Integrated Foot Pedal Control System for Hydraulic Power Take-Off Assembly for ATV

Abstract

An integrated foot-operated pump control system for a variable-flow hydraulic power take-off assembly for use with an ATV. The integrated foot-operated pump control system simplifies installation, removal, and re-installation of the hydraulic power take-off assembly, eliminates hand fatigue, and enhances safety. The integrated foot-operated pump control system is embodied in a hydraulic power take-off unit having a variable-flow pump with a flow control mechanism and a foot-operated pump control system having a foot pedal and a control cable that remain attached to the hydraulic power take-off unit when it is disconnected from the ATV.

Description

RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/751,768, filed Jan. 11, 2013.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention relates to a hydraulic power take-off assembly for all terrain vehicles (ATVs) or the like, and, more particularly, to an integrated foot pedal control system for a hydraulic power take-off assembly for use with an ATV.

2. Description of the Prior Art

A typical ATV is a small open single-rider vehicle having four wheels and generally designed for off-road use on various types of terrain or rough ground. The American National Standards Institute (ANSI) defines an ATV as a vehicle that travels on low-pressure tires, with a seat that is straddled by the operator, along with motorcycle-like handlebars for steering control. ATVs usually do not have windshields.

Other vehicles of similar size, power, and all-terrain capability have different names. For example, a UTV (utility task vehicle), sometimes called a “side-by-side,” is a four-wheel drive vehicle that usually is slightly larger than an ATV, usually has a conventional steering wheel, and provides seating for 2 or 4 people in a side-by-side arrangement. UTVs sometimes have windshields. UTVs often have small truck beds and, as a result, are popular among golf course maintenance personnel, parks and recreation departments, and any other users who need to travel over uneven terrain with people and materials.

ATVs and UTVs are traditionally sold by well-known manufacturers such as HONDA®, KAWASAKI®, ARCTIC CAT®, YAMAHA®, CAN-AM®, SUZUKI®, and POLARIS®. For the sake of simplicity, this application will refer to vehicles in this general class as “ATVs.”

An ATV is usually powered by an internal combustion engine that runs on gasoline or other suitable fuel (e.g. propane, diesel fuel, etc.) For moving the ATV, the engine is usually coupled to a pair of rear-drive wheels via the engine's drive shaft and an intermediate transmission. Some ATVs even include four wheel drive power train.

ATV's are often used for recreational purposes, but ATV manufacturer are also making models that are well-suited for use as general purpose work vehicles or utility vehicles (e.g. on a farm or other large property, for military purposes, etc.).

Due to the ever increasing demand to use ATVs as work vehicles, various implements have been designed to convert ATVs into more useful vehicles, such as lawn mowers, log splitters, electric generators, etc. However, these attachments normally came with significant drawbacks in that duplicate engines were needed to run the separate implements that may or may not be pulled by the ATV, which is very costly and needlessly weighs down the ATV. Conventional implements are custom installed and are cumbersome and time consuming to utilize in that they are required to be bolted onto the ATV engine and have to be completely unbolted and disassembled to operate the ATV in a normal function when not using the implement.

U.S. Pat. Nos. 7,284,625 and 7,600,594, invented by applicant and hereby incorporated by reference as if fully set forth herein, disclose a unique hydraulic power take-off (PTO) system for use with an ATV. The two patents more specifically disclose a quick connect/disconnect assembly for allowing a power transfer unit to be connected to and disconnected from an ATV. The power transfer unit detachably connects to an output shaft associated with the rotation of the ATV's engine (usually the engine's drive shaft) and then powers an implement connected to, carried by, or located near the ATV. The power transfer unit beneficially eliminates the need to have separate engines for the implements.

The preferred power transfer unit is a hydraulic pump that forces fluid through a hydraulic circuit and drives a hydraulic motor associated with the implement. The exemplary implements that could be driven with the hydraulic power transfer unit included a lawn mower, a water sprayer, a snow blower, an air compressor, a water pump, a post-hole digger, an electric generator, a wood chipper, and a log splitter.

In the typical ATV, the engine includes an engine case and a drive shaft or other engine shaft that extends from the engine case. Typically, the engine's drive shaft is accessible beneath the drive shaft cover or starter cover that is historically associated with a so-called “Recoil Starter.” In earlier ATVs, the drive shaft cover sometimes included a pull handle to permit the operator to hand start the engine in the event that the electrically-driven starter was inoperable. In more recent ATVs, however, the drive shaft cover often does not include a pull handle and the cover is just a cover.

In one commercial embodiment made according to the '625 and '594 patents, designed for retrofitting a hydraulic power take-off unit to a BRUTE FORCE® model ATV manufactured by KAWASAKI®, the starter cover is removed and a drive plate that carries a female coupler is retrofitted to the drive shaft. Then, the starter cover is replaced with a quick connect case that provides suitable quick connect features along its periphery and has a central aperture that exposes an outward face of the female coupler. Using a suitable quick connect/disconnect mechanism that mates with the features on the case, the hydraulic pump is connected to the quick connect case and, inside of the case, the hydraulic pump's input shaft and associated male coupler are mated with the female coupler.

The quick connect assembly and hydraulic power transfer unit disclosed in the '625 and '594 patents advantageously allows an ATV owner to power various implements by using the ATV's own engine—without requiring a duplicate engine on the implement.

The preferred hydraulic pump was a variable displacement pump (e.g. 0-15 gallons per minute, or GPM, of fluid flow), and in early experiments, the ATV was retrofitted with a corresponding pump control for controlling the flow of the pump and the resulting speed, force, etc. of the implement that is being driven by the hydraulic pump. In early experiments, the pump control was a hand-operated control located on the handle bars of the ATV. The hand-operated control typically consisted of a re-purposed hand lever and an associated cable. On some ATVs, one of the hand brakes was converted to a pump control (e.g. the left hand brake with redundantly operated the ATV's rear brake), and on others (e.g. KAWASAKI®), the parking brake lever (lockable in place) was converted to a pump control.

The quick connect/disconnect hydraulic PTO system and associated pump control represent a revolutionary advancement in the use of ATVs. However, there are certain drawbacks to a hand-operated pump control:

A hand-operated pump control implemented by converting a parking brake requires continued pressure, occupies one of the operator's hands, and may lead to operator fatigue;

A hand-operated pump control implemented by converting a parking brake reduced fatigue by allowing the operator to lock it in place, but if they fell off the ATV the hydraulic pump would continue pumping without the operator;

A hand-operated pump hand control system required that the control cable be installed and removed each time the PTO system was connected and disconnected from the ATV, necessitating additional action and possible adjustment each time.

Accordingly, a need has been developed in the art to provide an integrated foot-operated pump control that does not result in operator fatigue, does not occupy the operator's hands, does not continue operating (unless purposely intended), and does not require re-installation and adjustment when the system is re-attached to the ATV.

BRIEF SUMMARY OF THE INVENTION

It is a primary object of this invention to provide an integrated foot-operated pump control system for a hydraulic power take-off assembly for use with an ATV.

In a preferred embodiment, the invention comprises variable-flow hydraulic power take-off assembly adapted for an all-terrain vehicle (ATV) having an engine, comprising: a hydraulic power take-off unit comprising a variable-flow pump that has a flow control mechanism and may be connected to and disconnected from the ATV, the pump being rotationally-driven by the engine and adapted for powering hydraualic implements attached to or located near the ATV via hydraulic hoses; and a foot-operated pump control system that comprises a foot pedal, the foot-operated pump control system being integrated with the hydraulic power take-off unit, and controlling the flow control mechanism in correlation with a depression of the foot pedal, the foot-operated pump control system remaining with the hydraulic power take-off unit when it is disconnected from the ATV. In a more specific embodiment, the foot-operated pump control system comprises a foot pedal; and a control cable operatively connecting the foot pedal to the flow control mechanism of the pump.

While the apparatus and related method has or will be described for the sake of grammatical fluidity with functional explanations, it is to be expressly understood that the claims, unless expressly formulated under 35 USC 112, are not to be construed as necessarily limited in any way by the construction of “means” or “steps” limitations, but are to be accorded the full scope of the meaning and equivalents of the definition provided by the claims under the judicial doctrine of equivalents, and in the case where the claims are expressly formulated under 35 USC 112 are to be accorded full statutory equivalents under 35 USC 112. The invention can be better visualized by turning now to the following drawings wherein like elements are referenced by like numerals.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an ATV 10 (here a POLARIS® RANGER® UTV) that has been outfitted with a hydraulic power take-off assembly 100 having a variable-flow hydraulic pump 110 that is driven by the ATV's engine (opposite side of ATV and not visible), and a hydraulically-driven implement 20 (here a lawn mower) having a hydraulic motor 21 that is rotated by hydraulic fluid flowing through hydraulic hoses 131, 132 connected to a hydraulic pump (not shown, but see other figures);

FIG. 2 is a left-side perspective view of an ATV (here a KAWASAKI® BRUTE FORCE® ATV) with a hydraulic power take-off unit 100 connected to its engine and a hydraulic implement 20 (again, a lawn mower), the hydraulic power take-off unit 100 comprising, in accordance with a first preferred embodiment, a variable-flow pump 110, a reservoir cooler 120, reservoir hoses 121, 122, implement hoses 131, 132 that lead to the hydraulic motor 21 (not shown), and an integrated foot-operated pump control system 200;

FIG. 3 is a closer-in perspective view of the left side of the ATV 10 more clearly showing the foot-operated pump control system 200 comprised of a pedal and a pedal-operated cable 280 that controllably manipulates a flow control mechanism 150 associated with the variable-flow pump 110;

FIG. 4 is an exploded perspective view of the hydraulic power take-off unit 100 showing how the hydraulic PTO 100 is connected to and disconnected from an ATV 10 and, of significance, how the foot-operated pump control system 200 travels with the PTO 100 such that there is generally no need to re-attach or re-adjust the pump control system 200;

FIG. 5 is a perspective view of the hydraulic power take-off unit 100 of FIGS. 2, 3, and 4, separated from the ATV and more clearly showing its integrated foot pedal control system 200 from an engine-side perspective;

FIG. 6 is a perspective view comparable to FIG. 5, but visually distinguishing a portion of the hydraulic power take-off unit 100 from the additional components that make up the integrated foot pedal control system 200 and, in the preferred embodiment, a hydraulic pump handle 290 that helps the operator connect or disconnect the hydraulic PTO 100 to the ATV, protects the flow control mechanism 150, and helps the operator carry the unit 100 when separated from the ATV;

FIG. 7 is a close-up perspective view of the bottom bracket 220;

FIGS. 8 and 9 are top plan and edge views, respectively, of the bottom bracket 220 of FIG. 6 when flat;

FIG. 10. is a perspective view of the foot pedal arm 230;

FIG. 11 is an side elevational view of a central section 231 of the foot pedal arm 230 of FIG. 8, when flat, prior to having the tubes 232, 233, 234 welded thereto;

FIG. 12 is a perspective view of the control cable arm 240;

FIG. 13 is a side elevational view of the bottom cable bracket 240 when flat; and

FIG. 14 is a side view of the foot pedal arm assembly 250 formed from the foot pedal arm 230 and the bottom cable bracket 240.

FIG. 15 is a top plan view of the foot pedal arm assembly 250 of FIG. 11A;

FIG. 16 is a perspective view of the foot pedal 210;

FIG. 17 is a view of the foot pedal 210 when flat;

FIG. 18 is a perspective view of the top cable bracket 260

FIG. 19 is a side elevational view of the top cable bracket 260 when flat;

FIG. 20 is a perspective view of the hydraulic motor handle 290;

FIG. 21 is a side elevational view of the foot pedal 290 when flat; and

FIG. 22 is a closer-in perspective view, similar to FIG. 3, of the left side of a different ATV 10′ (here a YAMAHA® ATV) showing an alternative embodiment of foot-operated pump control system 200′ comprised of a pedal 210′ and a pedal-operated cable 280′ that controllably manipulates a flow control mechanism (not visible) associated with a variable-flow pump 110′.

The invention and its various embodiments can now be better understood by turning to the following detailed description of the preferred embodiments which are presented as illustrated examples of the invention defined in the claims. It is expressly understood that the invention as defined by the claims may be broader than the illustrated embodiments described below.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIG. 1 is a perspective view of a typical ATV 10 (here a POLARIS® RANGER® UTV) that has been outfitted with a hydraulic power take-off assembly 100 having a variable-flow hydraulic pump 110 (see FIG. 2) that is driven by the ATV's engine (opposite side of ATV and not visible), and a hydraulically-driven implement 20 (here a lawn mower) having a hydraulic motor 21 that is rotated by hydraulic fluid flowing through hydraulic hoses 131, 132 connected to a hydraulic pump (not shown, but see other figures). Other possible implements, to name but a few, include a log splitter, a leaf and debris blower, a chain saw, an impact wrench, a water pump.

FIG. 2 is a left-side perspective view of an ATV (here a KAWASAKI® BRUTE FORCE® ATV) with a hydraulic power take-off unit 100 connected to its engine and a hydraulic implement 20 (again, a lawn mower), the hydraulic power take-off unit 100 comprising, in accordance with a first preferred embodiment, a variable-flow pump 110, a reservoir cooler 120, reservoir hoses 121, 122, implement hoses 131, 132 that lead to the hydraulic motor 21 (not shown), and an integrated foot-operated pump control system 200.

FIG. 3 is a closer perspective view of the left side of the ATV 10 more clearly showing the foot-operated pump control system 200 comprised of a foot pedal 210 and a pedal-operated cable 280 that controllably manipulates a flow control mechanism 150 associated with the variable-flow pump 110. Any suitable flow control mechanism may be used. By way of example, one suitable flow control mechanism 150 is a so-called swashplate that supports a plurality of pistons and, by varying its angle, varies the fluid displacement associated with a cylinder block being reciprocated relative to the pistons.

FIG. 4 is an exploded perspective view of the hydraulic power take-off unit 100 showing how the hydraulic PTO 100 is connected to and disconnected from an ATV 10 and, of significance, how the foot-operated pump control system 200 travels with the PTO 100 such that there is generally no need to re-attach or re-adjust the pump control system 200. In this embodiment, as shown, once the ATV 10 has been retrofitted with the mating portions of a quick connect/disconnect system (e.g. items 17-21 consisting of a case 17, a female pump coupler 18, a drive plate 19, a collet 20, an oil seal 21, and a drive plate cup seal 22), then the hydraulic PTO 100 suitably outfitted with a male pump coupler 16 may be quickly connected to or disconnected from the ATV 10.

The following table may be used to further understand the exploded view of FIG. 4:

Item
No.	Description	Qty.
1	Hydraulic Cooling Reservoir Tank	1
2	Filter Assembly, Strainer In-tank	1
3	Cap, Hydraulic Cooling Reservoir Tank	1
4	Strap Handle	1
5	Fan, Hydraulic Cooling Reservoir Tank	1
6	Radiator, Hydraulic Cooling Reservoir Tank	1
7	Shroud, Hydraulic Cooling Reservoir Tank	1
8	⅜″ ID Push Lock Hose × 27″ w/adapter Fem -06 JIC	1
9	⅜″ ID Push Lock Hose × 29″ w/adapter Fem -06 JIC	1
10	92″ × .5″ Hydraulic Hose Assembly (08 ORB Male × 08 JIC	1
	Female)
11	90″ × .5″ Hydraulic Hose Assembly (08 ORB Male × 08 JIC	1
	Female)
12	Hydraulic Pump	1
13	Fitting -06 Male ORB × #6 Male JIC 90	2
14	Fitting, -08 MALE ORB × #8 Male JIC 90	2
15	Control Cable	1
16	Coupler, Pump Male	1
17	Casting Side Case	1
18	Coupler, Pump Female	1
19	Drive Plate	1
20	Collet	1
21	Oil Seal (40 × 50 × 4 ASN)	1
22	Cup, Seal Drive Plate	1
23	Flat Face Coupler (⅜″ body ¾″ UNF-16 thread)	1
24	Flat Face Nipple (⅜″ body ¾″ UNF-16 thread)	1

FIG. 5 is a perspective view of the hydraulic power take-off unit 100 of FIGS. 2 to 4, separated from the ATV 10, to more clearly show its integrated foot-operated pump control system 200 from an engine-side perspective.

As shown in FIG. 5, the preferred pump control system 200 generally comprises a foot pedal 210, a bottom bracket 220, foot pedal arm assembly 250 formed from a foot pedal arm 230 and a control cable arm 240, a top bracket 260, a control cable 280, and optionally, a hydraulic pump handle 290. The foot pedal arm 230 is pivotally attached to the bottom bracket. In operation, a downward force (or removal of such force) on the foot pedal 210 causes the foot pedal arm 230 to pivot relative to the bottom bracket 220, moving the control cable arm 240 counterclockwise such that the control cable 280 connected thereto is pulled (or relaxed) relative to an opposite end of the control cable 280 that is connected to the top bracket 260 and, thereafter, to suitable portions of the pump's flow control mechanism 150.

Owing to this unique arrangement, the operator can use his left foot to easily operate the hydraulic implement 20 (see FIGS. 1 and 2) without hand fatigue. Moreover, unlike the early hand-control systems, when the hydraulic PTO 100 is removed from the vehicle 10, the proper cable adjustment remains. This is because the foot-operated control system 200 has been integrated into the hydraulic PTO 100, i.e. they travel together. Finally, due to the spring forces associated with the flow control mechanism 150, the foot pedal 210 acts a so-called “dead man” switch if the operator falls of the vehicle.

For mobile applications, the operator simply uses his foot to depress the foot pedal 210 to achieve the desired flow rate from the hydraulic pump 110. Under carefully controlled circumstances (e.g. stationary applications on a level surface, with the wheels blocked, the parking brake on, and the idle turned up to a suitable RPM of, for example, above 1800 RPM), a pin may be used to keep the foot pedal 210 in a depressed state.

FIG. 6 is a perspective view comparable to FIG. 5, but visually distinguishing an original portion of the hydraulic power take-off unit 100 from the additional components that make up the integrated foot pedal control system 200 and, in the preferred embodiment, a hydraulic motor handle 290 that helps the operator connect or disconnect the hydraulic PTO 100 to the ATV, protects the flow control mechanism 150, and helps the operator carry the unit 100 when separated from the ATV.

FIGS. 7, 8 and 9 illustrate the construction and general operation of the preferred bottom bracket 220. FIG. 7 is a close-up perspective view of the bottom bracket 220, while FIGS. 8 and 9 are top plan and edge views, respectively, of the bottom bracket 220 of FIG. 6 when flat.

FIGS. 10 and 11 illustrate the construction of the preferred foot pedal arm 230, FIG. 10. being a perspective view of the fully assembled foot pedal arm 230 and FIG. 11 being a side elevational view of a central section 231 of the foot pedal arm 230 of FIG. 8, when flat, prior to having the tubes 232, 233, 234 welded thereto.

FIGS. 12 and 13 illustrate the construction of the preferred control cable arm 240, FIG. 12 being a perspective view of the control cable arm 240, and FIG. 13 being a side elevational view of the bottom cable bracket 240 when flat. As most clearly shown in FIG. 5, the control cable 280 is attached to the control cable arm 240 with a suitable fastener (not separately numbered).

FIGS. 14 and 15 illustrate the preferred foot pedal arm assembly 250 that is formed from an interconnected assembly of the foot pedal arm 230 of FIG. 10 and the control cable arm 240 of FIG. 12. FIG. 14 is a side view of the foot pedal arm assembly 250. FIG. 15 is a top plan view of the foot pedal arm assembly 250;

FIG. 16 is a perspective view of the foot pedal 210 and FIG. 17 is a view of the foot pedal 210 when flat. As should be clear from FIGS. 5 and 6, and from FIG. 10, the foot pedal 210 is connected to the foot pedal arm 230 via tube 232.

FIG. 18 is a perspective view of the top cable bracket 260 and FIG. 19 is a side elevational view of the top cable bracket 260 when flat. The top cable bracket 260 is bolted to a top portion of the pump 110, as shown in FIGS. 5 and 6, such that a terminal end of the control cable 280 is held near the pump's flow control mechanism 150.

Lastly, FIGS. 20 and 21 relate to the optional pump handle 290. In particular, FIG. 20 is a perspective view of the hydraulic pump handle 290 and FIG. 21 is a side elevational view of the foot pedal 290 when flat. The handle 290 helps the operator connect or disconnect the hydraulic PTO 100 to the ATV, protects the flow control mechanism 150, and helps the operator carry the unit 100 when separated from the ATV.

FIG. 22 is a closer-in perspective view, similar to FIG. 3, but of the left side of a different ATV 10′ (here a YAMAHA® ATV) showing an alternative embodiment of foot-operated pump control system 200′ comprised of a pedal 210′ and a pedal-operated cable 280′ that controllably manipulates a flow control mechanism (not visible) associated with a different variable-flow pump 110′. Here, the precise construction of the brackets and control arms are varied in constructions and location to suitably connect to the pump 110′ that couples to the ATV 10′, but the principles of construction and overall operation remain the same.

Many alterations and modifications may be made by those having ordinary skill in the art without departing from the spirit and scope of the invention. For example, foot-operated pump controls may be used, with our without a control cable and with varying kinds of flow control mechanisms. Alternative embodiments may also have some small portion of the foot-operated pump control system remain with the ATV, or its engine casing, and arrange for the portions to quickly and easily re-engage when the hydraulic PTO is reconnected.

Therefore, it must be understood that the illustrated embodiment has been set forth only for the purposes of example and that it should not be taken as limiting the invention as defined by the following claims. For example, notwithstanding the fact that the elements of a claim are set forth below in a certain combination, it must be expressly understood that the invention includes other combinations of fewer, more or different elements, which are disclosed in above even when not initially claimed in such combinations.

The words used in this specification to describe the invention and its various embodiments are to be understood not only in the sense of their commonly defined meanings, but to include by special definition in this specification structure, material or acts beyond the scope of the commonly defined meanings. Thus if an element can be understood in the context of this specification as including more than one meaning, then its use in a claim must be understood as being generic to all possible meanings supported by the specification and by the word itself.

The definitions of the words or elements of the following claims are, therefore, defined in this specification to include not only the combination of elements which are literally set forth, but all equivalent structure, material or acts for performing substantially the same function in substantially the same way to obtain substantially the same result. In this sense it is therefore contemplated that an equivalent substitution of two or more elements may be made for any one of the elements in the claims below or that a single element may be substituted for two or more elements in a claim. Although elements may be described above as acting in certain combinations and even initially claimed as such, it is to be expressly understood that one or more elements from a claimed combination can in some cases be excised from the combination and that the claimed combination may be directed to a sub-combination or variation of a sub-combination.

Insubstantial changes from the claimed subject matter as viewed by a person with ordinary skill in the art, now known or later devised, are expressly contemplated as being equivalently within the scope of the claims. Therefore, obvious substitutions now or later known to one with ordinary skill in the art are defined to be within the scope of the defined elements.

The claims are thus to be understood to include what is specifically illustrated and described above, what is conceptually equivalent, what can be obviously substituted and also what essentially incorporates the essential idea of the invention.

Claims

1. A variable-flow hydraulic power take-off assembly adapted for an all-terrain vehicle (ATV) having an engine, comprising:

a hydraulic power take-off unit comprising a variable-flow pump that has a flow control mechanism and may be connected to and disconnected from the ATV, the pump being rotationally-driven by the engine and adapted for powering hydraulic implements carried by, attached to, or located near the ATV via hydraulic hoses; and

a foot-operated pump control system that comprises a foot pedal, the foot-operated pump control system being integrated with the hydraulic power take-off unit, and controlling the flow control mechanism in correlation with a depression of the foot pedal, operative portions of the foot-operated pump control system remaining with the hydraulic power take-off unit when it is disconnected from the ATV.

2. The variable-flow power take-off assembly of claim 1 wherein the foot-operated pump control system comprises:

a foot pedal; and

a control cable operatively connecting the foot pedal to the flow control mechanism of the pump.

3. The variable-flow power take-off assembly of claim 2 further comprising:

a bracket that pivotally supports the foot pedal relative to the hydraulic power take-off unit and that supports a proximal end of the control cable near and operatively connected to the foot pedal; and

a second bracket that supports a distal end of the control cable near and operatively connected to the flow control mechanism.

4. The variable-flow power take-off assembly of claim 3 further comprising a pump handle for simultaneously carrying the hydraulic power take-off unit and foot-operated pump control system when not connected to the ATV.