FIE L D OF T H E INVE NTION

The present invention relates to clutch systems of the vehicles including four wheelers. Particularly, the present invention relates to an automatic clutch operating system for vehicles that includes changing of gears of vehicle manually.

BAC KG ROU ND OF T H E INVE NTION

Manual transmission vehicles are widely used across the globe. In the manual transmission four-wheeler vehicles, a clutch is operated by leg to change the gears or to allow the vehicle to slow or stop without shut down of the vehicle on a particular gear. It becomes hectic and tiring to operate the clutch in the heavy traffic where user/driver requires pressing of the clutch time to time for changing the gear or to slow or stop without shut down of the vehicle on a gear. F urther, there are many instances reported of leg pains as well as knee operations due to the constant use of the clutch. Therefore, people are looking out various alternatives. One of the options is automatic gear transmission vehicles. However, automatic transmission vehicles are expensive and also have less fuel average as compared to manual transmission vehicles. Now, various kits are available to convert manual transmission vehicles into automatic vehicle or semi-automatic vehicle. However, to convert into fully automatic vehicle, modifications are required in the vehicle system, which are complex and expensive. Moreover, does not guarantee the conversion of vehicle without problems.

To convert in the semi-automatic vehicle, various kits are available. The kits are fixedly adapted on the vehicle either below driver s seat and dashboard wherein heavy duty motor adapted below driver seat is connected to the vehicle clutch pedal via a pulley. Moreover, it comprises a controller box fitted on or near the dashboard. These kits are cumbersome and consume more space and time for fixing in the vehicle and requires different power arrangement.

Therefore, there is a need of a system that convert a manual transmission vehicle into semi-automatic vehicle which solves one or more of aforementioned problems.

S U MMARY OF T H E INVE NTION

Accordingly, the present invention in an embodiment provides an automatic clutch operating system for a vehicle, the automatic clutch operating system comprising an actuator assembly secured to a clutch pedal, for automatic operation of clutch, an anchor means connected to the body of the vehicle below the clutch pedal, a connecting means extending between the actuator assembly and the anchor means, and an input device for operating of the actuator assembly. The actuator assembly includes an electric motor, a winding mechanism adapted on the motor and a controller connected to the motor. According to the present invention, the connecting means is wound on the winding means of the actuator assembly extends to the anchor means. The motor winds-up the connecting means on the actuator member to depress the clutch and unwinds to release the clutch on receipt of the commands from the controller based on the instructions received from the sensor or as determined by the controller.

The automatic clutch operating system of the present invention is simple, compact, easy to assembly, requires less space as well as time to fix in the vehicle and inexpensive than the currently available solutions in the market.

B RIE F DE S C RIPTION OF DRAWING S

Reference will be made to embodiments of the invention, example of which may be illustrated in the accompanying figure(s). These figure(s) are intended to be illustrative, not limiting. Although the invention is generally described in the context of these embodiments, it should be understood that it is not intended to limit the scope of the invention to these particular embodiments.

F igure 1 shows an automatic clutch operating system according to the preferable embodiment of the present invention; F igure 2 shows exploded view of an actuator assembly of the automatic clutch operating system of a vehicle along with a controller according to a preferable embodiment of the present invention;

F igure 3 shows an exploded view of connection between an electric motor and a gear box according to the present invention;

F igure 4 shows a drum according to the present invention; and

F igure 5 shows a locking means according to a preferable embodiment of the present invention.

DE TAIL E D DE S C RIPTION OF TH E INVE NTION

Although specific terms are used in the following description for the sake of clarity, these terms are intended to refer only to the particular structure of the present invention selected for illustration in the drawings, and are not intended to define or limit the scope of the present invention.

The terms "a", "an", and "the" as used in the claims herein are used in conformance with long-standing claim drafting practice and not in a limiting way. Unless specifically set forth herein, the terms "a", "an", and "the" are not limited to one of such elements, but instead mean "at least one".

In general, the present invention provides an automatic clutch operating system for a vehicle to convert a manual transmission vehicle into semiautomatic vehicle. The automatic clutch operating system comprises an actuator assembly secured on the clutch pedal of the vehicle, an anchor means connected to the body of the vehicle below the clutch pedal, a connecting means extending between from the actuator assembly to the anchor means and an input device to actuate the actuator assembly for operating the clutch. The actuator assembly includes an electric motor, a winding mechanism adapted on the motor and a controller connected to the motor.

According to the present invention, the actuator assembly is preferably adapted on the upper side of clutch pedal of the vehicle. Alternatively, the actuator assembly can be adapted below the clutch pedal or integrated with the clutch pedal of the vehicle.

According to the present invention, the input device is a sensor adapted on the brake pedal of the vehicle. The sensor can be adapted within the brake pedal of the vehicle. The sensor adapted in the brake pedal captures motion of a leg of a person driving the vehicle on the brake pedal to automatically control the operation of clutch pedal. This sensor advantageously helps to capture data which can be used to operate the clutch optimally.

According to the present invention, the winding means comprises a drum mounted on a gearbox for winding the connecting means, said gearbox having a reduction ratio between 8-60 depending on motor speed and torque requirement. The gearbox preferably includes a worm gear.

According to the present invention, the drum has an opening for allowing fixing of the connecting means. The drum of the winding means also comprises a locking means for holding the connecting means on the drum when the clutch is operated manually.

According to the present invention, the winding means includes an encoder disc in configuration with a sensor to determine degree of rotation of the drum for operating the clutch.

According to the present invention, the automatic clutch operating system to be adapted on the upper side of the clutch pedal, comprises a housing designed to allow the pedal to be operated by foot even when system is attached.

The subject matter is now described with reference to the drawings, wherein like reference numerals are used to refer to like elements throughout. In the following description, for purpose of explanation, numerous specific details are set forth in order to provide a thorough understanding of the claimed subject matter. It may be evident however, that such matter can be practiced with these specific details. In other instances, well-known structures as shown in diagram form in order to facilitate describing the invention.

Referring F igure 1 shows an automatic clutch operating system (1000) according to a preferable embodiment of the present invention. As shown in the F igure 1 , the automatic clutch operating system (1000) comprised of an actuator assembly (100) mounted on a clutch pedal (101 ) of a vehicle (not shown), a sensor (200) as an input device mounted on a brake pedal (201 ) of the vehicle (not shown), an anchor means (300) connected to a body (not shown) of the vehicle below the clutch pedal (101 ) and a connecting means (171 ) extending between the actuator assembly (100) and the anchor means (300). As shown in F igure 1 , the actuator assembly is adapted on the upper side of the clutch pedal comprises a housing (not shown) designed to allow the clutch pedal (101 ) to be operated by foot even when system is attached.

Referring F igure 2 shows an exploded view of an actuator assembly (100) with a controller (130) of the automatic clutch operating system adapted on a clutch pedal (101 ) of the vehicle (not shown).

As shown in F igures 1 and 2, the actuator assembly (100) comprises a housing (1 90), a cover (1 10) adapted at top of the housing (1 90), a sensor (120), and a winding means connected to an electric motor (1 50). The controller (130) is adapted within the actuator assembly (100) and is connected to the sensor (200) provided on brake pedal (201 ) to operate the clutch and the sensor (120) adapted on the actuator assembly (100) to deactivate the system.

Referring F igures 2 and 3 shows the winding means comprising a gear box (140) with a shaft (145) mounted with an encoder disc (160) and a drum (170). The controller (130) on receipt of the input from the sensors (200) operates the gear box (140) causing the drum (170) to rotate at a specified degree. The degree of rotation of the drum (170) is determined based on rotation of the encoder disc (1 60) and the movement captured by the sensor (not shown) for measuring and limiting displacement of the clutch pedal (101 ).

The drum (170) has a connecting means (171 ) which is extended to an anchor (300) fixed to body of the vehicle. The rotation of the drum (170) enables the connecting means (171 ) to roll in or out on or from the drum (170) for controlling the movement of the clutch pedal (101 ). The connecting means is a high strength cable, rope, ribbon or wire. The anchor means is designed in such a way that allows the free rotation of the connecting means.

Referring F igure 2 and 3 shows an exploded view of an electric motor (1 50) connected to a gear box (140) according to an embodiment of the present invention. As shown in F igure 3, only two holes (225, 226) are required to insert bolts (227) as shown in F igure 2 in order to hold the gearbox (140) and motor (1 50) all together. The placement of through M3 holes (225, 226) are such that they go around all gears and other parts inside the gearbox (140) and reach out from the other side. As shown in F igure 3, the gear (221 ) is used in second stage allowing to place the motor (150) in line with the gearbox (140). The gearbox comprises a worm gear (221 ) wherein the worm gear (221 ) is connected to the gear (21 5) of the motor (1 50). The gearbox has a reduction ratio between 8-60 depending on the motor speed and torque requirement for displacement of the clutch pedal (101 ) of the vehicle. Referring F igures 4 and 5 show a drum (170) having a connecting means (171 ) according to the present invention. As shown in F igures, the connecting means (171 ) is fixed to the drum (170) through an opening (330) on upper side of the drum (170). The opening (330) facilities connection of the connecting means (171 ) to the drum (170) without a screw thereby eliminating damage to the connecting means (171 ) by providing a soft curve.

Referring F igure 5 shows a locking means (175) according to an embodiment of the present invention. As shown in F igure, the locking means (175) is adapted on the actuator assembly (100) in such a way that the locking means (175) holds the connecting means (171 ) wrapped on the drum (170) even when a user is operating the clutch pedal manually. In the figures, it is shown that the input device is a sensor adapted on the brake pedal. Alternatively, the input device includes a remote means configured to send parameters to the controller of the clutch pedal actuator. The remote means can be wirelessly connected and can be to adapt anywhere within the vehicle as per the user s requirement. Advantageously, the input device can be a push button connected to the actuator assembly. The push button may be preferably adapted on the hand gear of the vehicle allowing the user to operate the push button and the hand gear simultaneously to change the gear.

According to the present invention, the connecting means is a high strength rope or ribbon, directly connecting actuator assembly to the anchor means of the vehicle. The motor winds-up the cable on the drum to depress the clutch pedal and unwinds to release the clutch pedal on receipt of the commands from the controller based on the instructions received from the input device or as determined by the controller.

According to the present invention, the electric motor is selected from a group including brushed DC motor, brushless DC (BLDC) motor, induction motor and stepper motor and preferably the motor is BLDC motor which generates high torque in a small space enabling the automatic clutch operating system to be light and compact.

According to the preferable embodiment of the present invention, the actuator assembly is connected to an on-board diagnostic port of the vehicle to draw power and/or to connect with one or more sensors of the vehicle for configuring with operating parameters including rpm, speed of the vehicle, load on the engine, throttle position, accelerator pedal position, engine-coolant temperature, engine manifold pressure, oxygen sensor readings etc. to operate the clutch of the vehicle.

According to the present invention, the controller is configured to store user preference data through an input device, receive user input from the input device and operating parameters of the vehicle from the sensorand to process the received data and generate the optimum parameters to operate the motor of the actuator assembly for positioning the clutch pedal of the vehicle. According to further embodiment of the present invention, the automatic clutch operating system optionally comprises an output port to communicate the data with an external device for analysis of vehicle operation or driving pattern.

According to another embodiment of the present invention, the automatic clutch operating system comprises a sensor adapted on the actuator assembly or within the clutch pedal to sense user gesture to discontinue the automatic actuation system and allow the user to operate the clutch manually as per user s requirements.

According to one another embodiment of the present invention, the automatic clutch operating system comprises a sensor below the clutch pedal to sense the presence of obstacles including human foot between the clutch and body for alerting the user. The controller when receives signal that an obstacle for example user s foot is below the clutch pedal, the controller may generate an alarm to signal the user to remove the foot from the clutch pedal or it may restrict the movement of the clutch pedal so that the user s foot is not hurt.

According to the present invention, the automatic clutch operating system comprises of two operating modes namely automatic pedal operation mode and a manual operation mode.

In the automatic pedal operation mode, the automatic clutch operating system senses the gesture of the user on the brake pedal and presses the clutch pedal automatically at the right place and release it at the right speed and allows the user to do everything including change the gear, reducing the speed etc. for moving the car smoothly without stalling the engine.

According to the present invention, in a manual operation mode, the automatic clutch operating system allows the user to operate the clutch pedal manually as if the automatic clutch operating system of the present invention is not present. This allows the user to take control of the clutch operation and drive the car like any other manual transmission without any means to turning the automatic clutch operating system off or removal of the automatic clutch operating system. The automatic clutch operating system automatically turns on this mode when it detects that the driver is operating the clutch pedal using his/her leg.

The automatic clutch operating system of the present invention can be retrofit or integrate in the new vehicles. Moreover, the automatic clutch operating system of the present invention can be adapted removably to the existing vehicle making it useful to convert the manual transmission vehicle to the semi-automatic transmission vehicle. The automatic clutch operating system significantly reduces the cost making it economically feasible to the users. F or example, to retrofit the automatic clutch operating system of the present invention in a car, the actuator assembly of the automatic clutch operating system is fixed on top of the clutch and the actuator assembly is connected to an anchor adapted below the clutch of the car by fixing one end of a cable on the drum of the actuator assembly and winding the cable on the drum of the actuator assembly and fixing other end of the cable to the anchor means. A sensor with cover is adapted on a brake pedal of the vehicle and connected to the controller provided in the actuator assembly. The automatic clutch operating system is then connected to a diagnostic port of the vehicle to draw power and/or to connect with one or more sensors of the vehicle for configuring with operating parameter including rpm, speed of the vehicle to operate the clutch. Now, when the driver wishes to automatically control the clutch, the driver may touch the brake pedal or press the button of an input device of the actuator assembly of the automatic clutch operating system. Once the automatic clutch operating system is activated, the controller receives various parameters of operation of the vehicle, process the data, and generates the optimum parameter to operate the electric motor to depress and release the clutch pedal automatically.

The operation of the automatic clutch operating system of the present invention is explained herein below with reference to examples with different scenario to understand the present invention:

E xample 1 :

To drive any manual transmission vehicle, the driver has to engage the appropriate gear by shifting the gear lever. The vehicle s transmission and the engine are coupled via a clutch which allows gears to be engaged gently and also to allow full or partial engine engagement with the transmission. G enerally full engagement is preferred but there are situations like when the car is at a standstill when the full engagement can stall the engine or cause a severe jerk at such times partial engagement is required.

According to the present invention, to change the gear the clutch pedal has to be depressed fully. When the user wants to change the gear, he has to lift his leg from the accelerator pedal and simply has to touch the brake pedal which will instruct the automatic clutch operating system of the present invention to actuate and pull-in the clutch pedal and hold the clutch pedal fully pulled-in till the user is touching the brake pedal. S o the user will simply touch the brake pedal and hold his foot there while he changes the gear. Once the gear change is changed, the user has to lift his foot off the brake pedal and put it back on the accelerator. The automatic clutch operating system will determine how fast and how far the pedal needs to be released to ensure smooth movement of the vehicle. This also helps the user who wants to slow down the vehicle or stop by pressing the brake pedal, the clutch is always fully depressed.

E xample 2

There may be a scenario when the user may want to press the brake pedal but dont want the clutch to be depressed. For example, the vehicle is moving at 80 Kmph and the driver only wants to reduce it to 70 Kmph that is, in this case the user dont want the clutch to be pulled in even though the brake is pressed as he does not intend to change the gear or stop the car. In this scenario, the user can touch the clutch pedal of the vehicle, which will result in deactivation of the automatic clutch operating system due to the sensor on the clutch pedal and allows the user to use brake to reduce the speed without the depression of the clutch pedal.

E xample 3:

There may be scenario, when the user wants to take full control of the clutch operations even while the automatic clutch operating system is actively working. This can happen in cases where the terrain is such, for example on steep inclines like mountains or steep descents from hills the driver may want to operate the clutch and accelerator simultaneously to ensure that the vehicle moves smoothly as per his requirement. In this case also, the user has the option to touch the clutch pedal and if required press the clutch pedal. Whenever the clutch pedal is touched or pressed, the sensor present on the clutch pedal, deactivates the automatic clutch operation system of the present invention and allows the user to drive the vehicle as per his requirements.

E xample 4:

There is an always possibility that the user may touch the brake pedal while he has the other foot extended below the clutch pedal. In this case the automatic clutch operating system has a sensor below the pedal will sense the presence of any interference like the driver s foot and it will stop and retract the clutch pedal avoiding any pain to the driver as well as alert the user to remove the foot. The automatic clutch operating system of the present invention is compact, easily mountable, light weight and inexpensive and converts the manual driven vehicle into auto clutch manual transmission vehicle. F urther, the automatic clutch operating system of the present invention does not require substantial modifications in the vehicle as well as consumes very less space as compared to the presently available solutions. Moreover, the automatic clutch operating system of the present invention dont require space under the driver seat or bonnet of the vehicle. F urther, as in the present invention only clutch is operated automatically and the user has to change gears manually, the vehicle may give more average to the user compare to the automatic vehicles. The thickness of the clutch pedal increases substantially by 2 to 2.5 inch only if the automatic clutch operating system is retrofitted. F urthermore, the automatic clutch operating system of the present invention requires less power and draws from OBD port of the vehicle, no modifications in the battery system management is required in the vehicle. Also, the automatic clutch operating system of the present invention can be integrally fitted to the new vehicle at the time of manufacturing. Moreover, users can easily dissemble and reassemble the automatic clutch operating system without skilled worker.

The foregoing description of the invention has been set merely to illustrate the invention and is not intended to be limiting for example a term :gesture ~ referred in the specification also includes :touch~ a term :user~ includes a :driver~ a connection between input device and actuator assembly via controller includes wired and wireless connections. Therefore, though a best embodiment of the present invention has been shown and described in detail herein as required under the acts, it will be obvious to those skilled in the art that changes and modifications of the present invention, in its various aspects, may be made without departing from the invention in its broader aspects, some of which changes and modifications being matters of routine engineering or design, and others being apparent after study. As such, the scope of the invention should not be limited by the particular embodiment and specific construction described herein, but should be defined in the appended claims and equivalents thereof. Accordingly, the aim of the appended claims is to cover all such changes and modifications as fall within the true spirit and scope of the invention: