ATV Throttle Safety Switch Sealed Design
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Solution Overview
Problem
Conventional throttle control mechanisms in all-terrain vehicles are prone to failures due to moisture exposure, leading to tarnishing and corrosion, and complex gear designs that cause wear and tear, resulting in improper contact and potential sparking, especially in harsh off-road conditions.
Innovation Solution
A throttle control and safety switch device featuring a sealed design with a pivot shaft, first and second carriers, and a compression spring, where the safety switch is actuated only when the throttle actuating cable is stuck or broken, sending a cutoff signal to the engine control unit to shut off the engine, eliminating the need for complex gear mechanisms and reducing the risk of sparking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a conventional gear mechanism is used to transfer force from the throttle lever to the throttle cable, then the throttle control function is achieved, but the device complexity increases and wear and tear occurs leading to early failures
Solution Approach 1:
The patent removes the complex gear mechanism from the throttle control system and replaces it with a direct mechanical linkage system. The throttle lever is directly connected to the throttle cable through a simplified arrangement of links and pivots, eliminating unnecessary intermediate components while maintaining the throttle control function.
Solution Approach 2:
Instead of using a gear mechanism to amplify or modify the throttle lever movement, the patent inverts the approach by using a direct mechanical advantage system where the lever arm geometry itself provides the necessary force multiplication and movement transformation, simplifying the overall mechanism.
2Ease of operation
If a conventional switch mechanism without sealed compartment is used, then the throttle control function is maintained, but moisture enters the compartment causing tarnishing and corrosion of contact terminal
Solution Approach 1:
The patent introduces a sealed compartment design with gaskets and seals that enclose the contact terminals and switch mechanism. This protective enclosure prevents moisture and contaminants from entering the internal components, thereby preventing tarnishing and corrosion while maintaining the electrical contact function.
3Ease of operation
If plastic gear mechanism is used, then the throttle control is achieved, but wear and tear occurs affecting angular movement of throttle lever
Solution Approach 1:
The patent eliminates the plastic gear mechanism entirely and replaces it with a direct mechanical linkage system using metal components. This removal of the problematic plastic gears prevents wear and tear while maintaining the necessary angular movement and control function of the throttle lever.
Solution Approach 2:
The patent employs metal components with appropriate material properties in the throttle linkage system, providing both durability and smooth movement. The use of metal-to-metal or metal-to-composite interfaces in the linkage system offers superior wear resistance compared to plastic gears.
4Device complexity
If sluggish movement of contact terminal is allowed, then the switch mechanism is simple, but sparking occurs between contacts during contact making and breaking
Solution Approach 1:
The patent modifies the contact terminal movement characteristics by optimizing the mechanical linkage geometry and contact spring design. This ensures that the contacts make and break quickly and cleanly, minimizing arc duration and preventing carbon deposition while maintaining a relatively simple switch mechanism structure.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides a reliable and fail-safe mechanism that prevents engine failure due to throttle cable issues, reduces the risk of sparking, and maintains contact integrity by using sealed snap-type contacts, thus enhancing safety and reducing maintenance needs.
Implementation Method 1
causing a compression spring to push the second carrier along with the plunger portion towards the safety switch
Data Source
AI summary
A throttle control and safety switch device that serves the dual function of adjusting a throttle of an ATV (all-terrain vehicle) while turning off the engine in the event of failure of a throttle cable or if the throttle cable is stuck, is disclosed. The throttle control and safety switch device includes an operating lever connected to a pivot shaft for pivotal movement about an axis (A-A′). A first carrier connected to the pivot shaft includes a safety switch and a cable attachment portion to engage a throttle actuating cable. The safety switch transmits a cutoff signal to an electronic control unit (ECU) upon actuation by a plunger portion of a second carrier pivotally connected to the pivot shaft via fastener and connected to the first carrier via a dowel and slot arrangement.