FIELD OF INVENTION:

This invention relates to a cabin module for use in manufacture of both three and four wheel vehicles.

PRIOR ART:

A range of vehicles are operated on Indian roads, among these being three wheel vehicles and four wheel vehicles. Three wheel vehicles differ in construction, shape and styling point of view and employ different type of suspension system, steering systems and different controls like accelerator & brake etc.
Three wheel vehicles may have one wheel at front and two wheels at rear or two wheels at front and one wheel at rear side and hence have different suspension arrangements. With regard to steering arrangements, generally three wheeled vehicles are front wheel steered in case of single front wheel configuration. These are usually steered by a driver using a handlebar steering system and four wheel vehicles are usually steered by a driver using a steering wheel. Such suspension and steering systems are quite different in design and, often, complex.

OBJECT OF THE INVENTION.

It would be desirable to commonise, that is standardise, manufacturing steps and components for three and four wheel vehicles to the greatest extent possible. However, this is not a straightforward exercise. Three and four wheel vehicles are designed in different ways and are supplied to different market segments. As described above, three wheel vehicles have different suspension and steering systems to those suspension and steering systems used for four wheel vehicles. Further, driver seating position (with respect to length or distance from the front of the vehicle as well as with respect to width or distance from a centre longitudinal axis of the vehicle) is different as between three and four wheel vehicles.

Another desirable objective would achieve standardisation of cabin design for vehicles of three and four wheel type. However, this is not straightforward. There are a range of issues to be considered here, among these being comfort, aesthetics and cost from the customer standpoint and manufacturing efficiency and profitability from the manufacturer's standpoint. Customer and manufacturer are both concerned with cost.

A significant cost centre for a vehicle manufacturer is inventory. An idealised manufacturing system would result in vehicle components being sourced or manufactured by a vehicle manufacturer and then, immediately (from an accounting perspective), assembled into a final vehicle which is immediately (again from an accounting perspective) sold to a customer. Reality approaches this ideal but does not achieve it. Nearly always, the vehicle manufacturer must hold an inventory of vehicle components on hand. Such inventory, where not used, has cost implications for the manufacturer.

A vehicle manufacturer is likely to receive demand for three and four wheel vehicles. Demand for both vehicle types may be significant but is likely to fluctuate with time. Sometimes customer demand for three wheel vehicles may be higher than for four wheel vehicles and sometimes vice versa. Both three and four vehicles may be assembled at the same assembly or manufacturing site or in closely proximate sites.
It is an object of the present invention to provide a cabin module which can be used comfortably and economically for both three and four wheel vehicles.

DESCRIPTION OF INVENTION:
With this object in view, the present invention provides a cabin module forming at least part of a cabin structure for a vehicle and comprising structural members defining part of the cabin structure wherein said cabin module or said structural members are connectable to a plurality of vehicle component modules for vehicle assembly and said vehicle component modules connectable to said structural members are selected from the group consisting of vehicle component modules for three wheel vehicles and vehicle component modules for four wheel vehicles.

The vehicle component modules connectable to the cabin module may comprise, in particular, steering system modules and suspension system modules.

Steering systems and suspension systems typically differ markedly between three and four wheel vehicles so the ability to connect such different vehicle components to a common cabin module offers significant manufacturing advantages.

As another objective, advantageously, the cabin module provides a seat position common for both three and four wheel vehicles. The seat position is common in the longitudinal direction of the cabin module (and vehicle built upon it) with respect to front vertical plane. The ability to provide such a seat position for both three and four wheel vehicles provides the same level of ergonomic driving comfort to the driver of a three wheel vehicle and four wheel vehicles. For a three wheel vehicle, a vehicle typically having a single front wheel, an offset handlebar may be designed. That is, the handlebar may be offset a distance from the axis of the steering column and would be connected to the steering column conveniently as supported by a vertical pillar described further in the specification. Such construction is particularly advantageous in the three wheel vehicle, using the presently described cabin module and the offset handlebar allows comfortable seat position and operator, i.e. driver, posture when compared to conventional three wheel vehicles.

The cabin module is advantageously configured to have a substantially horizontally extending floor plane and a front vertical plane common for both three and four wheel vehicles. The floor plane corresponds with the floor of the cabin module and it supports loads, such as driver, passengers and other components in the cabin within the cabin module.

The front vertical plane conveniently extends substantially perpendicularly upward from the floor plane.
However, any desired inclination could be adopted.

The structural members referred to above are disposed relative to the floor and front vertical planes to achieve particular structural advantages, for example, mounting points for the above mentioned vehicle component modules. Such structural members may extend longitudinally, transversely or vertically with respect to the floor and front vertical planes. For example, at - or proximate - the sides of the front vertical plane may be located in upright structural members which may be in form of side pillars. Such structural members or side pillars are vertically extending and desirably, though not necessarily, extending perpendicularly to the floor plane. At, and possibly defining, the sides of the floor plane are substantially horizontally and longitudinally extending structural members, for example in the form of horizontal beams. Such structural members are interconnected to form an understructure or chassis for the vehicle in the case of both three wheel and four wheel vehicles. Cross members may connect the vertically and horizontally extending structural members to provide a cabin structure of greater rigidity and strength.

The cabin module provides a cabin space of similar volume for both three and four wheel vehicles rearward of the front vertical plane. This offers the possibility of a more spacious three wheel vehicle in particular. Forward of the front vertical plane, vehicle design features may markedly differ between three and four wheel vehicles. For example, in a three wheel vehicle, one wheel only is mounted forward of the front vertical plane. A four wheel vehicle would have a pair of wheels mounted forward of the front vertical plane.

In the case of a three wheel vehicle, the cabin module advantageously includes a vertical pillar extending vertically relative to the floor plane and forward of, though adjacent to, the front vertical plane. The vertical pillar should be located in a central position relative to the front vertical plane, to support components of a steering system, desirably a steering column of the steering system. The vertical pillar may extend perpendicularly relative to the floor plane but this is not essential. It could extend at an acute, or even obtuse, angle to the floor plane.

In the case of a four wheel vehicle, the cabin module may include a front cross member which extends transversely across the front vertical plane (and longitudinal axis of the vehicle) connecting the upright structural members referred to above. Additionally, a lower control structural member - forming part of the vehicle understructure or chassis - is located proximate a bottom edge of the front vertical plane for a four wheel vehicle. This lower control member, like the front cross member extends transversely across a longitudinal axis of the vehicle. A three wheel vehicle also advantageously includes a front cross member and lower control structural member though it would typically serve a different purpose than as described below.

Suspension and steering system components may be mounted to either or both of the front cross member and lower control structural member. For example, a twin arm suspension system may conveniently be used for the four wheel vehicle type. Such twin arm suspension systems include upper and lower control arms which extend parallel to a longitudinal axis of the vehicle. Upper control arms for each of a pair of front wheels for the four wheel vehicle may be mounted to the front cross member, conveniently in the form of a beam. Lower control arms of a twin arm suspension system may be mounted to the lower control structural member. The rack of a rack and pinion steering system may be connected to the front cross member.

Further vehicle components - and especially vehicle control components -may be commonised for both three and four wheel vehicles. Examples of commonisable control components include brake, accelerator and clutch (for vehicles with manual transmission). These controls are typically foot operated controls and show that commonisation of foot operated controls may advantageously be adopted. Some vehicle control components may be operated from steering wheel or handlebar. For example, the clutch could be operated from the handlebar of a three wheel vehicle.

Another aspect of the invention provides a three or four wheel vehicle comprising the cabin module as above described. Such vehicles may have engine mounted in rear, mid or front position. A three wheel vehicle may be configured to have a pair of wheels in either front or aft position.

The cabin module of the invention may be used to achieve economic efficiencies in the manufacture of three and four wheel vehicles. At the same time, the cabin module allows ergonomic benefits to be achieved. Common and comfortable seat position, consequential riding postures and driver ergonomics for three and four wheel vehicles can be achieved without compromising on suspension and steering geometry which could hamper vehicle handling.

The cabin module of the present invention may be more fully understood from the following description of a preferred embodiment thereof made with reference to the accompanying drawings in which:

Fig. 1 is a first schematic rear perspective view of first embodiment of the cabin module of the present invention when used in a three wheel vehicle.

Fig. 2 is a schematic rear perspective view of second embodiment of the cabin module of the present invention when used in a four wheel vehicle.

Fig. 3 is a second schematic rear perspective view of the cabin module of Fig. 1.

Fig. 4 is a second schematic rear perspective view of the cabin module of Fig. 2.

Fig. 5 is a schematic plan view of the cabin module of Figs. 1 and 3.

Fig. 6 is a schematic plan view of the cabin module of Figs. 2 and 4.

Fig. 7 is a schematic side view of the cabin module of Figs. 1, 3 and 5.

Fig. 8 is a schematic side view of the cabin module of Figs. 2, 4 and 6.

Fig. 9 is a schematic bottom view of the cabin module of Figs. 1,3,5 and 7.

Fig. 10 is a schematic bottom view of the cabin module of Figs. 2, 4, 6 and 8.

Fig. 11 is a schematic front view of the cabin module of Figs. 1, 3, 5, 7 and 9.

Fig. 12 is a schematic front view of the cabin module of Figs. 2,4,6, 8 and 10.

Fig. 13 is a schematic side view of a three wheel (3W) vehicle built using the cabin module as shown in Figs. 1,3,5,7,9 and 11.

Fig. 14 is a schematic side view of a four wheel (4W) vehicle built using the cabin module as shown in Figs. 2,4, 6, 8,10 and 12.

Figs. 1 to 12 show cabin modules 100, 100a forming part of the cabin structure of a vehicle. The cabin modules 100, 100a have a range of common features and can be used to form part of the cabin structure for both three and four wheel vehicles with significant manufacturing advantages. Cabin module 100 is used in three wheel vehicles. Cabin module 100a is used in four wheel vehicles. As far as possible, a common description for both cabin modules 100,100a, which both adopt the same basic structure, is provided below.

Cabin modules 100, 100a are both configured to have a substantially horizontally extending floor plane 110, 110a providing support for loads, such as driver, passengers and other components within the cabin space 190,190a.

Cabin modules 100,100a also include a front vertical plane 120, 120a located at a front end 112, 112a of the floor plane 110, 110a for both three and four wheel vehicles respectively, both types of vehicle having rear mounted engines and rear wheel drive for engineering convenience. Alternative engine location could be adopted, for example in mid or front position of the vehicle. Front vertical plane 120, 120a extends substantially perpendicularly upward from the floor plane 110, 110a. The front vertical plane 120, 120a is here defined by a front cabin wall. However, a forwardly angled portion 122, 122a of the front vertical plane may be provided in the vicinity of the brake and clutch foot pedal controls. Clutch pedal 185, 185a is indicated in Figs. 2 and 3. Brake pedal, included in both 3 and 4 wheel vehicles is shown as brake pedal lever 183 in Fig. 1 and pedal 183a in Fig. 2 and 4. For a three wheel vehicle, the clutch could be operated from the handlebar.

Cabin module 100, 100a includes other structural members forming part of the cabin structure and these structural members, described below, are disposed relative to the floor plane 110, 110a and front vertical plane 120, 120a. Such structural members extend either longitudinally, transversely or vertically with respect to the floor plane 110, 110a and front vertical plane 120, 120a. Several of these structural members have particularly important structural and operational roles being connectable to vehicle component modules which markedly differ as between three and four wheel vehicles as described below.
Proximate the sides 124, 124a of the front vertical plane 120, 120a are located upright or vertically extending structural members or side pillars 130, 130a. Side pillars 130, 130a extend vertically and perpendicularly upward from the floor plane 110, 110a. The side pillars 130, 130a may be formed integral with a vehicle understructure or chassis in the case of both three wheel and four wheel vehicles.
Extending between upper portions of side pillars 130, 130a is a windscreen 750, 750a.

Defining the sides 114, 114a of the floor plane 110, 110a are substantially horizontally and longitudinally extending structural members 116, 116a in the form of horizontal beams. Structural members 116, 116a form part of- a vehicle understructure or chassis in the case of both three wheel and four wheel vehicles. Rearwardly spaced cross members 118, 118a connect the horizontally and longitudinally extending structural members 116, 116a as shown in Figs. 9 and 10. While two such cross members 118, 118a are shown here, this is not intended to limit the number of cross members to be provided. The number of cross members 118, 118a will depend on the dimensions of the vehicle and the required rigidity and strength of the vehicle understructure or chassis. Structural members of any section may be used for the structural members 116, 116a, 118, 118a. Additional strengthening members for cabin modules 100, 100a may also be included if required.

As shown in Figs. 1 to 10, cabin module 100, 100a provides a cabin space 190, 190a of similar volume for both three and four wheel vehicles rearward of the front vertical plane 120, 120a. This offers the potential for a more spacious three wheel vehicle offering the driver and passengers of a three wheel vehicle ergonomic benefits and comfort previously restricted to four wheel vehicles. Forward of the front vertical plane 120, 120a, vehicle design features markedly differ between three and four wheel vehicles. For example, in the three wheel vehicle 1000 shown in Fig. 13, one wheel 200 only is mounted forward of the front vertical plane 120. However, a three wheel vehicle could have a pair of wheels mounted forward and a single wheel mounted aft. The four wheel vehicle 1000a (Fig. 14) has a pair of wheels 200a mounted forward of the front vertical plane 120a. Suspension and steering systems are different as well. Whilst a conventional suspension system is here used for the three wheel vehicle, suspension system for the four wheel vehicle is described in detail below.

In the case of a three wheel vehicle, the cabin module 100 includes a vertical pillar 150 extending vertically relative to the floor plane 110 and forward of, though adjacent to, the front vertical plane 120.

The vertical pillar 150 is located in a central position relative to the front vertical plane 120, to support components of a steering system 400, in particular the steering column 242 of the steering system 400.

The vertical pillar 150 extends, like side pillars 130 to which vertical pillar 150 is substantially parallel, and substantially perpendicularly to the floor plane 110. A tubular front cross member 125 extends transversely across the front vertical plane 120 (and longitudinal axis 105 of the vehicle). The position of vertical pillar 150 may be shifted with respect to positioning of driver seat along the transverse direction of the vehicle. A lower control structural member 128 (as shown in Figure 11) forming part of the vehicle understructure or chassis is located proximate a bottom edge 123 of front vertical plane 120.

In the case of a four wheel vehicle, the cabin module 100a includes a tubular front cross member 125a which extends transversely across the front vertical plane 120a (and longitudinal axis 105a of the vehicle) connecting the side pillars 130a described above. Additionally, a lower control structural member 128a - forming part of the vehicle understructure or chassis - is located proximate a bottom edge 123a of the front vertical plane 120a. This lower control structural member 128a like the tubular front cross member 125a, extends transversely across the longitudinal axis 105a of the vehicle. These features are most conveniently seen in Fig. 12.

Suspension and steering system components, for the four wheel vehicle, are mounted - as modules - to the tubular front vertical cross member 125a and lower control structural member 128a. As illustrated, a modular twin arm suspension system 300a is conveniently used for the four wheel vehicle type. Such twin arm suspension system 300a includes upper and lower control arms 311a and 312a which extend parallel to the longitudinal axis 105a of the vehicle. Upper control arms 312a, forming part of independent suspension means 315a for each of a pair of front wheels 200a for the four wheel vehicle, are mounted, at spaced locations, to the front cross member 125a. Lower control arms 311a of the twin arm suspension system 300a are mounted, at spaced locations, to the lower control structural member 128a. The rack 415a of a rack and pinion steering system 400a is connected to the front vertical plane cross member 125a at a desired rack angle. Driver 800a operates the steering system 400a by operating steering wheel 430a in conventional manner.

The cabin module 100, 100a provides a common seat position 900, 900a for operator or driver 800, 800a of both three and four wheel vehicles as conveniently shown by Figs. 5 and 6. The seat position is common in the longitudinal and vertical direction of the cabin module 100, 100a (or correspondent vehicle 1000, 1000a) with respect to steering control system 400, 400a and/or operator's foot 850, 850a operated controls, such as brake and clutch thereby providing same level of ergonomic driving comfort to the driver 800, 800a. For the three wheel vehicle having a single front wheel 200, an offset handlebar 240 is adopted. The handlebar 240, which could include clutch control if desired, is offset a distance from the axis of steering column 242 and is connected to the steering column 242 as supported by the above described vertical pillar 150. The cabin module and offset position of handlebar 240 provides a comfortable position and driving posture for driver 800 with improved ergonomics over conventional three wheel vehicles.

Further vehicle components - and especially control components - may be commonised for both three and four wheel vehicles. Examples of commonisable vehicle control components include brake, accelerator and clutch 185, 185a (for vehicles with manual transmission). These vehicle controls are foot 850, 850a operated controls for both three and four wheel vehicles. The foot operated controls 183, 183a and 185, 185a are commonised to both three and four wheel vehicles. Such commonisation further reduces manufacturing inventory and manufacturing cost.

The cabin module 100, 100a - as described above - may be used to achieve economic efficiencies in the manufacture of three and four wheel vehicles 1000, 1000a built using cabin modules 100, 100a and shown in Figs. 13 and 14. At the same time, the cabin module 100, 100a allows significant ergonomic benefits for driver 800, 800a and passengers to be achieved. Common and comfortable riding postures and driver 800, 800a ergonomics for three and four wheel vehicles can be achieved without compromising on suspension and steering geometry which could hamper vehicle handling.

Modifications and variations to the cabin module of the present invention may be apparent to the skilled reader of this disclosure. Such modifications and variations are deemed within the scope of the present invention.

Numeral Description
100,100a Cabin Modules
105,105a Longitudinal Axis of the Vehicle
110,110a Horizontally Extending Floor Plane
112,112a Front End of Floor Plane
114,114a Sides of the Floor Wall Plane 110,110a
116,116a Structural Members
118,118a Rearwardly Spaced Cross Members
120,120a Front Vertical Plane
122,122a Forwardly Angled Portion of the Front Vertical Plane 120,120a
123,123a Bottom Edge of Front Vertical Plane 120
124,124a Sides of the Front Vertical Plane 120,120a
125,125a Tubular Front Cross Member
128,128a Lower Control Structural Member
130,130a Side Pillars
150 Vertical Pillar in Cabin Module 100
183,183a Brake Pedal Lever
185,185a Clutch Pedal
190,190a Cabin Space
200,200a Front Wheel(s)
240 Offset Handlebar
242 Steering Column of Steering System 400
300a Modular Twin Arm Suspension System
311a, 312a Upper and Lower Control Arms
315a Independent Suspension Means for Each Pair of Front Wheels 200a
400 Steering System of 3 Wheeler
400a Rack and Pinion Steering System of Wheeler
415a Rack of the Pinion Steering System 400a
430a Steering Wheel
750,750a Windscreen
800,800a Driver
850, 850a Operator's Foot
900, 900a Common Seat Positions
1000 A Three Wheel Vehicle
1000a A Four Wheel Vehicle

WE CLAIM:

1. A cabin module forming at least part of a cabin structure for a vehicle and comprising structural members defining part of the cabin structure wherein said cabin module or said structural members are connectable to a plurality of vehicle component modules for vehicle assembly and said vehicle component modules connectable to said structural members are selected from the group consisting of vehicle component modules for three wheel vehicles and vehicle component modules for four wheel vehicles.

2. A cabin module as claimed in claim 1 wherein said vehicle component modules connectable to the cabin module include steering system modules and suspension system modules.

3. A cabin module as claimed in claim 1 or 2 providing a seat position common for both three and four wheel vehicles.

4. A cabin module as claimed in claim 3 wherein said seat position is ergonomic.

5. A cabin module as claimed in claim 4 comprising a front vertical plane; wherein said seat position is common in the longitudinal direction of the cabin module with respect to the said front vertical plane.

6. A cabin module as claimed in any one of the preceding claims wherein said cabin module is configured to have a substantially horizontally extending floor plane for supporting loads and a front vertical plane common for both three and four wheel vehicles.

7. A cabin module as claimed in claim 6 wherein said front vertical plane extends substantially perpendicularly upward from the floor plane.

8. A cabin module as claimed in claim 6 or 7 wherein at, or proximate to, the sides of said front vertical plane are located upright structural members in form of vertically extending side pillars.

9. A cabin module as claimed in claim 8 wherein said side pillars extend perpendicularly to said floor plane.

10. A cabin module as claimed in any one of claims 6 to 9 wherein at, and possibly defining, the sides of the floor wall plane are substantially horizontally and longitudinally extending structural members in the form of horizontal beams for forming an understructure or chassis for the vehicle.

11. A cabin module as claimed in claim 10 wherein cross members connect the vertically and horizontally extending structural members.

12. A cabin module as claimed in any one of claims 6 to 11 providing a cabin space of similar volume for both three and four wheel vehicles rearward of the front vertical plane.

13. A cabin module as claimed in any one of claims 6 to 12 for a three wheel vehicle and including a vertical pillar extending vertically relative to the floor plane and forward of, though adjacent to, the front vertical plane.

14. A cabin module as claimed in claim 13 wherein said vertical pillar is located in a central position relative to the front vertical plane, to support components of a steering system, desirably a steering column of the steering system.

15. A cabin module as claimed in any one of claims 6 to 14 including a front cross member which extends transversely across the front vertical plane (and longitudinal axis of the vehicle) connecting said upright structural members.

16. A cabin module as claimed in claim 15 further including a lower control structural member, forming part of the vehicle understructure or chassis, located proximate a bottom edge of the front vertical plane and extends transversely across a longitudinal axis of the vehicle.

17. A cabin module as claimed in claim 15 or 16 wherein suspension and steering system components are mounted to either or both of the front cross member and lower control structural member.

18. A cabin module as claimed in claim 17 for a four wheel vehicle having a twin arm suspension system including upper and lower control arms which extend parallel to a longitudinal axis of the vehicle and wherein said upper control arms for each of a pair of front wheels for said vehicle are mounted to the front cross member; and said lower control arms of a twin arm suspension system are mounted to the lower control structural member.

19. A cabin module as claimed in any one of claims 15 to 18 wherein the rack of a rack and pinion steering system is connected to the front cross member.

20. A cabin module as claimed in any one of claims 1 to 17 or 19 for a three wheel vehicle comprising an offset handlebar, said handlebar being offset a distance from the axis of the steering column and connected to the steering column.

21. A three wheel vehicle comprising a cabin module as claimed in any one of claims 1 to 17 or 19.

22. A four wheel vehicle comprising a cabin module as claimed in any one of claims 1 to 12 or 15 to 19.