Claims:WE CLAIM:

1. A hand starter assembly (301) for a motor vehicle (100), said hand starter assembly (301) comprising;
a shaft (407);
a hand grip (401);
a single hand lever member (408);
said single hand lever member (408) having a front portion (402), a middle portion (403) and a rear portion (404),
wherein said front portion (402) being squeezed to form a circular cross section profile and capable of receiving said hand grip (401), said middle portion (403) being flattened to form a substantially oval cross section profile, said middle portion extending rearwardly and being bent obliquely forming said rear portion (404), ;
wherein said shaft (407) being attached with said rear portion (404) of said single hand lever member (408) forming said hand starter assembly (301).
2. The hand starter assembly (301) for a motor vehicle (100) as claimed in claim 1, wherein said middle portion (403) and said rear portion (404) being flattened to form said substantially oval cross section profile of said middle portion (403) and a substantially rectangular cross section profile of said rear portion (404)
3. The hand starter assembly (301) for a motor vehicle (100) as claimed in claim 1, wherein said front portion (402) having a predetermined cross section diameter D after squeezing, and a minor diameter of said oval cross-sectional profile of said middle portion (403) having a predetermined diameter D1.
4. The hand starter assembly (301) for a motor vehicle (100) as claimed in claim 1, wherein said single hand lever member (408) being formed from a tube of a predetermined diameter D0, said tube being chopped to a predetermined length L.
5. The hand starter system (301) for a motor vehicle as claimed in claim 4, wherein said predetermined length L being in range of 650mm to 750mm.
6. The hand starter system (301) for a motor vehicle as claimed in claim 4, wherein said predetermined diameter D0 being in range of 25mm to 30mm.
7. The hand starter system (301) for a motor vehicle as claimed in claim 2 , wherein said middle portion (403) and said rear portion (404) of said single hand lever member (408) being flattened through a roller.
8. The hand starter system (301) for a motor vehicle as claimed in claim 3, wherein said diameter D of said first portion (402) being smaller than said diameter D1 of said middle portion (403).
9. The hand starter system (301) for a motor vehicle as claimed in claim 8, wherein said diameter D being in predetermined range of 18mm to 24mm.
10. The hand starter system (301) for a motor vehicle as claimed in claim 8, wherein said diameter of D1 being in predetermined range of 25mm to 30mm.
11. The hand starter system (301) for a motor vehicle as claimed in claim 1, wherein said middle portion (403) forming a predetermined angle A with said rear portion (404).
12. The hand starter system (301) for a motor vehicle as claimed in claim 11, wherein said predetermined angle A being in range of 130 degrees to 140 degrees.
13. The hand starter system (301) for a motor vehicle as claimed in claim 1, wherein said rear portion (404) having an opening (405) to accommodate said shaft (407) with a first elastic member (406).
14. A method of manufacturing a single hand lever member (408) of a hand starter assembly (301) for a motor vehicle (100), said method comprising steps of:
;
chopping a tube of a predetermined outer diameter D0 to a predetermined length L;
bending a portion of said tube thereby forming a predetermined angle A between the two portions of said tube;
flattening of said bend tube forming a substantially oval cross-sectional area having a minor diameter D1;
squeezing one end potion of said tube to a predetermined outer diameter D to obtain a single hand lever member including different cross section.
15. The method of manufacturing a single hand lever member as claimed in claim 14, wherein said predetermined outer diameter D0 being in range of 25mm to 30mm.
16. The method of manufacturing a single hand lever member as claimed in claim 14, wherein said predetermined length L being in range of 650mm to 750mm.
17. The method of manufacturing a single hand lever member as claimed in claim 14, wherein said predetermined angle A being in range of 130 degrees to 140 degrees.
18. A method of manufacturing a single hand lever member (408) of a hand starter assembly (301) for a motor vehicle (100), said method comprising steps of:
squeezing a portion of a tube of a predetermined outer diameter D0 to a predetermined outer diameter D forming a first portion (402), said first portion (402) having a circular cross section profile;
chopping said tube to a predetermined length L;
bending a non-squeezed portion of said tube thereby forming a predetermined angle A at said bend, said bend forming a middle portion (403) adjacent to said first portion (402), and a rear portion (404);
flattening said middle portion (403) and said rear portion (404) of said tube forming a substantially oval cross section profile of said middle portion (403) and said rear portion (404), said oval profile having a minor outer diameter being of a predetermined diameter D1, wherein predetermined outer diameter D1 being smaller than said predetermined outer diameter D, said method enabling obtaining a single hand lever member (408) having different optional cross section profiles along its length.
, Description:TECHNICAL FIELD
[0001] The present subject matter relates to a motor vehicle. More particularly, the present subject matter relates to a hand starter system for the motor vehicle.

BACKGROUND
[0002] In many countries of the world, a three wheeled motor vehicle is a significant mode of public transportation. It is vastly used as a point to point mode of transport in rural and urban areas also referred to as autorickshaw. Generally, the three wheeled saddle multi-track type motor vehicle has a driver compartment in a front portion and a passenger load compartment in a rear portion. In case of a passenger vehicle, the rear compartment comprises of a passenger seat. A driver is seated along the longitudinal midplane of the vehicle and operates the vehicle from the first compartment. A driver seat is provided in the front compartment so that the driver operates the vehicle in a sitting position. A suspension structure for three wheeled vehicle normally employs separate trailing arm with rear suspension system to support the body on the two rear wheel assemblies. Also, wheels are connected to a frame assembly by the suspension structure. Further, the vehicle is started by a starter system, with steerable front wheels controlled by the driver with a steering assembly of the vehicle.

BRIEF DESCRIPTION OF THE DRAWINGS
[0003] The detailed description is described with reference to a passenger transport layout of a three wheeled vehicle along with the accompanying figures. The same numbers are used throughout the drawings to reference like features and components.
[0004] Fig.1 is a side view of a motor vehicle as per one embodiment of the present invention.
[0005] Fig. 1a is a rear view of a motor vehicle as per one embodiment of the present invention.
[0006] Fig.2 is a frame assembly, as per one embodiment of the present invention.
[0007] Fig.3 is an assembled view of a hand starter system with floorboard as per one embodiment of the present invention.
[0008] Fig. 3a is a perspective view of a hand starter system as per one embodiment of present invention.
[0009] Fig.3b is a sectional view of a hand starter system as per one embodiment of present invention.
[00010] Fig. 4 is an exploded view of steering assembly as per one embodiment of the present invention.
[00011] Fig. 5 is a flowchart as per one embodiment of the present invention.
[00012] Fig. 5a is a flowchart as per one embodiment of the present invention.

DETAILED DESCRIPTION
[00013] A Starter system for a vehicle is a combination of mechanical and electrical components for propelling a vehicle. The starter system is of various types like electric, pneumatic, hydraulic, kick starter system or a hand starter system. In the electric starter system, the starter system converts electrical energy stored in an energy storage device into mechanical energy through various means. Heavy vehicle like truck is configured with the pneumatic self-starter system. Vehicles including diesel engines are propelled by means of the hydraulic starter system. The kick starter system cranks an engine, when a rider pushes a ratchet lever with foot. The kick starter system is typically configured in two wheeled vehicle along with electric starter system. The kick starter system is configured as an alternate means to start, when the electric starter system fails to start the vehicle.
[00014] Further, in motor vehicle like three-wheeler, the electric starter system along with the hand starter system or the hand starter system alone is configured to crank the engine and propel the vehicle. The hand starter system includes a grip, a hand lever, a shaft, a lever, a link rod etc., where the grip requires a smaller cross section area for ease of gripping and smooth accessibility of the hand starter system by a driver of the vehicle, whereas the hand lever requires a larger cross section area for cranking of the engine. Conventionally, the hand starter system is disposed either on left side or right side of a driver’s seat, on a floorboard of the motor vehicle. The driver while being seated on the vehicle pulls the hand lever of the hand starter system to crank the engine. The hand starter system is configured such that each of the component having different cross sections is fixedly attached together with various means like welding.
[00015] Thus, it is apparent from above paragraph that the starter system like hand starter system plays a very important role in starting of the vehicle, when the other starter system like electric starter system fails to start the vehicle so as to avoid the user from being stranded. Conventionally, the hand starter system is configured with multiple numbers of components having different cross section area. The grip is disposed on the hand lever of the hand starter system and is attached to a sheet metal part disposed on the hand lever of the system. The link arm includes plurality of connecting end, where one end is connected with the hand lever and another end is connected with the shaft of the starter system. A plurality of reinforcing members is disposed and covers a connecting portion of the hand lever and the link arm of the system to provide stability. The shaft is fixedly attached with the arm of the starter system. Further, the floorboard of the motor vehicle includes an opening confirming with the cross section area of the link arm ensuring ease of stowage and accessibility of the hand starter system for cranking the engine. When the hand lever of the hand starter system is pulled by the driver, the force exerted by the hand of the driver gets transferred to the link arm, the shaft and a link rod to crank the engine and thus propels the vehicle. However, this configuration raises another problem like increased number of components. The numbers of components like hand lever, sheet metal, reinforcing members and link arm are fixedly attached to each other through attachment means like welding, thus, raises problems like increased fixturing, increased manufacturing time etc. If the opening or recess provided in the floorboard is not aligned with the with the cross section area of the link arm, there is a chance of interference contact with the floor board resulting in undesirable constant vibration and rattling noise in the vehicle. Also, as the multiple components are welded together, this also leads to problem related to welding defect, increased heat affected joints, which leads to potential breakage of the joints on the components in long run of the vehicle. To overcome this problem, one solution is proposed that is to increase thickness of the component. This increases requirement of additional material, increasing weight of the hand starter system which is undesirable. Thus, there is a need of providing an improved hand starter assembly especially in the three wheeler vehicle.
[00016] In known arts, multiple ways has been proposed or disclosed to provide hand starter system with less number of components. One of the ways disclosed is to provide a uniform single hand lever member by various means like hydroforming welding or casting process, which is a costly and increases weight of the starter system. Further, if the uniform single lever is provided, it compromises on the requirement of different cross section area of the multiple components, thus decreasing stability of the hand starter system and resulting in a sub-optimal design. This also raises the chances of breakage of the component.
[00017] In another known art, a hand starter system is disclosed, where the hand starter system includes a hand lever, a grip. The hand lever includes an opening for fixedly attaching a rod provided for the grip. Thus the grip is disposed on the rod. The hand lever includes a uniform cross section, as area of the floorboard in the driver zone and passenger zone includes a step profile. Therefore, if the configuration as disclosed in the known art has to be implemented, there is a need to modify chassis design of the conventional vehicle, which is not desirable and not cost effective.
[00018] Hence, there exists a challenge of designing an improved hand starter assembly for a motor vehicle, for example, three wheeled vehicle with less number of components while maintaining required cross section area of the hand starter assembly without any major change in design and manufacturing set-up of the vehicle.
[00019] Therefore, there is a need to have an improved hand starter assembly in a motor vehicle, for example, three wheeled vehicle with reduced number of part count in the starter assembly. There is a need to have a solution for hand starter assembly which assists the driver while overcoming all of the above problems and other problems of known art.
[00020] The present invention provides a solution to the above problems while meeting the requirements of minimum modifications in the starter assembly, at low cost with ease of assembly etc.
[00021] With the above objectives in view, the present invention relates to the three wheeled motor vehicle and more particularly to the improved starter system in the motor vehicle with reduced number of components and including different optimal cross section areas.
[00022] As per one aspect of the present invention, a motor vehicle is provided with a frame structure. The frame structure of the motor vehicle includes a head tube, a main frame and a central frame. A floor board is supported on the central frame and extended to the rearward of the vehicle. The floorboard is further divided into the floor board of a front cabin (driver’s zone) and the floorboard of a rear cabin (passenger’s zone). The front cabin of the vehicle includes a driver seat assembly. The driver seat assembly includes a driver seat frame which is housed and attached with various attachment means, for example fasteners, on the top of the central frame and a pair of LH (left hand) side frame member and RH (right hand) side frame member. The rear cabin of the vehicle includes a passenger seat. The passenger seat is detachably attached to a metal sheet or a cover with various attachment means, for example fastener.
[00023] As per one aspect of the present invention, a hand starter assembly is disposed in the front cabin space over the floorboard of the vehicle. The hand starter assembly includes a single hand lever member, a shaft. The single hand lever member includes a front portion, a middle portion and a rear portion to form a single hand lever member. The front portion includes a diameter D, which is smaller than a diameter D1 of middle portion. Further, the middle portion is extended rearwardly and obliquely downwardly with respect to the floorboard of the vehicle in a predetermined range of angle A. The middle portion and rear portion of the single hand lever member is flattened and the rear portion includes an opening to accommodate shaft of the hand starter system with an elastic member. This facilitates ease of assembly of the shaft with the rear portion of the single hand lever member. The shaft of the hand starter system is further attached with a lever arm. The lever arm is fixedly attached with a link rod, where the link rod is connected to an engine. Thus, when the driver pulls the hand lever of the hand starter system by holding the grip, the link rod cranks the engine and thus propels the vehicle. This configuration provides a simple construction and ensures single hand lever member including different cross section area, which eliminates requirement of additional components including different cross section area to be attached with hand lever. Further, this configuration also reduces manufacturing/welding defect and thus improves life expectancy of the single hand lever member with different cross section.
[00024] In the ensuing paragraphs, the exemplary aspects of the present invention along with the embodiment in a three wheeled vehicle are disclosed. However, it is contemplated that the concepts of the present invention may be applied to any vehicle having hand starter system without defeating the spirit of the invention.
[00025] Further "front" and "rear", and "left" and "right" referred to in the ensuing description of the illustrated embodiment refer to front and rear, and left and right directions as seen in a state of being seated on a seat of the vehicle and looking forward. Furthermore, a longitudinal axis refers to a front to rear axis relative to the vehicle, while a lateral axis refers generally to a side to side, or left to right axis relative to the vehicle.
[00026] The present invention is now described briefly in connection with the rendered drawings. It should be noted that like elements are denoted by the same reference numerals throughout the description.
[00027] Fig. 1 & Fig 1a is a side & rear view of a three wheeled multi track motor vehicle (100) and Fig. 2 is a perspective view of a frame assembly of the motor vehicle in accordance with an embodiment of the present subject matter. For brevity, Fig 1, Fig 1a and Fig 2 shall be discussed together. In an embodiment, the frame structure (200) of the motor vehicle includes three compartments. A front compartment including a head tube (201) that mounts a steering means (106) of the motor vehicle and the head tube (201) is capable of steering a front wheel (101). A main frame (206) that connects the head tube (201) and a central member (203), a driver seat assembly (104) that is housed on top of the central member (203) and a pair of LH side member (205) and a RH side member (202). The motor vehicle also includes a pair of rear wheels (102) and a front fender (103) disposed above the front wheel (101). CNG cylinder etc. is housed in a power or energy storage housing area (110) under the driver seat assembly (104). A driver back rest (105) is provided in the driver compartment. In one embodiment, the frame assembly further includes a middle compartment that includes a passenger seat assembly (108) comprising of a seat base bottom and a back rest, a passenger barrier (107) restricting entry/exit of the passengers into the three wheeled vehicle in one direction, one or more lateral connecting bridge member (204) capable of mounting a passenger back rest. Further, in one embodiment, the frame assembly also includes a rear compartment that houses the cabin assembly (109), and a power unit (111) disposed substantially in the rear side of motor vehicle (fig. 1a).
[00028] Further, as per one embodiment of the present invention, a pair of rear frame members (214) extend upward from the left hand side member (205) and right hand side member (202) and further extends horizontally to a rearward side of the vehicle (100). The pair of rear frame members (214) includes a left frame member (213) and a right frame member (212) extending horizontally to rearward side of the vehicle. The left frame member (213) and right frame member (212) are connected by a plurality of lateral members (204, 208, 209) between them and the plurality of lateral members (204, 208, 209) are connected by a plurality of longitudinal connecting bridge members (210, 211) disposed as connecting bridges, ensuring rigid attachment of the frame assembly.
[00029] Fig. 3 is a assembled view of a hand starter assembly (301) in the motor vehicle as per one embodiment of the present invention. As per one embodiment of the present invention, a hand starter assembly (301) is disposed in the front cabin space over a floorboard (302) of the vehicle. The hand starter assembly (301) includes a single hand lever member (408), a shaft (407) (shown in Fig 4). The single hand lever member is obtained from a single tube chopped till length L and is of outer diameter D0, where as per a preferred embodiment the length L is in predetermined range of 650mm to750mm and D0 is in range of 25-30mm (as shown on fig. 3a). The straight tube is flattened, rolled and bend to form the single hand lever member (408). Further, as per one embodiment of the present invention, the hand starter assembly (301) is disposed either left side or right side of the driver’s seat in the vehicle over the floorboard, for providing ease of accessibility to the driver while starting the vehicle. Further, the floorboard (302) includes an opening for channelizing or routing and coupling the hand starter system to the engine of the vehicle.
[00030] Fig. 4 is an exploded view and Fig. 4a is a sectional view of the single hand lever member as per one embodiment of the present invention. As per one embodiment of the present invention, the single hand lever member (408) includes a front portion (402), a middle portion (403) and a rear portion (404) to form a single hand lever member (408). The front portion (402) is configured with a diameter D (shown at cross section E-E’) , where as per a preferred embodiment, D is in predetermined range of 18-24mm. The middle portion (403) is configured with a substantially oval shaped cross section profile with a minor diameter D1 (shown at cross section D-D’) of the oval. The minor diameter D1 being disposed orthogonal to the length direction of the single hand lever member (408) or along a width direction of the vehicle (100). This orientation provides enhanced stiffness to the hand starter assembly (301) in a direction of application of starting force or torque being applied by a rider of the vehicle (100). The diameter D is smaller than a diameter D1 of middle portion (403) , where as per a preferred embodiment the diameter D1 is in predetermined range of 25-30mm. Further, the middle portion (403) is extended rearwardly and obliquely downwardly with respect to the floorboard of the vehicle (100) at a predetermined angle A where the downwardly portion forms the rear portion (404) of the single hand lever member (408). The rear portion is configured with a substantially rectangular cross section profile (shown at cross section F-F’) formed by suitable forming or flattening operation. The predetermined angle A between the middle portion (403) and the rear portion (404), as per a preferred embodiment, is in range of 130-140 degrees with respect to the floorboard or a ground of the vehicle (100). The middle portion (403) and rear portion (404) of the single hand lever member (408) is flattened and the rear portion (404) includes an opening (405) to receive a shaft (407) of the hand starter system with a first elastic member (406). As per a preferred embodiment, the opening (405) is in a predetermined range of 34-45mm. This facilitates ease of assembly of the shaft (407) with rear portion (404) of the single hand lever member (408). As per an embodiment, the shaft (407) of the hand starter system (408) is further attached with a lever arm (not shown). The lever arm is fixedly attached with a link rod, where the link rod is coupled or connected to an engine. Thus, when the driver pulls the single hand lever member (408) of the hand starter assembly (301) by holding a hand grip (401) assembled on the front portion (402) of the single hand lever member (408), the link rod cranks the engine to start the engine and thus enables propelling the vehicle (100). The present invention ensures single hand lever member (408) has different optimal cross section area across its length, which eliminates requirement of additional or separate components of different cross section area to be attached or connected with each other to form the hand lever member for starting an engine of the vehicle (100). Further, this configuration also eases manufacturing while eliminating welding and its related defects completely and thus improves life expectancy, reliability and durability of the single hand lever member as well as the hand started assembly (301). Further, as per one embodiment of the present invention, the single hand lever member (408) is supported on the floorboard (302) of the vehicle through various supporting means like a supporting bracket (408) having a receiving portion to receive said hand lever member (408). The supporting bracket (410) further being coupled with a second elastic member (409) at its receiving portion on which the hand lever member (408) rests to enable effective vibration isolation of the hand lever member (408) from a vibration of the floorboard (302). The present invention enables ensuring ease of accessibility of the single hand starter member by the driver while being seated on a seat. Further, the supporting bracket (410) also restricts undesirable movement of the single hand lever due to vibration in the vehicle.
[00031] Fig. 5 is a flowchart explaining manufacturing methodology to form a single hand lever member with different optimal cross section is explained. As per one embodiment of the present invention, in S501, a metal tube is obtained of an outer diameter D0. In S502, the tube is chopped within predetermined length L. In S503, the tube, after chopping, is bend within a predetermined angle A, through a bending operation forming the angle A between the two bend portions. The predetermined angle A is in range of 130-140 degrees. Further, after bending a portion of the tube, in S504, the tube is flattened with various means for example, rollers forming the middle portion (403) and the rear portion (404) where the cross-sectional profile of the tube is made substantially oval with a minor diameter being D1. As per one embodiment of the present invention, in S505, one end portion of said tubeis squeezed forming a front portion (402) such that the squeezed portion has a circular cross section profile with a predetermined diameter D, where D being greater than D1 and the first portion (402) conforms to a profile of the grip to be assembled at the front portion (402). The present invention reduces manufacturing difficulty and eliminates welding defects while providing a single hand lever member including different optimal cross sections and thus improves life expectancy of the single hand lever member (408) of the hand starter assembly (301).
[00032] Fig. 5a is a flowchart explaining methodology to form a single hand lever member (408) with different optimal cross section as per another embodiment of the present invention. As per one embodiment of the present invention, in S506, a metal tube is obtained of a predetermined outer diameter D0. In S507, a portion of the tube, is squeezed forming a diameter D, D being smaller than D0 and the squeezed portion forming a front portion (402). The squeezed portion profile conforms to a profile of the grip. In S508, the tube is chopped within predetermined length L, where the L is in range 650-700mm. In S509, the non-squeezed portion of the tube, a bend is performed forming a predetermined angle A at the bend region. The predetermined angle A forming a middle portion (403) and rear portion (404) having the predetermined angle A between them and middle portion (403) being adjacent to said first portion (402). Further, after bending of the tube, in S510, the middle portion (403) and the rear portion (404) of the tube is flattened with various means for example, rollers thereby forming a substantially oval cross sectional profile of the middle portion (403) and the rear portion (404). The oval profile having a minor outer diameter D1 where D1 being smaller than D. The present invention reduces manufacturing difficulty and eliminates welding defects while providing a single hand lever member (408) with different optimal cross section profiles along its length and thus improves life expectancy of the single hand lever member (408) of the hand starter assembly (301).
[00033] The invention helps in overcoming the problem of manufacturing defects while welding different components including different optimal cross section area with the hand lever to form a hand starter system while maintaining the overall weight and compact layout of the vehicle and in a cost effective manner.
[00034] Advantageously, the embodiments of the present invention, describes the potential modifications in the hand starter system of the vehicle.
[00035] Many other improvements and modifications may be incorporated herein without deviating from the scope of the invention.
List of reference symbol:
Figure 1:
100: Motor Vehicle
106: steering means
101: Front Wheel
104: Driver Seat Assembly
102: Rear Wheels
103: Front Fender
110: Power Storage Housing Area
108: Passenger Seat Assembly
105: Rider Back Rest
107: Passenger Barrier.
109: Cabin Assembly
111: Internal Combustion Engine
Figure 2:
201: Head Tube
206: Main Tube
203: Central Tube
205: LH Side member
202: RH Side member
214: A pair of rear frame member
204, 208, 209: Lateral members
210, 211: Connecting bridge members
212: Right Hand Rear Frame
213: Left Hand Rear Frame
Figure 3:
301: Hand Starter Assembly
302: Floorboard

Figure 4:
401: Hand Grip
402: First Portion
403: Middle Portion
404: Rear Portion
405: opening
406: first elastic member
407: shaft
408: single hand lever member
409: Second elastic member
410: Supporting bracket