FORM 2
THE PATENTS ACT 1970
(39 of 1970)
&
THE PATENTS RULES, 2003
COMPLETE SPECIFICATION
(See Section 10; rule 13)
TITLE OF THE INVENTION
An improved coupling assembly mechanism for towing and delatching of a vehicle carrier for a simulated crash test
APPLICANTS
TATA MOTORS LIMITED, an Indian company
having its registered office at Bombay House,
24 Homi Mody Street, Hutatma Chowk,
Mumbai 400 001 Maharashtra, India
INVENTOR
Sharad Kadam; Atul A. Date; P Kannan; Milind Tank
Indian national
of TATA MOTORS LIMITED an Indian company
having its registered office at Bombay House,
24 Homi Mody Street, Hutatma Chowk,
Mumbai 400 001 Maharashtra, India
PREAMBLE TO THE DESCRIPTION
The following specification particularly describes the invention and the manner in which it is to be performed.

Field of invention:
This invention relates to a coupling assembly mechanism for towing and delatching of a carrier for a simulated crash test.
Background of invention
Crash tests are simulated in a crash safety laboratory to study the technical details of a real crash test. One of the ways to simulate a crash test is to keep the test vehicle or sub system on a moving trolley or carrier and impact it against a crash barrier. The carrier is propelled to the required test speed and it is stopped before a barrier and the vehicle or sub system, placed on the carrier, moves ahead with own inertia & impacts against the barrier. Such a test procedure is popularly used while simulating side impacts.
The carrier is propelled by coupling it to a propelling system which consists of an endless wire rope accelerating up to the required test speed. The coupling used in the test set up ensures that the carrier is propelled as long as its speed is less than the speed of the propelling system. In case, if the carrier speed is more than the propelling system, there is a possibility that the carrier may disengage from the coupling & therefore from the propelling system.
Sometimes there is need to abort the test in the case of emergency. In such situation, both the propelling system and the carrier are applied with their own emergency brakes. These brakes need to be synchronized such that the carrier is braked after the propelling system otherwise it may damage the coupling between the carrier and the propelling system.
Objects of the invention
The main objective of the present invention is to provide an improved coupling assembly for towing and delatching of a carrier for a simulated crash test such that the braking system of the propelling mechanism can brake the propelling system as well as the carrier.

Another objective of the present invention is to provide an improved coupling assembly for towing and delatching of a carrier for a simulated crash test such that the latching and delatching of the carrier with the propelling mechanism can be controlled by actuation of a plunger.
Yet another objective of the present invention is to provide an improved coupling assembly for towing and delatching of a carrier for a simulated crash test which is simple in construction and cost effective.
Summary of invention:
An improved coupling assembly mechanism for towing and delatching of a vehicle carrier for a simulated crash test comprising:
- a coupling body having bottom, middle and top parts rigidly attached to each other by fasteners,
- an actuating plunger and at least two actuating links being placed between the said top & middle parts,
- support pins being further engaged with each of said actuating links in such a manner that engaging and disengaging of said support pins can done by pushing or dragging said actuating plunger, so as to engage or disengage an anchor provided with said carrier, said anchor is coupled to a trolley.
A collate is provided on endless wire rope of propelling system to engage with matching tapered cavity of said coupling assembly.
Said anchor has a tapered end engagable with a catcher provided on said top part of the coupling assembly.
Said support pins are positioned near the centre plane of the coupling in such a way that when the speed of wire rope is reduced, the anchor is partially dislodged from the catcher but is restricted by said support pins.

Said plunger is pushed inwards, actuating links are actuated and the support pins move away from the centre of the coupling and the anchor disengages from the catcher.
A method of simulated crash test using improved coupling assembly mechanism for towing and delatching of a vehicle comprising the following steps:
- the support pins are moved away by pushing action of the plunger & the anchor is engaged with the catcher;
- the plunger is pulled outwards;
- the carrier is then engaged with the coupling;
- the collate is fixed to the wire rope in the vicinity and engaged with matching taper of the coupling assembly;
- the carrier is then propelled by the propelling system to attain the desired speed;
- the plunger hits the stopper bracket, the support pins are moved away and the carrier is delatched from the coupling;

- the carrier moves away further with own inertia by disengaging from the propelling system;
- the collate extension hits the stopping bracket and it gets dislodged from the coupling assembly;
- the vehicle hits impact barrier and after that carrier stopping system stops the carrier.
A method of abortion of simulated crash test using improved coupling assembly mechanism for towing and delatching of a vehicle comprising the following steps:
- the propelling system is stopped;
- the support pins are oriented at the centre of the coupling assembly, the carrier support plate is in contact with the coupling and therefore the carrier follows the propelling system and consequently the carrier is also braked;
Brief description;
Figure - 01 shows side & top views of a test set up for a simulated crash test,

Figure - 02 shows partial side, top & isometric views of the said test set up focusing
on the front end of the carrier,
Figure - 03, shows exploded view of the collate & the wire rope assembly
Figure - 04 shows the details of the stopper bracket,
Figure - 05 shows partial side, top & isometric views of the front end of the carrier,
Figure - 06 shows side, top & isometric views of the anchor fitted to the carrier,
Figure - 07 shows the exploded view of the improved coupling assembly,
Figure - 08 shows front, side, top & isometric views of the bottom part of the
coupling assembly,
Figure - 09 shows front, side & isometric views of the middle part of the coupling
assembly,
Figure - 10 shows front & top views, top & bottom isometric views of the top part
of the coupling assembly,
Figure - 11 shows side & top views of the actuating plunger of the coupling
assembly,
Figure - 12 shows side & top views of the first operating link of the coupling
assembly,
Figure - 13 shows side & top views of the second operating link of the coupling
assembly,
Figure - 14 shows side & top views of the support pin of the coupling assembly,
Figure - 15 shows partial side & top views of the front end of the carrier, when the
coupling is engaged with the carrier,
Figure - 16 shows partial side & top views of the front end of the carrier, when the
carrier is disengaged from the coupling,
Detailed description:
A plunger actuated improved coupling which is used between a carrier & the propelling system, is used for a simulated crash test. When the plunger is actuated, the coupling gets disengaged from the carrier & therefore the carrier is disengaged from the propelling system. When the plunger is not actuated, the carrier & the

propelling system are engaged together & the emergency brakes applied on the propelling system also brakes the carrier. The plunger is actuated by a stopping bracket in the track of the propelling system. Placement of the stopping bracket decides the actuation of the coupling during the test sequence.
Referring now to the drawings wherein the showings are for the purpose of illustrating a preferred embodiment of the invention only, and not for the purpose of limiting the same.
Figure 01 shows side and top views of a typical simulated crash test set up. It shows vehicle carrier (1), endless wire rope (2) of the propelling system, coupling mechanism (3) joining the said carrier with the said wire rope of the propelling system, a stopper bracket (4) for actuating the said coupling which is rigidly fixed to the test floor, a test vehicle (5) kept on the said carrier, an impact barrier (6) for impacting the vehicle and a carrier stopping system (7).
Figure 02 shows partial views of the front end of the carrier. It shows the said carrier, the said endless wire rope, the said stopper bracket & the said coupling connected to the said carrier. It also shows actuating plunger (3.5) for the coupling actuation. The said endless wire rope is provided with a tapered collate (3.2) for engagement with the coupling.
Figure 03 shows the exploded view of the collate (3.2) & the endless wire rope (2) assembly. The said collate is a sleeve with inner part (not shown in fig.) in completely circular shape & the outer part (not shown in fig) tapered. The said collate is split into 2 parts as shown. The collate is used to couple the said wire rope to the coupling using taper fit between the said collate & the said coupling. A matching taper is also provided to the coupling for engagement of the said collate. When the collate is engaged with the coupling, the wire rope movement is transferred to the said coupling. The collate is assembled to the said wire rope by fixing its two parts by suitable fasteners. The said Collate is held at its position on

the said wire rope by friction. The collate & the said actuating plunger dimensions are so worked out that plunger hits the stopper bracket before the collate extension..
Figure 04 shows the details of the said stopper bracket. The stopper bracket consists of a base plate (4.1) which is fixed to the test floor. At one end of the bracket 2 "L" - shaped vertical plates (4.2) are attached to the base plate. A top plate (4.3) is attached to the said vertical plates as shown. When the coupling assembly hits the stopper bracket, the actuating plunger hits the second vertical face (4.5) and the collate hits the first vertical face (4.4). the distance (4.6) between the said first & second vertical faces is predetermined in order to synchronise the actuation of the said plunger and dislodging of the said collate from the said coupling. The position of this stopper bracket determines the decoupling of the said carrier in the test sequence.
Figure 05 shows partial views of the front end of the said carrier provided with anchor (1.1) to engage with the coupling assembly. The propelling movement of the propelling system is imparted to the said carrier through the said anchor.
Figure 06 shows the constructional details of the said anchor (1.1). The anchor is attached to the front end of the carrier through suitable fasteners through the mounting holes (1.1.2). The anchor has been provided with a tapered end (1.1.1). Figure 07 shows the exploded view of the coupling assembly. The coupling body consists of 3 parts, bottom (3.1), middle (3.3) & top (3.4) which are rigidly attached to each other by suitable fasteners. An actuating plunger (3.5) and actuating links (3.6, 3.7) are placed between the said top & middle parts. One support pin (3.8) is further engaged with each of the said actuating links as shown. The figure also shows the endless wire rope (2) of the propelling system, the collate (3.2) provided on the said endless wire rope, engages with the matching tapered cavity created after assembly of the said bottom & middle part of the coupling assembly. The figure further shows the said anchor (1.1) of the carrier with a tapered end (1.1.1)

which is engaged with a catcher (3.4.6) provided on the top part of the coupling assembly.
Figure 08 shows views of the bottom part (3.1) of the said coupling. The bottom part has been provided with a tapered cavity (3.1.1) for engagement with the said collate (3.2) provided on the endless wire rope (2) of the propelling system. It has also been provided with threaded holes (3.1.2) for attaching it with the middle part (3.3) of the said coupling assembly by suitable fasteners.
Figure 09 shows views of the middle part (3.3) of the said coupling assembly. The bottom end of the said middle part is attached to the said bottom part (3.1) through suitable fasteners through the plurality of inner holes (3.3.2). The said bottom end has also been provided with a tapered cavity (3.3.1) for engagement with the said collate (3.2). When the middle part is assembled with the bottom part, the said cavities join up to make a complete tapered cavity to engage with the said collate (3.2). The top end of the middle part contains a rectangular slot (3.3.5) for guiding the movement of the said actuating plunger (3.5). The middle part is attached to the said top part (3.4) of the coupling through another set of plurality of outer threaded holes (3.3.3 and 3.3.4).
Figure 10 shows the views for the said top part (3.4) of the said coupling assembly. Its top end contains a catcher (3.4.6) for engaging with the tapered end of the said anchor (1.1). Its top end has also been provided with two inclined slots (3.4.1) for guiding the movement of the said support pins (3.8). Its bottom end has been provided with a slot (3.4.4) for guiding the movement of the said actuating plunger (3.5). The front part of the top part has been provided with a step (3.4.5) for accommodating the said operating links (3.6 & 3.7). The top part has been provided with counter bored holes (3.4.2) & plain holes (3.4.3) for attaching it with the said middle part (3.3).

Figure 11 shows views of the actuating plunger (3.5). It is preferably rectangular in shape. It has been provided with a step (3.5.2) to suit the combined width of the said first & second actuating links. It has also been provided with a hinge pin (3.5.1) for pivoting the said first & second actuating pins. For improving understanding of the component, its front (F) & rear (R) ends have been indicated. Its front end engages with the said stopper bracket (4) during decoupling. Its rear end (3.5.2) is guided in the said slots (3.3.5 & 3.4.4) of said middle & upper parts.
Figure 12 & figure 13 show the first operating link (3.6) & the second operating link (3.7) respectively. For improving understanding, the front (F) & rear (R) ends have been indicated in these figures. Both of these pins have been provided with 2 clear holes (3.6.4 & 3.7.3). The front hole is for engaging with the said hinge pin (3.5.1) on the actuating plunger. The rear holes are for engaging with the support pins (3.8) explained in the subsequent figures.
The said first actuating pin has been provided with angular steps on top (3.6.1) & bottom faces (3.6,2) (fig 12 needs to be corrected. Slot is not seen in fig). The said second actuating pin has been provided with angular slot (3.7.1) only on bottom face. These angular slots allow the angular movements of the pins during movement of the said actuating plunger.
Figure 14 shows the support pin (3.8). This pin is preferably oblong in shape. It has been provided with a slot (3.8.1) & pivot pin (3.8.2). The support pins are engaged with corresponding holes in the said first & second actuating pins through the said through holes (3.6.4 & 3.7.3). The support pin has been provided with an oblong shape particularly make it guide appropriately in the inclined slots (3.4.1) of the said top part (3.5),
Figure 15 & 16 shows the partial top & side views of the carrier assembly to explain the operation of the said coupling.
Figure 15 shows the coupling during propelling of the said carrier by the said endless wire rope of the propelling system. This configuration is termed as

"latched" configuration. The said collate is engaged with the matching tapered cavity of the said coupling assembly & the coupling assembly is therefore engaged with the said wire rope. The anchor of the trolley (1.1) is engaged with the matching catcher (3.4.6) on the coupling. The plunger (3.5) is fully extended. The support pins (3.8) are positioned near the centre plane of the coupling. In this configuration, if the wire rope speed is reduced, the anchor (1.1) is partially dislodged from the catcher (3.4.6) however it is restricted at this position by the support pins (3.8) & therefore the tapered end of the anchor (1.1.1) remains with the catcher. In this configuration, if the propelling system is braked, the wire rope speed is reduced. The said anchor tries to come out of the said catcher however the said support pins retain them in its position and the said carrier also slows down with the wire rope. As a result braking of the propelling system is also applied to the carrier.
In the case of prior art, the coupling does not contain any mechanism like the support pins which ensures engagement of the anchor & the catcher during braking of the propelling system. Therefore braking of the propelling system disengages the anchor and the carrier continues to move forward. The carrier is therefore also provided with a separate braking system for stopping.
Figure 16 shows the coupling configuration in what is termed as "delatched" configuration. In this configuration, the plunger (3.5) is pushed inwards, as indicated by an arrow mark. It further actuates the said first & second actuating links & moves the support pins (3.8) away from the centre of the coupling. In this configuration, if the propelling system is slowed down, the anchor (1.1.1) disengages from the catcher (3.4.6) and the carrier moves ahead by own inertia. Such free movement of the carrier is desired at the end of the test sequence when the vehicles/sub system installed on the carrier is to be thrown towards the impact barrier.

During a typical test sequence, the support pins are moved away by pushing action of the plunger & the anchor is engaged with the catcher. The plunger is pulled outwards. The carrier is then engaged with the coupling. The collate is fixed to the wire rope in the vicinity & engaged with matching taper of the coupling assembly. The carrier is then propelled by the propelling system to attain the desired speed. At the end of the test sequence, the plunger hits the stopper bracket, the support pins are moved away & the carrier is delatched from the coupling. The carrier moves away further with own inertia. With this the carrier disengages from the propelling system. Subsequently the collate extension hits the stopping bracket and it gets dislodged from the coupling assembly..
Further the vehicle hits impact barrier and after that carrier stopping system stops the carrier.
In the case of emergency, the test requires to be aborted. In such situation, the propelling system is stopped. Since the plunger is not actuated, the support pins are oriented at the centre of the coupling assembly (figure 15), the carrier support plate is in contact with the coupling & therefore the carrier follows the propelling system which means the carrier is also braked. However such test abortion is possible only when the collate and/or plunger have not contacted the stopper bracket.
In the case of prior art design both the carrier & the propelling system have their own brakes and the carrier brakes are applied after it has been delatched from the propelling system.
In another embodiment of the system there can be an alternative arrangement by reversing the sequence by putting coupling assembly in trolley and actuating plunger in drive system according to convenience.
Advantages of the proposed system is to control latching & delatching of the carrier from the propulsion system as desired, integrated breaking of the carrier along with the propulsion system in the event of emergency.

The foregoing description is a specific embodiment of the present invention. It should be appreciated that this embodiment is described for purpose of illustration only, and that numerous alterations and modifications may be practiced by those skilled in the art without departing from the spirit and scope of the invention. It is intended that all such modifications and alterations be included insofar as they come within the scope of the invention as claimed or the equivalents thereof

We claim
1. An improved coupling assembly mechanism for towing and delatching of a
vehicle carrier for a simulated crash test comprising:
- a coupling body having bottom, middle and top parts rigidly attached to each other by fasteners,
- an actuating plunger and at least two actuating links being placed between the said top & middle parts,
- support pins being further engaged with each of said actuating links in such a manner that engaging and disengaging of said support pins can done by pushing or dragging said actuating plunger, so as to engage or disengage an anchor provided with said carrier, said anchor is coupled to a trolley.

2. The improved coupling assembly as claimed in claim 1 wherein, a collate is provided on endless wire rope of propelling system to engage with matching tapered cavity of said coupling assembly.
3. The improved coupling assembly as claimed in claim 1 wherein, said anchor has a tapered end engagable with a catcher provided on said top part of the coupling assembly.
4. The improved coupling assembly as claimed in claim 1 wherein, said support pins are positioned near the centre plane of the coupling in such a way that when the speed of wire rope is reduced, the anchor partially dislodged from the catcher, is restricted by said support pins.
5. The improved coupling assembly as claimed in claim 1 wherein, when said plunger is pushed inwards actuating links are actuated and the support pins move

away from the centre of the coupling and the anchor is allowed to disengage from the catcher.
6. A method of simulated crash test using improved coupling assembly mechanism
for towing and delatching of a vehicle comprising the following steps:
- the support pins are moved away by pushing action of the plunger & the anchor is engaged with the catcher provided on the carrier;
- the plunger is pulled outwards;
- the carrier is then engaged with the coupling;
- the collate is fixed to the wire rope in the vicinity and engaged with matching taper of the coupling assembly;
- the carrier is then propelled by the propelling system to attain the desired speed;
- the plunger hits the stopper bracket, the support pins are moved away and the anchor is delatched from the coupling;

- the carrier moves away further with own inertia by disengaging from the propelling system;
- the collate extension hits the stopping bracket and it gets dislodged from the coupling assembly;
- the vehicle hits impact barrier and after that carrier stopping system stops the carrier.
7. A method of abortion of simulated crash test using improved coupling assembly
mechanism for towing and delatching of a vehicle comprising the following steps:
- the propelling system is stopped;
- the support pins are oriented at the centre of the coupling assembly, the carrier support plate is in contact with the coupling and therefore the carrier follows the propelling system and consequently the carrier is also braked.

8. An improved coupling assembly mechanism for towing and delatching of a vehicle carrier for a simulated crash test and methodology of the same substantially as hereinabove described with reference to the accompanying drawings.