Claims:I/We Claim:
1. A saddle-ride type vehicle (100) sensor mounting structure (303), said saddle-ride type vehicle (100) comprising:
at least one front wheel (105);
a brake disc (201) mounted to a wheel axle (204) of said at least one front wheel (108), said brake disc (201) is configured to rotate with said front wheel (108);
a pulsar plate (401) mounted to said wheel axle (204) of said front wheel (108), said pulsar plate (401) is configured to rotate with said front wheel;
a pair of front fork (108) configured to pivotally support said front wheel (1051), said pair of front fork (108) includes an inner tube (108b) slidably connected to an outer tube (108a);
a brake caliper assembly assembly (202) functionally connected to said front wheel (105) for controlling said front wheel (105);
a brake caliper assembly support structure (304) to enable mounting of said brake caliper assembly assembly (202) to one or more caliper mounting portions (301, 302) on said outer tube (108a); and
a sensor unit (305) configured to detect speed of the front wheel (105) by detecting rotation of the pulsar plate (401), said sensor unit (305) is mounted to said outer tube (108a).
2. The saddle ride type vehicle (100) sensor mounting structure (303) as claimed in claim 1, wherein said sensor unit (305) is disposed away from a tangential axis (ZZ`) passing through a bottom edge (108ae) of said outer tube (108a) and a bottom portion (304e) of said brake caliper assembly support structure (304).
3. The saddle ride type vehicle (100) sensor mounting structure (303) as claimed in claim 1, wherein said sensor unit (305) includes a sensor body (305a) comprising a sensor body axis (xy), said sensor body axis (xy) is passing through center of said sensor body (305a), said sensor body axis (xy) is disposed away from said tangential axis (lm).
4. The saddle ride type vehicle (100) sensor mounting structure (303) as claimed in claim 1, wherein said sensor mounting structure (303) includes a sensor mounting portion (303b) and a sensor body receiving portion (303a).
5. The saddle ride type vehicle (100) sensor mounting structure (303) as claimed in claim 1 or claim 4, wherein said sensor mounting portion (303b) and a center of said wheel axle (204) lie along a joining axis (lm).
6. The saddle ride type vehicle (100) sensor mounting structure (303) as claimed in claim 5, wherein said joining axis (lm) is orthogonally intersecting said sensor body axis (xy).
7. An outer tube (108a) of a front suspension assembly (108) for mounting a sensor unit (305) in a vehicle, said outer tube (108a) comprising:
one or more calliper mounting portions (301, 302) and
said sensor mounting structure (303) disposed on an extended surface (501) adjoining a bottom edge (108ae) of the outer tube (108a).
8. The outer tube (108a) as claimed in claim 7, wherein the sensor mounting structure (303) is disposed adjoining a bottom edge (108ae) of the outer tube (108a) and away from the one or more calliper mounting portions (301, 302). , Description:TECHNICAL FIELD
[0001] The present subject matter relates to a saddle-ride type vehicle, more particularly but not exclusively to mounting of a sensor unit on the saddle-ride type vehicle.
BACKGROUND
[0002] In recent times, to make the riding of the vehicle safe for the rider has attained high importance. Accordingly, certain devices and vehicular parts are required in the two-wheeled vehicles. One such device is an anti-lock braking system (ABS) mounted in the vehicle to prevent skidding of the vehicle that may occur due to wheel locking during sudden braking conditions. For such a system (ABS) to function efficiently, one of the critical inputs required is speed of the wheel during vehicle running condition. Generally, vehicle speed is computed based on the wheel speed, which is detected using wheel speed sensors that are located in the vicinity of the wheel. The input from the wheel speed sensor is sent to the ABS control module for further processing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0003] The detailed description is described with reference to an embodiment of a two wheeled saddle type motorcycle along with the accompanying figures. The same numbers are used throughout the drawings to reference like features and components.
[0004] Figure 1 depicts a left side view of a two wheeled vehicle, in accordance with an embodiment of the present subject matter.
[0005] Figure 2 illustrates a right-side view of a front suspension assembly.
[0006] Figure 3 illustrates a left side view of an outer tube of the front suspension assembly.
[0007] Figure 4 illustrates a detailed view of a right-side view of the front suspension assembly.
[0008] Figure 5 illustrates a detailed view of a portion of the outer tube.
Figure 6 illustrates a detailed view of a portion of the outer tube.
DETAILED DESCRIPTION OF THE INVENTION
[0009] Typically, a two wheeled vehicle comprises of a rear wheel and a front wheel. Any one of the front and rear wheels or both the front wheel and the rear wheel are provided with brake disc to control the speed of the wheels. The brake disc is mounted to a wheel axle at the centre of the wheel. A pulsar plate is mounted to the axle of the wheel. The ABS is fitted in the vehicle. The functioning of the speed sensor is dependent on the pulsar plate. The pulsar plate is configured to rotate along with the brake disc. The pulsar plate is configured to include rectangular slots alternated by rectangular projections. The rectangular slots are equally spaced to each other.
[00010] There are two types of sensors found on today's vehicles. The two types of sensor include the passive type sensors and the active type sensors. The active type sensors are configured to create a digital signal. This type of digital wheel speed sensor uses a hall effect or a variable reluctance signal with a square wave pattern.
[00011] A Hall effect sensor is a device that is used to measure the magnitude of a magnetic field. The output voltage of the device is directly proportional to the magnetic field strength through it.
[00012] The Hall Effect sensors comprise a thin piece of rectangular p-type semiconductor passing a continuous current through itself. When the device is placed within a magnetic field, the Hall voltage is detected between the sense contacts.
[00013] One of the disadvantages of using hall effect sensors is that, the sensors can produce an offset voltage when there are physical inaccuracies, i.e whenever the hall effect sensor plates are not in alignment with slots in the pulsar plate.
[00014] In a known art, an additional and exclusive bracket is used to mount the brake calliper to an outer tube of the front suspension assembly in the vehicle. The bracket is mounted such that it is sandwiched between a brake calliper and a brake calliper mounting portion on the front suspension assembly. The speed sensor is mounted on the bracket used to mount the brake calliper. The position of speed sensor and orientation of speed sensor is very critical to meet ABS function and also enable ease of service.
[00015] The alignment of the speed sensor in mounted condition may change over a period of time due to manufacturing variations in the bracket that is used to mount the speed sensor. In particular, stack up variation due to machining tolerance of the bracket occurs. Further, the fasteners used to mount the bracket may loosen creating a lose fit assembly locally. The loosened bracket affects the positioning of the speed sensor. Thereby the speed sensor misaligns with the slots of the pulsar plate.
[00016] Generally, hall effect speed sensors are used in speed sensor for detecting pulse from pulsar plate that is attached to the wheel. The pulsar plate has rectangular slots which are used by sensor to generate signals. For this purpose, the sensor elements are placed in alignment with pulsar plate slots for proper pulse generation. If the sensor element is not aligned properly to pulsar plate slots, the speed sensor may provide erratic pulse signals to an electronic control unit (ECU). This may affect normal functioning of the ABS.
[00017] Therefore, the mounting of the speed sensor by use of additional brackets is not preferred.
[00018] Further, the braking system consists of a brake disc, which is attached to the wheel of the vehicle. The braking function is done by actuating the brake lever which in turn pushes the brake pads against the rotating disc which retards the speed of the brake disc due to friction between the brake disc and the brake pads. Due to frequent usage of braking function, the brake pads tend to get worn out and requires frequent replacement.
[00019] The frequency of brake pad replacement depends on riders riding style and usage patterns of the brakes. Generally, the brake pads are assembled inside the brake calliper assembly. Hence it is necessary to detach the brake calliper assembly to replace the brake pads. During removal of the brake calliper assembly, it is required to remove the speed sensor mounting as well, since both the brake calliper assembly and the speed sensor are mounted on the common bracket. The speed sensor is housed on the bracket by a means of one or more screw mountings. This results in hanging of speed sensor mounting and has risk of potential damage to speed sensor surface during the replacement of brake pads.
[00020] In the above explained known art, the mounting of the sensor is dependent on the bracket for mounting the brake calliper. Every time, the brake pads require servicing, the sensor mounting has to be disassembled. This makes the frequent servicing of the brake pads as well as access to the sensor mounting a difficult task. The undesirable disassembling of the sensor mounting consumes additional valuable time and might also lead to additional wear and tear frequently. Consequently, this increases the cost of the mountings. Thus there exists a need for an improved solution for a sensor mounting for a vehicle overcoming all of the above cited problems and other problems known in the art.
[00021] The present invention provides an efficient and effective mounting for the wheel speed sensor on the vehicle, the mounting for the wheel speed sensor according to the present subject matter addresses all of the above discussed problems existing in the known art.
[00022] According to an embodiment, the present invention is for a sensor mounting structure for a saddle-ride type vehicle. The saddle ride type vehicle includes a front wheel, a brake disc mounted to a wheel axle of the front wheel. The brake disc is configured to rotate with the front wheel.
[00023] Further a pulsar plate is mounted to the wheel axle of the front wheel. The pulsar plate is configured to rotate along with the front wheel. The pulsar plate includes rectangular slots on an outer diametrical surface. The vehicle includes a front suspension assembly comprising a pair of front forks. The front suspension assembly is for steering the vehicle. The pair of front forks pivotally support the front wheel. The pair of front fork includes an inner tube that is slidably connected to an outer tube.
[00024] Further, a brake caliper assembly is functionally connected to the front wheel for controlling the speed of the front wheel. The brake caliper assembly is mounted on the outer tube through a brake caliper assembly support structure
[00025] The brake caliper assembly support structure is used to enable mounting of the brake caliper assembly to one or more caliper mounting portions on the outer tube. Further, the outer tube is configured to support a portion of a sensor unit. The sensor unit is configured to detect the speed of the front wheel. This is done by detecting the rotation of the pulsar plate.
[00026] The senor unit comprises an in-built sensing element. The sensing element is configured to sense the rectangular slot in the pulsar plate. The wheel speed is sensed by the sensor unit based on the slots that pass by beneath the sensing element.
[00027] The sensor unit is mounted to a sensor receiving portion on the outer tube. The sensor receiving portion includes a sensor mounting portion and a sensor body receiving portion. The sensor receiving portion is disposed on an extended surface. The extended surface is adjoining an end portion of the outer tube. The extended surface is formed by the process of casting. The sensor receiving portion is disposed below the caliper mounting portions.
[00028] According to another embodiment of the present invention, the sensor unit and the sensor mounting portions are disposed away from a tangential axis. The tangential axis is passing through a bottom edge of the outer tube and a bottom portion of the brake caliper assembly support structure.
[00029] The sensor unit includes a sensor body comprising a sensor body axis. The sensor body axis is passing through the center of the sensor body such that the sensor body axis is disposed away from the tangential axis. The mounting of the sensor unit is independent of the mounting of the brake caliper assembly. Thus, the wear and tear of the sensor mounting and potential damage that could occur due to frequent dismounting drawback of the known art is prevented with the present invention.
[00030] According to an embodiment of the present invention, the sensor unit is directly attached to the outer tube. The outer tube is configured with a sensor mounting structure. The sensor mounting structure is capable of receiving the sensor unit. In an embodiment of the present invention, the sensor unit does not require an additional bracket to get mounted on to the outer tube. Instead, the sensor mounting structure itself, includes the sensor receiving portion, to where the sensor unit is mounted. Therefore, through the present invention, the need of additional bracket to mount the sensor unit is eliminated. This present invention, in addition to the above said technical enhancement, enables maintaining the sensor unit in its assembled condition which desired in order to attain the efficient reading of the movement of the pulsar plate. Further, due to elimination of the additional bracket, the dangling issues of the sensor unit, due to loosening of the mountings of the bracket, that lead to breakage of sensor unit itself is prevented. Therefore, a stable, consistent, reliable and efficient functioning of the sensor unit is achieved according to the present invention.
[00031] According to an embodiment of the present invention, the wheel axle, the sensor mounting portion, and the sensor body are in-line. The sensor mounting portion and the center of the wheel axle lie along a joining axis. The joining axis is intersecting the sensor body axis perpendicularly. The sensor mounting portion is configured to keep the sensor body in the aligned direction as determined during the assembly or mounting of the sensor unit. The sensor body is not disturbed by any other surrounding parts due to the presence of independent sensor mounting. Therefore, the sensor body remain in-line with the center of the wheel axle and the sensor mounting, which in turn achieves the required positioning of the sensor body over the rectangular slots in the pulsar plate. The consistency in the positioning of the sensor body over the rectangular slots is enabled to achieve better functionality of the sensor unit, which can provide error free inputs to the ABS unit. Wheel speed sensors are a necessary ABS component. In particular, the wheel speed sensors are used to inform the ABS control module of rotational wheel speed.
[00032] The same is achieved in a reliable, secure as well as durable manner by the proposed invention. The sensor body is disposed close to the rectangular slots such that when viewed from the side view, the rectangular slots lie beneath the sensory body.
[00033] The above and other features, aspects and advantages of the subject matter will be better understood with regard to the following description, appended claims and accompanying drawings.
[00034] Figure 1 depicts a left side view of a two wheeled vehicle, in accordance with an embodiment of the present subject matter. The vehicle (100) comprises a vehicle frame assembly (not shown) supporting a front wheel (105) and a rear wheel (106). The front wheel (105) and the rear wheel (106) are rotatably supported by front suspension assembly (108) and the rear suspension assembly (109), respectively. In one embodiment, the rear wheel (106) may be additionally supported by a swing arm (107). Further, the front wheel (105) is steerable by a handle bar assembly (114), which is functionally connected to the front wheel (105) for maneuvering the vehicle. The handlebar assembly (114) is configured to support at least one headlamp assembly (103).
[00035] In the present embodiment, an engine assembly (110) which is basically a power unit of the vehicle is mounted to a front lower portion of the frame structure by means of two or more engine mounting brackets. The engine assembly (110) is connected to a muffler (not shown in figure) being part of an exhaust system (111), which is capable of attenuating noise and treating harmful exhaust gases before emitting the exhaust gases to the atmosphere. The muffler assembly extends rearwards to the right side of the rear wheel (106). The engine is coupled to a transmission system for transferring power to the rear wheel (106). Further, the swing arm (107) extending rearwards is swingably connected to a lower rear portion of the frame structure. A chain case (112) is attached to the swing arm (107) assembly and helps in covering a chain during vehicle functioning.
[00036] In a front portion of the vehicle, a fuel tank assembly (102) is arranged immediately behind the handlebar and is disposed over an internal combustion engine. The handle bar (114) assembly supports an instrument cluster, vehicle controls including throttle, clutch, or electrical switches. An upper portion of the front wheel (108) and the rear wheel (106) are covered by a fender assembly in order to prevent mud and water getting deflected towards the vehicle and entering the steering shaft or engine and an exhaust system.
[00037] Further, a seat assembly (104) is mounted to the vehicle frame assembly and disposed rearward of the fuel tank assembly (102). The rider can operate the vehicle (100) in a seated position on the seat assembly (104). Further, to improve the overall aesthetics of the vehicle with plurality of panel covers (113) are provided mounted to the frame member and covering the frame member and/or parts of the vehicle (100). Also, the vehicle (100) may be provided with plurality of mechanical, electronic, and electromechanical system (not shown in figure) and may include an anti-lock braking system, a vehicle safety system, or an electronic control system.
[00038] Figure 2 illustrates a right-side view of a front suspension assembly. The front suspension assembly (108) comprises the front wheel (105), a pair of front forks (203). The pair of front forks (203) includes an outer tube (108a) and an inner tube (108b) each. The inner tube (108b) is slidably connected to the outer tube (108a). The speed of the wheel is controlled by a braking system (not shown). The braking system includes one or more brake levers provided on the handlebar assembly (not shown). The actuation of the brake lever by the rider, actuates the brake caliper assembly (202), which in turn controls the speed of the front wheel (105) by restricting the movement of the brake disc (201). The brake disc is attached to a wheel axle (204) of the front wheel (105). The brake caliper assembly (202) is mounted to a portion of the outer tube (108a). The brake caliper assembly (202) is mounted to the outer tube (108a) through a brake caliper assembly support structure (205).
[00039] Depending upon the usage pattern of the rider, the application of brakes takes place. Accordingly, the brake caliper assembly is configured to restrict the movement of the brake disc (201) by enabling contact of the brake disc (201) with one or more brake pads (not shown). The wear and tear of the brake pads is inevitable due to its intense usage pattern. The replacement of the brake pads takes place frequently and can be easily carried out by removing the mounting members and the brake caliper assembly support structure (205). The mountings used to mount the brake caliper assembly is independent of the mountings of other parts. Due to the frequent replacement of the brake pads, none of the surrounding mountings of the other vehicular parts are disturbed according to the present invention. As a result, the time consumed in carrying out the replacing of the brake pads is reduced considerably.
[00040] Figure 3 illustrates a left side view of an outer tube of the front suspension assembly. The outer tube (108a) is configured to integrally support one or more caliper mounting portions (301, 302) and sensor mounting portion (303). In an embodiment, the outer tube along with the one or more caliper mounting portions (301, 302) and the sensor mounting portion (303) are integrally formed through the process of casting. Each of the one or more caliper mounting portions (301, 302) and the sensor mounting portion (303) include receiving provisions (301a, 302a, and 303a) respectively. In the present embodiment, the sensor mounting portion (303) is disposed below the one or more caliper mounting portions (301, 302). In an embodiment, the sensor mounting portion (303) is disposed adjoining a bottom edge (108ae) of the outer tube (108a) and away from the other mounting portions. The sensor mounting portion (303) includes sensor mounting portion (303b) and a sensor body receiving portion (303a). The one or more caliper mounting portions (301, 302) and the sensor mounting portion (303) are circular in shape.
[00041] According to another embodiment of the present invention, the caliper mounting portion (302), and the sensor mounting portion (303) are disposed on an extended surface (501) adjoining bottom edge (108ae) of the outer tube (108a).
[00042] Figure 4 illustrates a detailed view of a right-side view of the front suspension assembly. The one or more caliper mounting portions (301, 302) are configured to receive the brake caliper assembly (202) and the brake caliper assembly support structure (304). The brake caliper assembly support structure (304) is sandwiched between the one or more caliper mounting portions (301, 302) and the brake caliper assembly (202). Further, the sensor mounting portion (303) is configured to receive the sensor unit (305). In the present embodiment, the sensor unit (305) is disposed away from the brake caliper assembly (202). The mounting of the brake caliper assembly (202) and the sensor unit (305) are independent of each other. This way, the sensor unit (305) is not disturbed by the surrounding components and hence, the sensor unit (305) remains in the assembled position. The positioning of the sensor unit is critical for detecting the movement of the pulsar plate (401). The pulsar plate (401) is disposed co-axial to the wheel axle (204). The sensor unit (305) is placed above the pulsar plate (401) at a close proximity.
[00043] Figure 5 illustrates a detailed view of a portion of the outer tube. According to an embodiment of the present invention, the sensor mounting portion (303b) and a center of the wheel axle (204) lie along a joining axis (lm). The joining axis (lm) is orthogonally intersecting a sensor body axis (xy). The sensor body axis (xy) passes centrally and vertically along a sensor body (305a) of the sensor unit (305). In this particular, configuration, the pulsar plate (401) is disposed co-axial to the wheel axle (204). The sensor body (305a) remains along the joining axis (lm) while having the pulsar plate (401) co-axial to the wheel axle (204). This is an efficient way for the sensor unit (305) to detect the movement of the pulsar plate (401). The sensor unit (305) remains so, as the sensor mounting portion (303b) is isolated from other surrounding mountings and is left undisturbed throughout, unless called for servicing or replacement of the sensor unit (305). The occurrence of the same can be predicted do be a rare scenario, as the sensor mounting portion (303b) remains stable, thereby providing stability to the sensor unit (305). Further, as illustrated in the figure, the portion of the pulsar plate (401) is disposed beneath the sensor body (305a). This position of the pulsar plate (401) with respect to the sensor body (305a) is maintained constant according to the present invention. Therefore, an efficient functioning of the sensor unit (305) is achieved.
[00044] Figure 6 illustrates a detailed view of a portion of the outer tube. According to an embodiment of the present invention, the sensor unit (305) is disposed away from a tangential axis (ZZ`) passing through a bottom edge (108ae) of the outer tube (108a) and a bottom portion (304e) of said brake caliper assembly support structure (304).
[00045] Further, the sensor unit (305) includes a sensor body (305a) comprising a sensor body axis (xy), the sensor body axis (xy) is passing through center of said sensor body (305a), said sensor body axis (xy) is disposed away from said tangential axis (ZZ`).
[00046] According to an embodiment of the present invention, the sensor unit (305) is positioned in coordinate such that it is placed away from the space from the tangential axis (ZZ`). By this, the brake caliper assembly (202) servicing is carried out for the replacement of the disc pads without disturbing the sensor unit (305) from the assembled condition.
[00047] Therefore, an efficient, real time functioning of the sensor and stable operation of the sensor unit (305) is achieved.
[00048] Further, according to another embodiment of the present invention, the exit of the sensor hose wire (not shown) is positioned perpendicular to the line joining the axis, the joining axis (lm) between sensor body (305a) and sensor mounting portion (305b). This enables the routing of sensor hose wire to move away from the one or more brake caliper assembly mounting portions (301, 302) on the outer tube (108a).
[00049] 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.

Brief description of reference numerals:

100 Vehicle
102 Fuel tank assembly
103 Headlamp assembly
104 Seat assembly
105 Front wheel
106 Rear wheel
107 Swing arm
108 Front suspension assembly
108a Outer tube
108ae Bottom edge
108b Inner tube
109 Rear suspension assembly
110 Engine assembly
111 Exhaust system
112 Chain case
113 Panel covers
114 Handlebar assembly
202 Brake caliper assembly
203 Pair of front forks
204 Wheel axle
301, 302 Brake caliper mounting portions
303 Sensor mounting structure
303a Sensor body receiving portion
303b Sensor mounting portion
304 Brake caliper support structure
304e Bottom portion
305 Sensor unit
305a Sensor body
305b Sensor mounting portion
401 Pulsar plate
lm Joining axis
xy Sensor body axis
ZZ` Tangential axis