Description:FORM 2

THE PATENTS ACT, 1970
(39 of 1970)
&
The Patents Rules, 2003

COMPLETE SPECIFICATION
(See Section 10 and Rule 13)

A BRAKE ASSEMBLY FOR A VEHICLE

APPLICANT:

TVS MOTOR COMPANY LIMITED, an Indian Company at: “Chaitanya”, No.12 Khader Nawaz Khan Road, Nungambakkam, Chennai 600 006.

The following specification particularly describes the invention and the manner in which it is to be performed.

 
TECHNICAL FIELD
[0001] The present subject matter relates generally to a brake assembly of a vehicle. More particularly but not exclusively, the present subject matter relates to a drum brake assembly of a two or three wheeled vehicle.

BACKGROUND
[0002] Conventionally, for two or three wheeled vehicles, four bar linkage mechanism is used in drum brake system that include brake pedal, brake rod, cam lever and vehicle frame member on which the cam lever is pivotably mounted. When brake pedal is pressed, a force/movement is transmitted to brake shoe through the brake rod, cam lever and the revolute joints between them. Over a period of time, due to wear and tear, the usage leads to free play of the brake pedal. The free play of brake pedal therefore has to be adjusted for effective transmission of force from the brake pedal to the brake shoe in the brake assembly. Conventionally, this free play is adjusted by an adjuster nut which is threaded in the brake rod at the location where the brake rod is connected to the cam lever.
[0003] Further, in conventional two-wheeled vehicles, the free play/wear has to be adjusted manually by either the rider or the mechanic. The nut is adjusted manually which moves the cam lever along the length of the connecting rod using the adjuster nut. This adjustment is done to reduce the extra free play and achieve the appropriate free play.
[0004] In the absence of this adjustment, the effectiveness of brake system is reduced. Also, the manual adjustment of free play may vary from person to person which further leads to drop is braking performance. It has been observed the manual adjustment is not accurately done by the users. Since, the manual adjustment is not correctly or accurately done by the user, this could lead to the adjuster nut being over tightened and then the brake shoe may contact the brake drum even when brake lever is released. This leads to more wear of the brake assembly.
[0005] Also, in SBS (synchronous braking system), single brake lever is connected to both front and rear brakes, wherein upon the application of the brake lever the brakes get actuated in synchronous way in both front and rear brakes. If free play is higher in one of the brakes (either front or rear), then SBS may not be effective.
[0006] Therefore, it is critical to provide a brake assembly that provides an automatic wear adjustment mechanism that not only avoids manual adjustment but also address the above-mentioned problems.

BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The details are described with reference to an embodiment of a brake assembly along with the accompanying figures. The same numbers are used throughout the drawings to reference similar features and components.
[0008] Figure 1a and 1b illustrate, respectively, a side and perspective views of the brake assembly of a vehicle in one embodiment of the invention. Figure 1c and 1d 1b illustrate, respectively, a side and perspective views of the brake assembly of a vehicle without the first lever according to one embodiment of the invention.
[0009] Figure 2 illustrates a perspective view of a close up of the brake assembly in one embodiment of the invention.
[00010] Figure 3 illustrates a side view of a close up of the brake assembly of the vehicle in one embodiment of the invention without the first lever.
[00011] Figure 4 illustrates a perspective view from a direction opposite to that in Figure 3 of the brake assembly of the vehicle in one embodiment of the invention without the first lever.
[00012] Figure 5 illustrates a bottom view of the brake assembly of the vehicle in one embodiment of the invention without the first lever.
[00013] Figure 6 illustrates an exploded view of the brake assembly of the vehicle in one embodiment of the invention without the first lever.
[00014] Figure 7 illustrates a magnified perspective view of the brake assembly of the vehicle in one embodiment of the invention showing a predetermined clearance between a first rotating member and a second rotating member.
[00015] Figure 8 illustrates another magnified view of the predetermined clearance between the first rotating member and the second rotating member of the brake assembly of the vehicle in one embodiment of the invention from a direction opposite to that in Figure 7.

DETAILED DESCRIPTION
[00016] In order to achieve one or more of the above-mentioned objectives and other related objectives, the present invention provides a brake assembly for a two-or three wheeled vehicles.
[00017] As per one embodiment of the invention, a brake assembly for a vehicle is provided that comprises a first lever which is being configured to receive a braking force from a user of the vehicle, the first lever is connected to a connecting member which further connects the first lever to a second lever. The second lever is pivotably connected to a brake shoe assembly. The second lever is configured to be pivoted by the connecting member upon application of the braking force. A brake adjuster member is attached to the connecting member. The brake adjuster member is being configured to adjust a pivot position of the second lever to adjust a free play between the connecting member and the first lever wherein the brake assembly includes a first rotating member which is operably connected to the brake adjuster member. The brake adjuster member is configured to be actuated upon a rotation of the first rotating member. The first rotating member is operably connected to the connecting member. The first rotating member is configured to be selectively rotated upon a motion of a second rotating member which is subjected to the satisfaction of a predetermined condition.
[00018] As per one embodiment of the invention, in the brake assembly, the predetermined condition is contact of the first rotating member with the second rotating member.
[00019] As per one embodiment of the invention, in the brake assembly, the first lever is a brake lever or a brake pedal being operated by a user of the vehicle.
[00020] As per one embodiment of the brake assembly, the connecting member is a brake rod or a brake cable.
[00021] As per one embodiment of the invention, in the brake assembly, the second lever includes a first end and a second end. The first end of the second lever is pivotably attached to the brake shoe assembly. The second end of the second lever is operatively connected to the connecting member.
[00022] As per one embodiment of the invention, in the brake assembly, the second end of the second lever includes a second lever opening. The second lever opening is configured to receive a support portion.
[00023] As per one embodiment of the invention, in the brake assembly, the connecting member includes a first end and a second end. The first end of the connecting member is being detachably attached to the first lever. And the second end of the connecting member is being received into a support opening of the support portion.
[00024] As per one embodiment of the invention, in the brake assembly, the second end of the connecting member protrudes through the support opening of the support portion. The brake adjuster member is rotatably attached to the protruding portion of the second end of the connecting member. The first rotating member is installed on the brake adjuster member. The brake adjuster member is configured to abut the second end of the connecting member.
[00025] As per one embodiment of the invention, in the brake assembly, the second rotating member is operably connected to the first rotating member. The second rotating member is being attached to the second lever. A motion of the connecting member causes relative motion between the second rotating member and the first rotating member.
[00026] As per one embodiment of the invention, in the brake assembly, the first rotating member is configured to rotate the brake adjuster member to automatically adjust a free play in the second lever and the connecting member upon wearing of a brake shoe in the brake shoe assembly beyond a predetermined level.
[00027] As per one embodiment of the invention, in the brake assembly, the first rotating member is press fitted over an anti-reverse bearing. The anti-reverse bearing is mounted over the brake adjuster member that ensures unidirectional rotation of the brake adjuster member by the first rotating member.
[00028] As per one embodiment of the invention, in the brake assembly, a clipper means is disposed between the anti-reverse bearing and the brake adjuster member.
[00029] As per one embodiment of the invention, in the brake assembly, the first rotating member and the second rotating member being bevel gears include teeth on the outer circumference of the first rotating member and the second rotating member. The first rotating member and the second rotating member are being configured with a predetermined clearance between teeth of the first rotating member and the second rotating member.
[00030] As per one embodiment of the invention, in the brake assembly, the second rotating member is fixedly attached to the second lever.
[00031] As per one embodiment of the invention, in the brake assembly, the predetermined clearance is in a range of 3 degrees to 15 degrees.
[00032] As per one embodiment of the invention, in the brake assembly, a number of the teeth on the first rotating member and the second rotating member ranges from 4 to 15.
[00033] The embodiments of the present invention will now be described in detail with reference to an embodiment in a brake assembly of a vehicle along with the accompanying drawings. However, the disclosed invention is not limited to the present embodiments.
[00034] Figure 1 illustrates various side and perspective views of the brake assembly 200 including a first lever 101F in one embodiment of the invention. In the embodiments shown in Fig. 1a and Fig. 1b, the brake assembly 200 have the first lever 101F in the form of a foot operated brake lever. The embodiments shown in Fig. 1c and Fig. 1d show the brake assembly 200 without the first lever 101F. The first lever 101F is configured to receive the braking force by a user of the vehicle. In this aspect the brake assembly 200 being shown is a drum brake assembly being installed in a hub of rear wheel of a two or three wheeled vehicle. A skilled person would appreciate that the same configuration can be achieved in other types of vehicles like four wheelers and wheels other than the rear wheel. It is to be noted that the first lever 101F is not limited to the said instances as the same may vary upon the type of vehicle used and the procedure of applying brakes to slow down the speed of the vehicle. It may also be appreciated that the first lever 101F can also be a hand operated brake lever (not shown) in another aspect of the invention.
[00035] Figure 2 and Figure 3 illustrate perspective and side views respectively of a close up of the brake assembly 200 of the vehicle in one embodiment of the invention. Figure 2 and Figure 3 have been taken together for discussion. The second lever 101S is pivotably connected to a brake shoe assembly from a first end. The second lever 101S is configured to be pivoted by a connecting member 103 at its second end upon application of the brake force by the user. The second lever 101S is configured to have a pair of second lever openings 101Sop on its second end. The connecting member 103 is responsible for connecting the first lever 101F (shown in Fig. 1) to the second lever 101S. The connecting member 103 is a brake rod, in this embodiment, which is having a first end which is detachably attached to the first lever 101F. A second end of the connecting member 103 is received into a support opening 108op (shown in Fig. 6) of a support portion 108 (shown in Fig. 6). The second lever 101S is also operatively connected to the second end of the connecting member 103. However, the connecting member 103 is not limited to brake rod as it can also be deployed by means of brake cable or some ratchet mechanism.
[00036] Figure 4 illustrates a side perspective view of the brake assembly 200 of the vehicle in one embodiment of the invention. In the said embodiment, the brake assembly 200 have a pair of rotating members that includes a first rotating member 102F and a second rotating member 102S. The first rotating member 102F is operably connected to the connecting member 103. The first rotating member 102F is also configured to be selectively rotated upon a motion of the second rotating member 102S subject to satisfaction of a predetermined condition that involves a contact of the first rotating member 102F with the second rotating member 102S. The contact is caused due to motion of the connecting member that causes relative motion between the first rotating member 102F and second rotating member 102S. The second rotating member 102S is operably connected to the first rotating member 102F. The second rotating member 102S is attached to the second lever 101S. The first rotating member 102F and the second rotating member 102S, in this embodiment are bevel gears. It is also possible to realize the benefits of this invention using other types of rotating members including but not limited spur gears, cylindrical gears, worm gears, bevel gears. The first rotating member 102F and the second rotating member 102S include a predetermined clearance C (shown in Fig. 7 and 8) between teeth on their respective outer circumferences. The number of the teeth on the first rotating member 102F and the second rotating member 102S range from 4 to 15.
[00037] Figure 5 and Figure 6 illustrate a top and exploded view of the brake assembly 200 of the vehicle in various embodiments of the invention. Figure 5 and Figure 6 have been taken together for discussion. The first rotating member 102F is operably connected to a brake adjuster member 105. The brake adjuster member 105 is configured to be actuated upon a rotation of the first rotating member 102F. As already described, the first rotating member 102F is selectively rotated upon a motion of the second rotating member 102S. The said motion is subject to the satisfaction of a predetermined condition. The brake adjuster member 105 abuts the second end of the connecting member 104. The first rotating member 102F is configured to rotate the brake adjuster member 105 to automatically adjust a free play in the second lever 101S and the connecting member 103 upon wearing of a brake shoe in the brake shoe assembly beyond a predetermined level. The first rotating member 102F is press fitted over an anti-reverse bearing 107. The anti-reverse bearing 107 is mounted over the brake adjuster member 105 which ensures unidirectional rotation of the brake adjuster member 105 by the first rotating member 102F. The second end of the second lever 101S includes the second lever opening 101Sop which is configured to receive the support portion 108. Also, the second end of the connecting member 103 protrudes the support opening 108Sop of the support portion 108. The brake adjuster member 105 are rotatably attached to the protruding portion of the second end of the connecting member 103. A clipper means 106 is disposed between the anti-reverse bearing 107 and the brake adjuster member 105. The clipper means 106 aids in arresting looseness while holding the movement of anti-reverse bearing 107 during vibrations.
[00038] Figure 7 and Figure 8 illustrate expanded views of the predetermined clearance C between the first rotating member 102F and second rotating member of the brake assembly 200 of the vehicle in various embodiments of the invention. The predetermined clearance C between the teeth of the first rotating member 102F and the second rotating member 102S. The predetermined clearance C between the first rotating member 102F and the second rotating member 102S helps to avoid the movement of the brake adjuster member 105 (shown in Fig. 6) for small feed in the first lever 101F (shown in Fig. 1) or when there is no adjustment is required. The predetermined clearance C between the first rotating member 102F and the second rotating member 102S is designed such that the brake adjuster member 105 rotates when there is more in the brake shoes resulting in free play or more movement of the first lever 101F.
[00039] The predetermined clearance lies in the range of 3 degrees to 15 degrees. However, the same is not limited and may vary upon various manufacturing constraints.
[00040] The brake assembly described in the present subject matter is simpler and involves lesser number of parts, particularly those focused on the adjustment mechanism. Moreover, the simple brake assembly enables the compact rear wheel assembly of the two or three wheeled vehicle to become more compact. Further, the brake assembly of the present subject matter is reliable and optimally applies the actuation forces to both the front and the rear brake control cables with a predetermined ratio as it automatically adjusts the free-play (if any).
[00041] The automatic brake adjustment mechanism of the present brake assembly has enhanced reliability in terms of performance benefit and safety. Similarly, the automatic brake adjustment mechanism of the present brake assembly works only if free play exceeds a threshold value. Further, the brake adjustment mechanism eliminates the mechanical adjustment thereby no additional effort is required to precisely adjust the brakes. Furthermore, no special skills are required to precisely manually adjust the brakes as the system automatically adjusts the brakes.
[00042] The embodiments of this invention are not limited to particularly described brake assemnnly or systems and/or vehicles as the embodiments can vary and will be understood by skilled artisans to be implementing the single inventive concept. It is further to be understood that all terminology used herein is for the purpose of describing particular embodiments only, and is not intended to be limiting in any manner or scope. For example, as used in this specification and the appended claims, the singular forms “a,” “an” and ““they”” can include plural referents unless the content clearly indicates otherwise. Further, when introducing elements/components/etc. of the assembly/system described and/or illustrated herein, the articles “a”, “an”, “the”, and “said” are intended to mean that there is one or more of the element(s)/component(s)/etc. The terms “comprising”, “including”, and “having” are intended to be inclusive and mean that there may be additional element(s)/component(s)/etc. other than the listed element(s)/component(s)/etc.
[00043] This written description uses examples to provide details on the disclosure, including the best mode, and also to enable any person skilled in the art to practice the disclosure, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the disclosure is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.
[00044] It is to be understood that the aspects of the embodiments are not necessarily limited to the features described herein. Many modifications and variations of the present subject matter are possible in the light of above disclosure.

 
List of Reference numerals:

100 Vehicle
101F First lever
101S Second lever
101Sop Second lever opening
102F First rotating member
102S Second rotating member
103 Connecting member
105 Brake adjuster member
106 Clipper means
107 Anti-reverse bearing
108 Support portion
108op Support openings
200 Brake assembly
, Claims:We Claim:
1. A brake assembly (200) for a vehicle (100), the brake assembly (200) comprising:
a first lever (101F), the first lever (101F) being configured to receive a braking force from a user of the vehicle (100);
a connecting member (103), the connecting member (103) connecting the first lever (101F) to a second lever (101S), the second lever (101S) being pivotably connected to a brake shoe assembly, the second lever (101S) being configured to be pivoted by the connecting member (103) upon application of the braking force;
at least one brake adjuster member (105), the brake adjuster member (105) being attached to the connecting member (103), and the brake adjuster member (105) being configured to adjust a pivot position of the second lever (101S) to adjust a free play between the connecting member (103) and the first lever (101F);
wherein
the brake assembly (200) includes a first rotating member (102F), the first rotating member (102F) being operably connected to the brake adjuster member (105), the brake adjuster member (105) being configured to be actuated upon a rotation of the first rotating member (102F),
the first rotating member (102F) being operably connected to the connecting member (103), and the first rotating member (102F) being configured to be selectively rotated upon a motion of a second rotating member (102S) upon satisfaction of a predetermined condition.
2. The brake assembly (200) as claimed in claim 1, wherein the predetermined condition is a contact of the first rotating member (102F) with the second rotating member (102S).
3. The brake assembly (200) as claimed in claim 1, wherein the first lever (101F) being one of a brake lever or a brake pedal.
4. The brake assembly (200) as claimed in claim 1, wherein the connecting member (103) being one of a brake rod or a brake cable.
5. The brake assembly (200) as claimed in claim 1, wherein
the second lever (101S) includes a first end and a second end,
the first end of the second lever (101S) being pivotably attached to the brake shoe assembly; and
the second end of the second lever (101S) being operatively connected to the connecting member (103).
6. The brake assembly (200) as claimed in claim 5, wherein
the second end of the second lever (101S) including a second lever opening (101Sop), the second lever opening (101Sop) being configured to receive a support portion (108).
7. The brake assembly (200) as claimed in claim 6, wherein
the connecting member (103) includes a first end and a second end;
the first end of the connecting member (103) being detachably attached to the first lever (101F); and
the support portion (108) including a support opening (108op), the support opening (108op) being configured to receive a portion of the second end of the connecting member (103).
8. The brake assembly (200) as claimed in claim 7, wherein
the second end of the connecting member (103) protrudes through the support opening (108op) of the support portion (108);
the brake adjuster member (105) being rotatably attached to the second end of the connecting member (103);
the first rotating member (102F) being installed on the brake adjuster member (105); and the brake adjuster member (105) being configured to abut the second end of the connecting member (104).
9. The brake assembly (200) as claimed in claim 1, wherein
the second rotating member (102S) being operably connected to the first rotating member (102F); the second rotating member (102S) being attached to the second lever (101S); and
a motion of the connecting member (103) causes relative motion between the second rotating member (102S) and the first rotating member (102F).
10. The brake assembly (200) as claimed in claim 1, wherein
the first rotating member (102F) being configured to rotate the brake adjuster member (105) to automatically adjust a free play in the second lever (101S) and the connecting member (103) upon wearing of a brake shoe in the brake shoe assembly beyond a predetermined level.
11. The brake assembly (200) as claimed in claim 1, wherein
the first rotating member (102F) being press fitted over an anti-reverse bearing (107); and
the anti-reverse bearing (107) being mounted over the brake adjuster member (105) thereby ensuring unidirectional rotation of the brake adjuster member (105) by the first rotating member (102F).
12. The brake assembly (200) as claimed in claim 11, wherein a clipper means (106) is disposed between the anti-reverse bearing (107) and the brake adjuster member (105).
13. The brake assembly (200) as claimed in claim 1, wherein
the first rotating member (102F) and the second rotating member (102S) are bevel gears;
the first rotating member (102F) and the second rotating member (102S) including teeth on the outer circumference of the first rotating member (102F) and the second rotating member (102S); and
the first rotating member (102F) and the second rotating member (102S) being configured with a predetermined clearance (C) between teeth of the first rotating member (102F) and the second rotating member (102S).
14. The brake assembly (200) as claimed in claim 1, wherein the second rotating member (102S) is fixedly attached to the second lever (101S).
15. The brake assembly (200) as claimed in claim 13, wherein the predetermined clearance being in a range of 3 degrees to 15 degrees.

16. The brake assembly (200) as claimed in claim 13, wherein a number of the teeth on the first rotating member (102F) and the second rotating member (102S) range from 4 to 15.

Dated this the 6th day of March 2023

(Digitally Signed)
Sudarshan Singh Shekhawat
IN/PA-1611
Agent for the Applicant