U.S. patent application number 10/087348 was filed with the patent office on 2002-10-17 for modular, vertically-integrated manufacturing method for a lawn and garden implement.
Invention is credited to Johnson, Kevin L., McDonner, Orville R., Ruebusch, Richard T., Stenz, Kenneth J..
Application Number | 20020148114 10/087348 |
Document ID | / |
Family ID | 27375662 |
Filed Date | 2002-10-17 |
United States Patent
Application |
20020148114 |
Kind Code |
A1 |
Ruebusch, Richard T. ; et
al. |
October 17, 2002 |
Modular, vertically-integrated manufacturing method for a lawn and
garden implement
Abstract
A method of manufacturing an implement, including providing a
first group of engine types and a second group of transmission
types at a common, first manufacturing facility, selecting a
desired module configuration, selecting a desired engine from the
first group, a desired transmission from the second group,
connecting the selected engine and transmission together in the
desired module configuration to provide a base of the implement,
transporting the base to a second facility, providing a working
device at the second facility, and connecting the working device to
the base of the implement at the second facility.
Inventors: |
Ruebusch, Richard T.; (New
Albany, IN) ; McDonner, Orville R.; (Salem, IN)
; Johnson, Kevin L.; (Douglas, GA) ; Stenz,
Kenneth J.; (Mt. Calvary, WI) |
Correspondence
Address: |
BAKER & DANIELS
111 E. WAYNE STREET
SUITE 800
FORT WAYNE
IN
46802
|
Family ID: |
27375662 |
Appl. No.: |
10/087348 |
Filed: |
March 1, 2002 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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60272892 |
Mar 2, 2001 |
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60289434 |
May 8, 2001 |
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Current U.S.
Class: |
29/888.01 |
Current CPC
Class: |
F16H 2057/0335 20130101;
Y10T 29/49231 20150115; F16H 3/083 20130101 |
Class at
Publication: |
29/888.01 |
International
Class: |
B21K 003/00 |
Claims
What is claimed is:
1. A method of manufacturing an implement, comprising: (1)
providing a first group of engine types and a second group of
transmission types at a common, first manufacturing facility; (2)
selecting a desired module configuration; (3) selecting a desired
engine from the first group and a desired transmission from the
second group; (4) connecting the selected engine and transmission
together in accordance with the desired module configuration to
provide a base of the implement; (5) transporting the base of the
implement to a second facility; (6) providing a working device at
the second facility; and (7) connecting the working device to the
base of the implement at the second facility.
2. The method of claim 1, wherein step (1) further comprises
providing a third group of steering mechanism types at the common,
first manufacturing facility.
3. The method of claim 2, wherein step (3) further comprises
selecting a desired steering mechanism from the third group.
4. The method of claim 3, wherein step (4) further comprises
connecting the steering mechanism with the engine and
transmission.
5. The method of claim 1, wherein the first group includes vertical
shaft engines and horizontal shaft engines.
6. The method of claim 1, wherein the second group includes
hydrostatic transaxles, manual shift transaxles, and friction drive
transaxles.
7. The method of claim 2, wherein the third group includes a spring
clutch and trigger controlled steering mechanism and a
bidirectional clutch and intuitive steering mechanism.
8. The method of claim 1, further comprising selecting a working
device from the group consisting of an auger assembly, a
cultivating blade assembly, and a mower blade assembly.
9. The method of claim 1, further comprising, after step (7):
providing a handle at the second facility; and attaching the handle
to the base of the implement at the second manufacturing
facility.
10. The method of claim 1, further comprising, after step (4):
providing at least two wheels at the first manufacturing facility;
and attaching the wheels to the transmission at the first
manufacturing facility.
11. The method of claim 1, further comprising, after step (4):
providing a drive linkage at the first manufacturing facility; and
attaching the drive linkage at the first manufacturing facility to
the base of the implement and selected parts to provide a driving
connection therebetween.
12. The method of claim 1, wherein, after step (7), a substantially
completed implement is produced, and further comprising: packaging
the substantially completed implement; and transporting the
substantially completed implement from the second manufacturing
facility to one of a wholesaler, a retailer, and a customer.
13. The method of claim 1, wherein step (6) further includes
providing a drive linkage with the working device.
14. The method of claim 13, wherein step (7) includes connecting
the drive linkage of the working device to the working device and
the base of the implement.
15. A method of manufacturing an implement, comprising: (1)
providing a first group of engine types, a second group of
transmission types, and a third group of steering mechanism types
at a common, first manufacturing facility; (2) selecting a desired
module configuration; (3) selecting a desired engine from the first
group, a desired transmission from the second group, and a desired
steering mechanism from the third group; (4) connecting the
selected engine, transmission, and steering mechanism together in
accordance with the desired module configuration to provide a base
of the implement; (5) transporting the base of the implement to a
second facility; (6) providing a working device at the second
facility; and (7) connecting the working device to the base of the
implement at the second facility.
16. The method of claim 15, wherein the first group includes
vertical shaft engines and horizontal shaft engines.
17. The method of claim 15, wherein the second group includes
hydrostatic transaxles, manual shift transaxles, and friction drive
transaxles.
18. The method of claim 15, wherein the third group includes a
spring clutch and trigger controlled steering mechanism and a
bidirectional clutch and intuitive steering mechanism.
19. The method of claim 15, further comprising selecting a working
device from the group consisting of an auger assembly, a
cultivating blade assembly, and a mower blade assembly.
20. The method of claim 15, further comprising, after step (7):
providing a handle at the second manufacturing facility; and
attaching the handle to the base of the implement at the second
manufacturing facility.
21. The method of claim 15, further comprising, after step (4):
providing at least two wheels at the first manufacturing facility;
and attaching the wheels to the transmission at the first
manufacturing facility.
22. The method of claim 15, further comprising, after step (4):
providing a drive linkage at the first manufacturing facility; and
attaching the drive linkage at the first manufacturing facility to
the base of the implement and selected parts to provide a driving
connection therebetween.
23. The method of claim 15, wherein, after step (7), a
substantially completed implement is produced, and further
comprising: packaging the substantially completed implement; and
transporting the substantially completed implement from the second
manufacturing facility to one of a wholesaler, a retailer, and a
customer.
24. The method of claim 15, wherein step (6) further includes
providing a drive linkage with the working device.
25. The method of claim 24, wherein step (7) includes connecting
the drive linkage of the working device to the working device and
the base of the implement.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit under 35 U.S.C.
.sctn.119(e) of U.S. Provisional Application No. 60/272,892, filed
Mar. 2, 2001 and U.S. Provisional Application No. 60/289,434, filed
May 8, 2001.
BACKGROUND OF THE INVENTION
[0002] 1. Field of Invention
[0003] The present invention relates to the manufacture of small
utility or lawn and garden implements, such as snow throwers,
mowers, and tillers, for example, which include among other
components, an engine, a transaxle, and a clutch and steering
mechanism.
[0004] 2. Description of the Related Art
[0005] Small utility or lawn and garden implements, such as snow
throwers, mowers, and tillers, generally include an engine for
supplying mechanical motion to a working device and also to a
transaxle, which in turn transfers the mechanical motion to ground
engaging wheels to drive the implement. Typically, the engine and
the transaxle are manufactured separately from one another.
[0006] Typically, implements 20, such as snow thrower 22 (FIGS.
2A-2B) and lawnmower 23 (FIG. 3) are manufactured by a process
shown schematically in FIG. 1, in which engine 24 is manufactured
at a first manufacturing facility 44 by an engine manufacturer,
transaxle 26 is manufactured at a second manufacturing facility 46
by a transaxle manufacturer, and engine 24 and transaxle 26 are
then separately shipped or transported to third manufacturing
facility 48 for final assembly of implement 20 by an implement
manufacturer. First, second, and third manufacturing facilities 44,
46, and 48 may be located remote from one another. The term
"remote", as used herein, refers to the distance between
manufacturing facilities, wherein it is contemplated that
manufacturing facilities which are remote from one another are
separate from one another, and may be located either close to one
another or a great many miles away from one another, but where the
facilities are not located within the same building or comprise two
sections of a common assembly line.
[0007] Often, the engine manufacturer, the transaxle manufacturer,
and the implement manufacturer are three separately owned and
operated manufacturing entities. At third manufacturing facility 48
of the implement manufacturer, engine 24 and transaxle 26 are
connected to one another, and additional components of implement
20, such as wheels 32, handle 30 and working device 28, are
additionally connected to engine 24 and/or transaxle 26 to
substantially complete the assembly of implement 20. From third
manufacturing facility 48 of the implement manufacturer, implement
20 is shipped or transported to retailer/dealer 50, where implement
20 is ultimately sold to consumer 52.
[0008] There are several problems with this approach to
manufacturing implement 20, however. For example, from the
viewpoint of the implement manufacturer, separate, perhaps
non-interchangeable engines and transaxles require maintenance of a
very large inventory of both engines and transaxles. Further, the
implement manufacturer must perform the additional manufacturing
operation of connecting the correct engines and transaxles to one
another, which increases labor and assembly costs for the implement
manufacturer.
[0009] Additionally, if the implement manufacturer desires engines
of different sizes and/or output shaft orientations, and/or
transaxles of different types, the implement manufacturer must
ensure that the engines and transaxles are operatively compatible
with one another, to coordinate the transporting of the engines and
transaxles to its facility, and to make sure that the engines and
transaxles are delivered on schedule, which requires the implement
manufacturer to expend significant resources dealing with each of
the engine manufacturer and the transaxle manufacturer.
[0010] Additionally, this method may not allow interchangeable
parts to be used. Rather, the engine selected, i.e. engine A, may
only fit one transaxle, i.e. transaxle A, thereby preventing the
assembly of different modules utilizing different parts. Ideally,
instead of using only engine A with transaxle A, engine A would be
used with transaxle B and engine B with transaxle A, and so forth
utilizing a wide range of engines and transaxles. A manufacturing
system which would allow a selection of any transaxle and any
engine to create a module would be desirable.
[0011] From the viewpoint of each of the engine and transaxle
manufacturers, the need to design and manufacture many specific
engines and transaxles which are compatible with certain other
respective engines or transaxles in order to suit the needs of
multiple implement manufacturers is undesirable and costly.
However, the ability of having different engines being compatible
with many different transaxles and vice versa would allow the
engine and the transaxle manufacturers to manufacture engines and
transaxles without the requirement of suiting the needs of multiple
implement manufacturers.
[0012] What is needed is a method for manufacturing small utility
or lawn and garden implements, which is simplified and versatile as
well as allowing for the interchangeability of parts and the
creation of modules from the different parts selected.
SUMMARY OF THE INVENTION
[0013] The present invention provides a method of manufacturing an
implement, including providing a first group of engine types and a
second group of transmission types at a common, first manufacturing
facility, selecting a desired module configuration, selecting a
desired engine from the first group and a desired transmission from
the second group, connecting the selected engine and transmission
together in the desired module configuration to provide a base of
the implement, transporting the base to a second facility,
providing a working device at the second facility, and connecting
the working device to the base at the second facility.
[0014] The present invention further provides a method of
manufacturing an implement, including providing a first group of
engine types, a second group of transmission types, and a third
group of steering mechanism types at a common, first manufacturing
facility, selecting a desired module configuration, selecting a
desired engine from the first group, a desired transmission from
the second group, and a desired steering mechanism from the third
group, connecting the selected engine, transmission, and steering
mechanism together in the desired module configuration to provide a
base of the implement, transporting the base to a second facility,
providing a working device at the second facility, and connecting
the working device to the base at the second facility.
[0015] The present invention also provides that the first group
includes vertical shaft engines and horizontal shaft engines of
various displacement, the second group includes hydrostatic
transaxles, manual shift transaxles, and friction drive transaxles,
and the third group includes a spring clutch and trigger actuated
steering mechanism and an intuitive steering mechanism. The working
device includes an auger assembly, a cultivating blade assembly, or
a mower blade assembly.
[0016] An advantage of the inventive method of producing an
implement is that the usage of different parts to create various
combinations, or modules, is promoted. Rather than rely on a single
engine being attached to a single transaxle or steering mechanism,
or a one-to-one relationship between engines and transaxles or
steering mechanism, all of the parts required for the implement may
be interchanged to provide implement bodies with different
qualities. Further, the inventive method promotes vertical
integration, thereby facilitating assembly process control by a
single entity and reducing costs of manufacture.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The above-mentioned and other features and advantages of
this invention, and the manner of attaining them, will become more
apparent and the invention itself will be better understood by
reference to the following description of an embodiment of the
invention taken in conjunction with the accompanying drawings,
wherein:
[0018] FIG. 1 is a schematic representation of a previous method of
manufacturing implements such as the snow throwers of FIGS. 2A and
2B and the lawnmower of FIG. 3;
[0019] FIG. 2A is a perspective view of an exemplary previous
implement which may be manufactured in accordance with the method
of the present invention, the implement is shown as a snow
thrower;
[0020] FIG. 2B is a side view of another exemplary previous
implement which may be manufactured in accordance with the present
invention, the implement is shown as a snow thrower similar to the
snow thrower of FIG. 2A;
[0021] FIG. 3 is a perspective view of an exemplary previous
implement which may be manufactured in accordance with the method
of the present invention, the implement is shown as a
lawnmower;
[0022] FIG. 4 is a perspective view of the engine and transaxle
module of the implement of FIG. 2A;
[0023] FIG. 5 is a top plan view of a transmission showing
engagement of a drive belt with an output pulley of a power source
and corresponding to a pivot arm position which provides the
greatest axle speed;
[0024] FIG. 6 is a perspective view of one embodiment of a friction
drive transaxle;
[0025] FIG. 7 is a perspective view of one embodiment of a
hydrostatic transmission;
[0026] FIG. 8 is a schematic view of a first embodiment of a manual
gear shift transaxle incorporating an epicyclic steering
mechanism;
[0027] FIG. 9 is a schematic view of a second embodiment of a
manual gear shift transaxle incorporating a ball and collar
steering mechanism;
[0028] FIG. 10 is a schematic view of a generic clutch in
conjunction with an engine and a transaxle;
[0029] FIG. 11A is a sectional view of a spring clutch used in
conjunction with a trigger actuated steering mechanism;
[0030] FIG. 11B is a perspective view of the spring clutch of FIG.
11A;
[0031] FIG. 12 is a view of the bidirectional wheel clutch used in
conjunction with an intuitive steering mechanism;
[0032] FIG. 13 is a view of the clutch of FIG. 12 in the neutral
position;
[0033] FIGS. 14A and 14B are views of the clutch of FIG. 12 in the
two respective engaged positions;
[0034] FIG. 15 is a flowchart depicting a process of manufacture in
accordance with the present invention;
[0035] FIG. 16 is a flow diagram depicting module configurations
and the relationship between the configurations in accordance with
the inventive method; and
[0036] FIG. 17 is a diagram of the relationship between the
manufacturing facilities.
[0037] Corresponding reference characters indicate corresponding
parts throughout the several views. The exemplification set out
herein illustrates one embodiment of the invention and such
exemplification is not to be construed as limiting the scope of the
invention in any manner.
DETAILED DESCRIPTION
[0038] For the purposes of promoting an understanding of the
principles of the invention, reference will now be made to the
embodiments illustrated in the drawings and specific language will
be used to describe the same. It will nevertheless be understood
that no limitation of the scope of the invention is thereby
intended.
[0039] Existing implement 20 is shown in FIGS. 2A-3, and is
representatively shown as snow thrower 22 (FIGS. 2A-2B) and
lawnmower 23 (FIG. 3), similar to that disclosed in U.S. patent
application Ser. No. 09/785,431, filed Feb. 16, 2001, the
disclosure of which is expressly incorporated herein by reference.
As shown in FIGS. 2A-3, implement 20 includes engine 24,
transmission 26 attached to engine 24, working device 28, handle 30
(of which two embodiments 30a and 30b are shown), and wheels 32.
Implement 20 also includes a steering mechanism by which the
operator may easily control turning of the implement. It should be
noted that transmission 26 may be a transaxle, therefore the terms
transaxle and transmission are used interchangeably within this
disclosure.
[0040] As shown in FIG. 2B, engine 24 includes output shaft 34
connected by drive linkage 36 which is shown in FIG. 2B as a pair
of flexible belts, for example, to each of input shaft 38 of
transaxle 26 and input shaft 40 of working device 28. Engine 24 is
shown in FIGS. 2A and 2B as a horizontal shaft engine for use in a
horizontal shaft application; however, in accordance with the
method of the present invention, vertical shaft engines may also be
accommodated as required by the implement design. Additionally, the
inventive method accommodates two-stroke or four-stroke engines, or
engines of different displacements as desired.
[0041] Transaxle 26 may be of any known type, such as a gear-driven
transaxle having a fluid brake and epicyclic gear arrangement or a
plurality of manually-shifted gears therein which control the speed
of the implement. For example, transaxle 26 may be of the basic
type disclosed in U.S. Pat. No. 5,971,881, issued Oct. 26, 1999,
the disclosure of which is expressly incorporated herein by
reference. A variable speed, reversible transmission utilizes two
pumps for variably controlling the speed of the output shaft or
axle. A rotatable input member is connected to a drive source which
drives first and second epicyclic gear trains that, in turn, drive
two pumps, and as fluid flow through each pump is variably
restricted, thereby braking the respective ring gear of each
epicyclic gear train, the planet gears linked to an output member
revolve about the input member or sun gear to cause the output
member to rotate in a forward or reverse direction. Alternatively,
transaxle 26 may be of the known type and basic design exemplified
by commercially available 1300, 2500 or 2600 Series transaxles
manufactured by Tecumseh Products Company.
[0042] Transaxle 26a of FIG. 5 includes a pair of belts 62, 64
respectively engaged with a pair of pulley assemblies at three
respective variable radial positions of engagement between each
belt and pulley. Pivot pulley assembly 58 is rotatably attached to
a selectively rotatable pivot arm pivotably supported by a housing,
and transmission pulley assembly 60 is rotatably attached to a
drive member rotatably supported within the housing and selectively
engageable with axle 42. Transmission belt 64 is initially engaged
with pivot pulley assembly 58 at a first radial position and is
initially engaged with transmission pulley 60 at a second radial
position. Additionally, drive belt 62 is initially engaged with
second pulley 59 at a third radial position. Each of the radial
positions is variable and may be varied by movement of the
rotatable pivot arm. As the pivot arm moves pivot pulley assembly
58 toward second pulley 59, the distance between pulley 59 and
pulley assembly 58 becomes less while the distance between
transmission pulley assembly 60 and pulley 59 becomes greater. The
change in distances allows the pulley halves of pulley 59 to come
closer, increasing its diameter and changing the radial position of
belt 62, while belt 64 becomes tighter, causing belt 64 to separate
the pulley halves of pulley 60, reducing its diameter and changing
the radial position of belt 64. The pulley halves of pulley
assembly 58 may be separated or allowed to move closer together
depending upon the change in the radial positions of belts 62 and
64 in conjunction with pulley 59 and pulley assembly 60. It should
be noted that transaxle 26a of FIG. 5 is utilized with vertical
shaft engines, whereas transaxles 26b-26e, described hereinbelow,
are used with horizontal shaft engines. As the inventive
manufacturing method allows greater flexibility in manufacturing,
vertical shaft engines may be used as easily as horizontal shaft
engines.
[0043] Referring to FIG. 6, transaxle 26b may be a friction drive
transaxle including first friction disk member 112, which is driven
by engine 24, and second friction disk member 114 driving input
shaft 38 of transaxle 26b and rotatable about an axis having an
axis of rotation perpendicular to that of first friction disk
member 112. Friction disk member 114 is radially movable to
driveably engage first friction disk member 112 and axially
moveable to vary the axle speed. Axial movement of member 114 past
the center of rotation of member 112 reversely drives axle 42.
[0044] Transaxle 26c may also be a hydrostatic transaxle, such as
that disclosed in U.S. Pat. No. 6,151,990, issued Nov. 28, 2000, or
U.S. patent application Ser. No. 09/498,692, filed Feb. 7, 2000,
the complete disclosures of which are expressly incorporated herein
by reference. Such transaxles 26c, one of which is shown in FIG. 7,
include pump 106 driven by input shaft 38 thereof which is fluidly
connected to motor 108 having output shaft 110 for driving axle
42.
[0045] Axles 42 of transaxle 26d are in driving engagement with
ground engaging wheels 32. Transaxle 26d, as shown in FIG. 8, may
include a geartrain with first and second epicyclic gear
arrangements 54, each of which are selectively drivingly coupled to
only one of axles 42, independently of the other axle, such that
neither, only one, or both of the axles are drivingly coupled to
the geartrain. Each epicyclic gear arrangement is surrounded by a
band brake which is individually, operatively connected to a
trigger 130 on each grip of handle 30 of implement 20.
[0046] Referring to FIG. 9, transaxle 26e includes a manual gear
shift, or a key-shift, transmission which is used in conjunction
with hub assemblies 56, described hereinbelow, to propel an
implement. As is known, a key-shift transmission includes a
multiplicity of gears representing different operating speeds, and
one of which is selected by the operator through a speed selector
and movement of a fork disposed within the shaft upon which the
gears are mounted.
[0047] Referring to FIG. 3, trigger operated steering allows the
implement to be propelled by the operator's releasing one or both
of a pair of triggers 130 mounted on the left and right grips of
its handle 30b. Handle 30 may include a single grip structure for
grasping, such as handle 30a in FIGS. 2A-2B has, or consist of two
separate grip portions for grasping, such as handle 30b of FIG. 3
has. Either structure may include triggers 130, although triggers
130 are shown on handle 30b. Implement 20 is powered through turns
by partially or fully engaging the trigger on the side
corresponding with the direction of the turn. Full engagement of
trigger 130 disengages driving power to wheel 32 on the selected
side, while partial engagement restricts the driving power to wheel
32 on the selected side. For example, if the operator wishes to
turn implement 20 to the right, the operator would at least
partially engage the trigger 130 on the right side of implement 20,
disengaging driving power to the right wheel. Meanwhile, wheel 32
on the left side of implement 20 remains powered and becomes the
driving wheel, thereby causing implement 20 to turn to the right by
using the right wheel as an axis of rotation. Triggers 130 may be
attached to a cable or other linkage device for operating a clutch
mechanism, such as the torsion spring friction clutch, described
hereinbelow, or for operating a band brake mechanism (FIG. 8),
described above or a shift collar mechanism (FIG. 9), described
hereinbelow.
[0048] Alternatively, transaxle 26e, as shown in FIG. 9, may
include a single axle operatively coupled to the geartrain about
which are disposed two hub assemblies 56, each of which extends
from the casing and is selectively engaged with axle 42
independently of the other hub assembly. Neither, only one, or both
of hub assemblies 56 may then be coupled to axle 42. A trigger 130
located on each grip of handle 30b (FIG. 3) is operatively
connected with shift collar 128 of each hub assembly 56 such that
when a trigger is pulled, the shift collar 128, in operative
communication with the pulled trigger, moves to allow independent
engagement of the associated hub assembly 56 to axle 42. Such
trigger actuated steering is described above.
[0049] When the base of implement 20 is assembled, it includes
engine 24, transaxle 26, and steering mechanism 74, which requires
handle 30 and a clutch mechanism or other functionally related
mechanisms, such as the band brake mechanism or the shift collar
mechanism, as described above. Additionally, steering mechanism 74
may be a trigger actuated steering means or an intuitive steering
means. A portion of a generic base of implement 20 is shown in FIG.
10 as including engine 24, and transaxle 26, which may be of any
type described above, in module 90. To module 90 are connected
axles 42 attached to generic wheel hubs 132 and wheels 32.
Surrounding axles 42 are generic clutch mechanisms 134 which may be
of any suitable type, such as the torsion spring friction clutches
described below.
[0050] In association with trigger actuated steering, as described
above, clutches 134 may be torsion spring friction clutch, located
at each wheel 32, in which input hub 122 and wheel hub 120 have
axially adjacent cylindrical portions about which is disposed
torsion spring 96, as shown in FIG. 11A. Within wheel hub 120 are a
plurality of one-way roller bearings 136 which allow axle 42 to
directly engage wheel hub 120 when axle 42 is reversely rotated but
allow axle 42 to freely rotate in the forward direction relative to
wheel hub 120. Disposed about the outer diameter of spring 96 is
control collar 98. Pawl 100 (FIG. 11B) is pivotally attached to
implement 20 and is biased by spring 116 into engagement with one
of the slots 118 in control collar 98, preventing rotation of
control collar 98 in the forward direction. When a trigger 130
(FIG. 3) is pulled, pawl 100 is disengaged from control collar 98
of the corresponding wheel, allowing wheel hub 120 to rotate in the
forward direction. As wheel hub 120 is allowed to rotate, the
spring diameter is allowed to contract, bringing that wheel's input
hub 122 and wheel hub 120 into clutched engagement through spring
96.
[0051] Intuitive steering includes a bi-directional clutch, such as
the Bi-Directional Clutch designed and manufactured by the Motion
Control Division of Hilliard Corporation of Elmira, N.Y., and is
not trigger operated. With intuitive steering, a change in the
direction and/or speed of the implement causes the bi-directional
clutch, located at each wheel 32, to sense the change and to allow
overrunning of its respective wheel 32. Sensing the change in
direction and speed is accomplished with a roller ramp design which
allows roller 68 (maintained within roll cage 70) to move between
outer race 72 and multiple flat cams 66, as shown in FIG. 12, to
engage and disengage engine 24 (not shown) and transaxle 26 (not
shown). In the neutral, or disengaged, position, rollers 68 are
allowed to rotate freely, as shown in FIG. 13. In the engaged
positions, depicted in FIGS. 14A and 14B, rollers 68 cause
engagement between inner cam 66, roll cage 70, and outer race 72.
As this is a bi-directional clutch, engagement will occur when
roller 68 moves in either direction.
[0052] Although exemplary engines, transmissions, clutch means and
steering means have been discussed, the present invention is not
limited to a method in which only these parts or these particular
types of parts are processed. The process, as described
hereinbelow, is applicable to the manufacture of any walk-behind
implement that requires the assembly and/or combination of several
parts. Therefore, other types of engines, transmissions, steering
means, and clutch means would be usable in the process as well as
other parts, such as handles, housings, and the like. Additionally,
the process may be used to assemble single stage and multiple stage
implements.
[0053] Referring to FIG. 15, the inventive process of manufacture
will now be discussed. At first manufacturing facility 102 several
options for engine 24, transaxle 26, and steering mechanism 74 are
provided, from which the selection of the specific parts to include
in implement 20 is made. Although engine, transmission, and
steering mechanism possibilities are presented in the figure, any
items required for the implement, including the working devices
(not shown), may be provided in the selection pool. At first
manufacturing facility 102, one unit of each part is selected to be
included in the implement base, as seen in block 76.
[0054] The different module configurations, which are selected
(block 124), will be discussed with reference to FIG. 16. Two parts
are connected in each module configuration 90, 92, 94 with a single
module and another part being connected to provide the base of
implement 20. For example, engine 24 and transmission 26, each of
any type, as appropriate, are connected to create one engine and
transmission module 90 while the steering mechanism 74 is
maintained as a single part, with module 90 and steering mechanism
74 then being connected to create the base of implement 20. The
same process applies to modules 92, 94 created by connecting engine
24 or transaxle 26 to steering mechanism 74 in other configurations
as seen in FIG. 16.
[0055] Referring again to FIG. 15, engine 24, transaxle 26, and
steering mechanism 74 are connected in the proper module
configurations, as shown in block 78. Once that is done, the final
connections between the modules, or a single module comprising one
of engine 24 and transaxle 26 and steering mechanism 74, connected
to the other of engine 24 and transaxle 26, are made to create the
base of implement 20 (block 80). As first manufacturing facility
102 is used for assembly of the parts to create the base of
implement 20, the base must be transported to second manufacturing
facility 104 (block 82) to connect the base of implement 20 to the
selected working device 28 (block 84). Referring to FIG. 17, second
manufacturing facility 104 may be located in a separate facility
from first manufacturing facility 102, such as in the known
"remote" configuration described above, or second manufacturing
facility 104 may be in the same facility as first manufacturing
facility 102, as represented by the dashed lines, since
manufacturing facilities 102, 104 may designate locations on a
single assembly line. Additionally, first manufacturing facility
102 may include a plurality of separate facilities where portions
of assembly may occur. For example, transmission 26 may be
transported to an engine manufacturing facility where transmission
26 and engine 24 are assembled to form module 90, or engine 24
transported to a transmission manufacturing facility for assembly.
Module 90 may then be transported to another facility for assembly
with steering mechanism 74 to form the base of implement 20.
[0056] Continuing along the path provided in FIG. 15, the base is
transported to second manufacturing facility 104 (block 82) at
which working device 28 is selected (block 84) and assembled to the
base (block 86). Working device 28 may be, for example, an auger
assembly, such as is used in snow thrower 22 (FIGS. 2A-2B), a
mowing assembly, such as is used in lawnmower 23 (FIG. 3), or a
cultivating blade assembly, such as that used in a tiller, each of
which are available at the second manufacturing facility 104. In
any case, the base of implement 20 is assembled at first
manufacturing facility 102, and working device 28 is connected to
the base at second manufacturing facility 104 (block 86). Working
device 28 includes its own drive linkage which is connected to the
base of implement 20 at the same time as working device 28 (block
86), thereby providing the driving means necessary for operation of
working device 28.
[0057] Referring again to FIG. 17, at first manufacturing facility
102, two wheels 32 may be provided as attachments to transaxle 26.
Drive linkage 36 may also be provided between engine 24 and
transaxle 26 as part of module 90 or as part of the final
connections between other selected modules at first manufacturing
facility 102. Such drive linkage 36 is used to provide the actual
driving means between engine 24 and transaxle 26. At second
manufacturing facility 104, handle 30 is provided and attached to
implement 20 to complete assembly for transportation and sale.
[0058] Shown in dashed lines in FIG. 15, since it is not a required
step of manufacturing, is packaging (block 88) and transporting
(block 126) the substantially completed implement to the sales
facility, such as, for example, a wholesaler, a retailer, or a
manufacturer's dealer, or directly to the customer, as through, for
example, an Internet sales web site.
[0059] While this invention has been described as having exemplary
processes, the present invention can be further modified within the
spirit and scope of this disclosure. This application is therefore
intended to cover any variations, uses, or adaptations of the
invention using its general principles. Further, this application
is intended to cover such departures from the present disclosure as
come within known or customary practice in the art to which this
invention pertains and which fall within the limits of the appended
claims.
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