said modular vehicle is in two-wheeled mode.

[0024] The braking assembly (500B) of the split type braking system (1000) assembled on the frame of the three wheeled vehicle and comprises of a brake pedal (300), a tandem master cylinder assembly (310), an actuator (400), a coupling unit (220), a junction box (315), and a pair of rear wheel brakes (320L and 320R). The brake pedal (300) is pivoted on the vehicle body and is mechanically connected to a pushrod (305) of the tandem master cylinder assembly (310).

[0025] The tandem master cylinder assembly (310) has two outlet ports (310a and 310b) and an inlet port (not shown in the figure). The inlet port is in hydraulic communication with the fluid reservoir so as to maintain the brake fluid flow during its operational condition. The outlet port (310a) of the tandem master cylinder assembly (310) is hydraulically connected to an input port (400a) of the actuator (400) through the hydraulic line (110); and the outlet port (310b) of the tandem master cylinder assembly (310) is hydraulically connected to the junction box (315) through the hydraulic line (110). Further, the said junction box (315) is configured to have a hydraulic communication with the rear wheel brakes (320L and 320R) via hydraulic lines (110).

[0026] Referring to Figs. 3 and 4, said actuator (400) has a body portion (410) and said body portion has a cylindrical chamber (410C) bored therein. The actuator (400) is mounted suitably on the body frame of the three-wheeled vehicle. The said cylindrical chamber (410C) is filled with working fluid therein and said cylindrical chamber / working chamber (410C) of the actuator (400) is in hydraulic communication with the tandem master cylinder assembly (310) through an input port (400a) of a banjo bolt (415) via hydraulic line (110). The cylindrical chamber (410C) of the actuator (400) houses a piston (420) in such a way that it divides the cylindrical chamber into two working chambers (410C1 and 410C2), where the chamber (410C1) is a fluid chamber filled with working fluid and the chamber (410C2) is a spring chamber which accommodates a spring (430).

[0027] The piston (420) is fitted to the one end of the push rod (450) and other end (free end) (FE) of the push rod (450) passes out through the opening (P) of the spring chamber (410C2) of the cylindrical chamber (410C) of the actuator (400). The said free end (FE) of the push rod (450) gets coupled with the third master cylinder assembly (215) through the detachable coupling unit (220) for transferring the mechanical output (400b) of the actuator (400) to the third master cylinder assembly (215). Said coupling unit (220) is selected from a pin type joint, a disc type engagement /disengagement, a push type coupling, a knuckle type coupling, a threaded stud, a male-female connection with lock, a push-button lock and a set of other positive locking system, etc.

[0028] Said opening (P) of the spring chamber (410C2) of the cylindrical chamber (410C) of the actuator (400) is closed by a cover (435) and said cover (435) is fitted with the body (410) of the actuator with the help of fastening means preferably selected from a plurality of screws (445). The cover (435) is configured to have a neck portion (435P) which works as a resting surface for a dust cover (440). The spring chamber (410C2) houses a piston spring (430) which rests against the bottom face of the piston and the inner face of the cover (435). The fluid chamber (410C1) has a bleeding passage (405B) and said passage is closed by a bleeder screw (405). The bleeding passage (405B) is provided with the bleeder screw (405) to remove the air from the fluid chamber (410C1) of the hydraulic actuator (400) and also it prevents the repetition of brake bleeding operation.

[0029] The said piston (420) is having a piston seal (425) to prevent the leakage of working fluid (oil) from fluid chamber (410C1) to spring chamber (410C2). Said piston seal (425) is configured to seal the gap between the outer peripheral surface of the piston (420) and the inner peripheral surface of the cylindrical chamber (410C) inside the actuator body (410) of the actuator (400). The said dust cover (440) is made of flexible rubber and is configured to prevent the ingression of foreign particles inside the hydraulic actuator body (410), where one end of said dust cover is fitted on the neck portion (435P) of the cover (435) and the other end is fixed on the push rod (450) via a positive fitting, where the positive fitting is selected from the group of an interference fitting, a push-fit, a clip-ring, an adhesive, etc.

[0030] When the two-wheeled vehicle is converted into the three-wheeled vehicle, the body frame of the two-wheeled vehicle is coupled with the body frame of the three-wheeled vehicle by the suitable latching mechanism. In this condition, the rear wheel of the two-wheeled vehicle is retracted above the ground and won’t be functional. The front wheel of the two-wheeled vehicle and the two rear wheels of the three-wheeled vehicle are only functional in this scenario of converting two wheeled vehicle to three wheeled vehicle. In this case, the braking assembly (500A) assembled on the two-wheeled vehicle gets engaged with the braking assembly (500B) assembled on the frame of three wheeled vehicles, where the free end (FE) of the push rod (450) of the actuator (400) of the braking assembly (500B) is mechanically coupled with the pushrod (215a) of the master cylinder assembly (215) of the braking assembly (500A) through the coupling unit (220) so as to make the positive connection between the actuator (400) mounted on the three wheeled vehicle body and the third master cylinder assembly (215) mounted on the two wheeled vehicle body and thereby form a single loop braking system (1000) for the modular vehicle. The coupling unit (220) is selected from a pin type joint, a disc type engagement /disengagement, a push type coupling, a knuckle type coupling, a threaded stud, a male-female connection with lock, a push-button lock and a set of other positive locking system, etc.

[0031] When the vehicle is in three-wheeled vehicle mode (as shown in Fig. 1), all the functional wheels (two rear wheels and one front wheel) are operated by the brake pedal (300) for its braking. When the user actuates the pedal (300), and the exerted force on the brake pedal pushes the pushrod (305) of the tandem master cylinder assembly (310). This movement of the pushrod (305) exerts the pressure on the fluid inside the tandem master cylinder assembly (310), and this pressurized fluid is transferred in the different hydraulic lines through the output ports (310a and 310b). The hydraulic line connected to the outlet port (310a) of the tandem master cylinder assembly (310) exerts the hydraulic pressure in the fluid chamber (410C1) of the actuator (400) which consequently pushes the piston (420) of the hydraulic actuator (400) against the piston spring (430) making the forward movement of the pushrod (450). When the pushrod (450) of the hydraulic actuator (400) moves in the forward direction, the pushrod (215a) of the master cylinder assembly (215) pushes the piston of the master cylinder assembly (215) generating hydraulic pressure therein. This hydraulic pressure makes the working fluid (oil) to flow to the brake caliper assembly (205) having two working pistons through the inlet port (205b) via the hydraulic line (110) to actuate the brake disc (210) of the front brake. In this condition, the inlet port (205a) and its loop with front brake lever (200) is non-functional (idle).

[0032] Simultaneously, the outlet port (310b) of the tandem master cylinder assembly (310) which is hydraulically connected to the junction box (315), transfers the hydraulic pressure inside the junction box (315) through the hydraulic line (110). Further, the said junction box (315) transfers the hydraulic pressure to the rear wheel brakes (320L and 320R). In this case, the rear brake lever (100) mounted on the handlebar and its associated loop leading to the rear brake of two wheeler is non-functional.

[0033] When the three-wheeled vehicle is converted into the two-wheeled vehicle, the body frame of the two-wheeled vehicle is detached from the body frame of the three-wheeled vehicle. In this case, the push rod (450) of the actuator (400) of the braking assembly (500B) which is mounted on the body frame of the three-wheeled vehicle will be de-coupled from the pushrod (215a) of the master cylinder assembly (215) of the braking assembly (500A) which is mounted on the body frame of the two-wheeled vehicle.

[0034] In case of the two-wheeled vehicle mode (refer Fig. 2), the user actuates the brake lever (100) which is mounted on the left side of the handlebar and then the mechanical force of the brake lever (100) is converted to the hydraulic pressure by the master cylinder assembly (100M). The generated hydraulic pressure is transferred to the rear brake (115) by the hydraulic line (110) and actuates the brake in the rear wheel. When the user needs to apply the brake in the front wheel, the user will actuate the right-hand brake lever (200) and then the mechanical force of the brake lever (200) is converted to the hydraulic pressure by the master cylinder assembly (200M). The generated hydraulic pressure is transferred to the first input (205a) of the caliper assembly (205) body where one piston is working. The hydraulic pressure inside the caliper assembly (205) actuates the piston and exerts a braking force on the brake disc (210) of the front wheel. In this case, the second input (205b) of the caliper assembly (205) body having two working pistons and its hydraulic connection with the third master cylinder assembly (215) is non-functional.

[0035] The system and method of the present invention in accordance with the discussed embodiment provide the following technical advantages that contribute to the technological advancement of the split type of single brake circuit for two-wheeled cum three-wheeled vehicles:
- The split type braking system is very compatible and effective for the modular vehicle i.e. two-wheeled vehicle converted to the three-wheeled vehicle and vice-versa.
- The braking system of the present invention is provided with a hydraulic actuator which has a bleeding screw that prevents the repetition of brake bleeding operation.
- The proposed invention provides a mechanical coupling of a hydraulic actuator and a master cylinder assembly which makes the decoupling operation very easy and smooth.
- The proposed invention does not require any skilled person for coupling and decoupling of braking assemblies (500A and 500B) of split braking system of the modular vehicle.
- The proposed invention reduces the brake pedal effort by increasing/decreasing the piston size of the hydraulic actuator.
- The proposed invention provides a cost effective solution and simpler design of a split type braking system for a modular vehicle.

[0036] The foregoing description of the specific embodiment of the invention will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.
,CLAIMS:We Claim

1. A split type braking system (1000) a modular vehicle comprising of a braking assembly (500B), a braking assembly (500A) and a coupling unit (220)
wherein,
- the braking assembly (500B) is configured to comprise of an actuator (400), a brake pedal (300), a tandem master cylinder assembly (310), a junction box (315), a plurality of hydraulic lines (110) and a pair of rear wheel brakes (320L and 320R);
- the braking assembly (500A) is configured to comprise of a rear brake lever (100) on the left side of the handlebar, a front brake lever (200) on the right side of the handlebar, a first master cylinder assembly (100M), a second master cylinder assembly (200M), a third master cylinder assembly (215), a front brake caliper (205), a plurality of hydraulic lines (110), a rear wheel brake (115) and a front wheel brake disc (210);
- said braking assembly (500B) is detachably coupled with the third master cylinder assembly (215) of the braking assembly (500A) through the coupling unit (220) for transferring the mechanical output (400b) of the actuator (400) to the third master cylinder assembly (215); and
- said coupling unit (220) is selected from a pin type joint, a disc type engagement /disengagement, a push type coupling, a knuckle type coupling, a threaded stud, a male-female connection with lock, and a push-button lock to have positive locking.

2. The split type braking system (1000) as claimed in claim 1, wherein
- the actuator (400) is configured to have a body portion (410) and said body portion has a cylindrical chamber (410C) bored therein;
- said cylindrical chamber (410C) of the actuator (400) houses a piston (420) and said piston (420) is configured to divide the cylindrical chamber (410C) into two working chambers (410C1 and 410C2);
- the chamber (410C1) is a fluid chamber and is filled with working fluid (oil), and the chamber (410C2) is a spring chamber and is configured to accommodates a spring (430);
- said fluid chamber (410C1) is configured to have a bleeding passage (405B) and said passage (405B) is closed by a bleeder screw (405); and
- said cylindrical chamber / working chamber (410C) of the actuator (400) is in hydraulic communication with the tandem master cylinder assembly (310) through an input port (400a) of a banjo bolt (415) via hydraulic line (110).

3. The split type braking system (1000) as claimed in claim 2, wherein
- the piston (420) is fitted to one end of a push rod (450) and other end (free end) (FE) of said push rod (450) is configured to pass through an opening (P) of the spring chamber (410C2) in the cylindrical chamber (410C) of the actuator (400); and
- said free end (FE) of the push rod (450) is configured to get coupled with the third master cylinder assembly (215) through the detachable coupling unit (220).

4. The split type braking system (1000) as claimed in claim 3, wherein
- the opening (P) of the spring chamber (410C2) in the cylindrical chamber (410C) of the actuator (400) is closed by a cover (435) and said cover (435) is fitted with the body (410) of the actuator (400) with the help of fastening means selected from screws (445);
- the spring chamber (410C2) is configured to house a piston spring (430) and said spring (430) rests against the bottom face of the piston (420) and the inner face of the cover (435); and
- said cover (435) has a neck portion (435P) which is configured to provide a resting surface for a dust cover (440).

5. The split type braking system (1000) as claimed in claim 4, wherein
- the piston (420) is configured to have a piston seal (425) to seal the gap between the outer peripheral surface of the piston (420) and the inner peripheral surface of the cylindrical chamber (410C) inside the actuator body (410) of the actuator (400) and thereby prevent the leakage of working fluid (oil) from fluid chamber (410C1) to spring chamber (410C2); and
- the dust cover (440) is made of flexible rubber wherein one end of said dust cover (440) is fitted on the neck portion (435P) of the cover (435) and the other end is fixed on the free end (FE) of the push rod (450) by a positive fitting selected from an interference fitting, a push-fit, a clip-ring, and an adhesive so as to prevent the ingression of foreign particles inside the hydraulic actuator body (410).

6. The split type braking system (1000) as claimed in the preceding claims, wherein
- the rear brake lever (100) is in communication with the first master cylinder assembly (100M) mounted on the handlebar of a vehicle and said first master cylinder assembly (100M) is in hydraulic communication with the rear wheel brake (115) through the hydraulic line (110);
- the front brake lever (200) is in communication with the second master cylinder assembly (200M) mounted on the handlebar of a vehicle and said second master cylinder assembly (200M) is hydraulically connected to the front brake caliper (205); and
- said brake caliper assembly (205) is configured to exert braking force on the brake disc (210) of the front wheel of the vehicle.

7. The split type braking system (1000) as claimed in claim 6, wherein
- the brake caliper assembly (205) is configured to have two inputs ports (205a and 205b);
- the input port (205a) of the brake caliper assembly (205) is in hydraulic communication with the front brake lever (200) via hydraulic line (110) and is configured to have one working piston; and
- the input port (205b) of the caliper assembly (205) is in communication with the third master cylinder assembly (215) and is configured to have two working pistons to exert consistent and uniform brake force.

8. The split type braking system (1000) as claimed in claim 7, wherein
- the third master cylinder assembly (215) is configured to have a mechanical input/pushrod (215a) and a hydraulic output (215b);
- the said mechanical input (215a) is detachably coupled with the braking assembly (500B) when the two-wheeled vehicle is converted into the three-wheeled vehicle;
- the hydraulic output (215b) of the said third master cylinder assembly (215) is in communication with input port (205b) of the caliper assembly (205) via hydraulic line (110);
- the third master cylinder assembly (215) has a hydraulic reservoir which is connected to a cylinder of the master cylinder assembly (215) via an inlet valve to supply brake fluid into the third master cylinder assembly (215); and
- said third master cylinder assembly (215) is configured to be non-functional when the said modular vehicle is in two-wheeled mode.

9. The split type braking system (1000) as claimed in claim 8, wherein
- the brake pedal (300) of the braking assembly (500B) is pivoted on the vehicle body and is mechanically connected to the pushrod (305) of the tandem master cylinder assembly (310);
- said tandem master cylinder assembly (310) is configured to have two outlet ports (310a and 310b) and an inlet port;
- the outlet port (310a) of the tandem master cylinder assembly (310) is hydraulically connected to an input port (400a) of the actuator (400) through the hydraulic line (110); and the outlet port (310b) of the tandem master cylinder assembly (310) is hydraulically connected to the junction box (315) through the hydraulic line (110); and
- said junction box (315) is configured to have a hydraulic communication with the rear wheel brakes (320L and 320R) via hydraulic lines (110).

Dated this 9th day of July 2024

Sahastrarashmi Pund
Head – IPR
Endurance Technologies Ltd.

To,
The Controller of Patents,
The Patent Office, at Mumbai