IP Library Granted Patent US 11,591,032
Granted Patent B1
US 11,591,032 · App. 17/546,500 · Granted Feb 28, 2023

Land vehicles incorporating brake systems and methods therefor

Inventors: Robert Willison (Lebanon, OH); Donald L. Wires (Loveland, OH); Gary Cain (Loveland, OH)
Assignee: Workhorse Group Inc.
B62D63/04B60K7/0007B60T1/005B60T1/065B62D33/06F16D55/22F16D63/006F16D65/183B60K2007/0092F16D2121/04F16D2121/18
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Quick Facts
Patent No.
US 11,591,032
App. No.
17/546,500
Granted
Feb 28, 2023
Kind
B1
Abstract

Land vehicles and methods of operating land vehicles are disclosed. A land vehicle includes a frame structure, a plurality of wheels, and a brake system. The frame structure includes a front cage that at least partially defines an operator cabin and a rear compartment positioned rearward of the front cage in a longitudinal direction. The plurality of wheels are supported by the frame structure. Each of plurality of wheels is sized to permit direct integration of an electric motor therein.

Claims (74)

1. A land vehicle comprising:

a frame structure including a front cage that at least partially defines an operator cabin and a rear compartment positioned rearward of the front cage in a longitudinal direction;

a plurality of wheels supported by the frame structure, wherein each of the plurality of wheels is sized to permit direct integration of an electric motor therein; and

a brake system coupled to each one of the plurality of wheels, wherein each brake system includes

a disc having a plurality of notches defined between circumferentially adjacent teeth of the disc,

a first braking device configured to contact an outer face of the disc to resist rotation of one of the plurality of wheels,

a second braking device circumferentially spaced from the first braking device about the disc that is configured to contact the outer face of the disc to resist rotation of the one of the plurality of wheels, and

a third braking device configured to contact one or more teeth of the disc to resist rotation of the one of the plurality of wheels,

wherein:

the disc includes an outer annular surface that extends circumferentially to at least partially define an outer diameter of the disc,

the teeth are disposed at an inner diameter of the disc,

the first braking device is configured to contact the outer face of the disc without enclosing the outer annular surface,

the second braking device is configured to contact the outer face of the disc without enclosing the outer annular surface,

the first braking device includes a first housing,

the second braking device includes a second housing,

the second housing has a different configuration from the first housing, and

the first housing defines a unitary structure that surrounds an open cavity extending axially all the way through the first housing.

2. The land vehicle of claim 1 , wherein the first braking device includes only one caliper and at least one piston at least partially housed by the only one caliper.

3. The land vehicle of claim 2 , wherein the at least one piston includes six pistons.

4. The land vehicle of claim 1 , wherein the second braking device is an electronic parking brake mechanism.

5. The land vehicle of claim 4 , wherein the third braking device is a parking pawl mechanism operated independently from the electronic parking brake mechanism.

6. The land vehicle of claim 5 , wherein the parking pawl mechanism includes a receptacle sized to receive a drive to permit manual release of the parking pawl mechanism in use of the land vehicle.

7. The land vehicle of claim 1 , wherein the operator cabin comprises:

a steering wheel;

an operator seat; and

a rack arranged in the operator cabin opposite the steering wheel and the operator seat that includes a plurality of trays.

8. The land vehicle of claim 7 , wherein:

the operator cabin comprises a pair of tracks affixed to a floor of the operator cabin and spaced apart from one another in the longitudinal direction;

the rack is movable along the pair of tracks in a lateral direction perpendicular to the longitudinal direction between a stowed position, in which the rack is disposed distant from the operator seat, and a delivery position, in which the rack is disposed close to the operator seat; and

the land vehicle has a gross vehicular weight rating (GVWR) of between 10,001 pounds and 14,000 pounds.

9. The land vehicle of claim 1 , further comprising a plurality of electric motors, wherein each of the plurality of electric motors is integrated directly into one of the plurality of wheels.

10. The land vehicle of claim 9 , wherein:

each of the plurality of electric motors is coupled to one of the plurality of wheels without any transmission gearing interposed therebetween; and

the land vehicle does not include an internal combustion engine.

11. A land vehicle comprising:

a frame structure including a front cage that at least partially defines an operator cabin and a rear compartment positioned rearward of the front cage in a longitudinal direction;

a plurality of wheels supported by the frame structure; and

a brake system coupled to each one of the plurality of wheels, wherein each brake system includes

a disc having a plurality of notches defined between circumferentially adjacent teeth of the disc,

a first braking device configured to contact an outer face of the disc to resist rotation of one of the plurality of wheels, and

a second braking device configured to contact one or more teeth of the disc to resist rotation of the one of the plurality of wheels,

wherein:

the disc includes an outer annular surface that extends circumferentially to at least partially define an outer diameter of the disc,

the teeth are disposed at an inner diameter of the disc,

the first braking device is configured to contact the outer face of the disc without enclosing the outer annular surface,

the first braking device includes a housing having an open cavity extending axially therethrough that is at least partially arranged radially inward of the inner diameter of the disc,

the open cavity extends axially all the way through the housing of the first braking device, and

the housing of the first braking device defines a unitary structure that surrounds the open cavity.

12. The land vehicle of claim 11 , wherein the first braking device is an electronic parking brake mechanism.

13. The land vehicle of claim 12 , wherein the second braking device is a parking pawl mechanism operated independently from the electronic parking brake mechanism.

14. The land vehicle of claim 13 , further comprising a third braking device circumferentially spaced from the first braking device about the disc that is configured to contact the outer face of the disc to resist rotation of the one of the plurality of wheels, wherein the third braking device includes only one caliper and a plurality of pistons at least partially housed by the only one caliper.

15. The land vehicle of claim 11 , wherein the operator cabin comprises:

a steering wheel;

an operator seat; and

a rack arranged in the operator cabin opposite the steering wheel and the operator seat that includes a plurality of trays.

16. The land vehicle of claim 15 , wherein:

the operator cabin comprises a pair of tracks affixed to a floor of the operator cabin and spaced apart from one another in the longitudinal direction;

the rack is movable along the pair of tracks in a lateral direction perpendicular to the longitudinal direction between a stowed position, in which the rack is disposed distant from the operator seat, and a delivery position, in which the rack is disposed close to the operator seat; and

the land vehicle has a gross vehicular weight rating (GVWR) of between 10,001 pounds and 14,000 pounds.

17. The land vehicle of claim 16 , further comprising a plurality of electric motors, wherein:

each of the plurality of electric motors is integrated directly into one of the plurality of wheels;

each of the plurality of electric motors is coupled to one of the plurality of wheels without any transmission gearing interposed therebetween; and

the land vehicle does not include an internal combustion engine.

18. A method of operating a land vehicle that includes (i) a frame structure having a front cage that at least partially defines an operator cabin and a rear compartment positioned rearward of the front cage in a longitudinal direction, (ii) a plurality of wheels supported by the frame structure, and (iii) a brake system coupled to each one of the plurality of wheels, the method comprising:

operating the land vehicle in a park operating range; and

operating the brake systems when the land vehicle is in the park operating range, wherein operating the brake systems when the land vehicle is in the park operating range comprises selectively activating one or more electronic parking brake mechanisms of each brake system and selectively activating one or more parking pawl mechanisms of each brake system,

wherein selectively activating one or more electronic parking brake mechanisms of each brake system comprises contacting an outer face of a disc with a first braking device to resist rotation of a wheel coupled to the disc,

wherein contacting the outer face of the disc with the first braking device comprises contacting the outer face of the disc without enclosing an outer annular surface of the disc that extends circumferentially to at least partially define an outer diameter of the disc,

wherein the first braking device includes a housing having an open cavity extending axially therethrough that extends radially inward beyond an inner diameter of the disc,

wherein the housing includes a first exterior face and a second exterior face arranged opposite the first exterior face,

wherein the open cavity extends axially through at least one of the first and second exterior faces to define at least one opening in the at least one of the first and second exterior faces, and

wherein the housing defines a unitary structure that surrounds the open cavity.

19. The method of claim 18 , wherein operating the brake systems when the land vehicle is in the park operating range comprises activating the one or more parking brake mechanisms of each brake system and the one or more parking pawl mechanisms of each brake system contemporaneously.

20. The method of claim 18 , further comprising selectively releasing the one or more parking pawl mechanisms of each brake system manually subsequent to activation of the one or more parking pawl mechanisms of each brake system.

Assignments (7)
SECURITY INTEREST Recorded Dec 17, 2025
From: WORKHORSE GROUP INC.; WORKHORSE TECHNOLOGIES INC.; WORKHORSE PROPERTIES INC.; HORSEFLY INC.; STABLES & STALLS LLC; STABLES & STALLS REAL ESTATE I LLC; ROUTEHORSE LLC; OMAHA INTERMEDIATE, INC.; OMAHA INTERMEDIATE 2, INC.; ESG LOGISTICS CORP.; WORKHORSE MOTOR WORKS INC.; MOTIV POWER SYSTEMS, INC.
To: MOTIVE GM HOLDINGS II LLC
Reel/Frame 074006/0682 →
SECURITY INTEREST Recorded Aug 15, 2025
From: WORKHORSE GROUP INC.; WORKHORSE TECHNOLOGIES INC.; WORKHORSE MOTOR WORKS INC.; WORKHORSE PROPERTIES INC.; HORSEFLY INC.; STABLES & STALLS LLC; STABLES & STALLS REAL ESTATE I LLC; ROUTEHORSE LLC; ESG LOGISTICS CORP.; OMAHA MERGER SUBSIDIARY, INC.; OMAHA INTERMEDIATE, INC.; OMAHA INTERMEDIATE 2, INC.
To: MOTIVE GM HOLDINGS II LLC
Reel/Frame 072489/0426 →
RELEASE OF SECURITY INTEREST Recorded Mar 19, 2024
From: HIGH TRAIL SPECIAL SITUATIONS LLC
To: WORKHORSE GROUP, INC.; WORKHORSE TECHNOLOGIES, INC.; WORKHORSE MOTOR WORKS, INC.; WORKHORSE PROPERTIES INC.; HORSEFLY INC.; ESG LOGISTICS CORP.; STABLES & STALLS LLC; ROUTEHORSE LLC; STABLES & STALLS REAL ESTATE I LLC
Reel/Frame 066832/0728 →
SECURITY INTEREST Recorded Mar 18, 2024
From: WORKHORSE GROUP, INC.; WORKHORSE TECHNOLOGIES, INC.; WORKHORSE MOTOR WORKS, INC.; WORKHORSE PROPERTIES INC.; HORSEFLY INC.; ESG LOGISTICS CORP.; STABLES & STALLS LLC; ROUTEHORSE LLC; STABLES & STALLS REAL ESTATE I LLC
To: HORSEPOWER MANAGEMENT LLC
Reel/Frame 066816/0076 →
SECURITY INTEREST Recorded Dec 27, 2023
From: WORKHORSE GROUP INC.
To: HIGH TRAIL SPECIAL SITUATIONS LLC
Reel/Frame 066130/0303 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Oct 25, 2022
From: WILLISON, ROBERT; WIRES, DONALD L.; CAIN, GARY
To: WORKHORSE GROUP INC.
Reel/Frame 061526/0842 →
RELEASE OF SECURITY INTEREST Recorded Apr 7, 2022
From: U.S. BANK TRUST COMPANY, NATIONAL ASSOCIATION
To: WORKHORSE GROUP INC.
Reel/Frame 059530/0959 →
Cited By (2)
US 12,623,585 US 12,630,067