US007591.

337B2

(12) United States Patent (10) Patent No.: US 7,591,337 B2

Suhre et al. (45) Date of Patent: Sep. 22, 2009
(54) LEANING SUSPENSION MECHANICS 2,641,480 A 6, 1953 Bancroft
2,689,747 A 9/1954 Kolbe
(75) Inventors: Ryan J. Suhre, Linden, MI (US); 2.788.986 A 4, 1957 Kolbe
Andrew D. Massignan, Waukesha, WI sys
(US); Andrew H. Roth, West Bend, WI 2.961.254. A 1 1/1960 Muller
(US); Mark Hutchison, New Berlin, WI 3,008,729 A 11, 1961 Muller et al.
(US); Scott J. Saiki, Dousman, WI (US) 3,497,233 A * 2/1970 Bolaski, Jr. ............ 28O86.757
3,572,456 A 3/1971 Healy
(73) Assignees: Harley-Davidson Motor Company 3,610,358 A 10/1971 Korff
Group, LLC. Milwaukee, WI (US); 3,776,353 A 12, 1973 Roth
Delphi Technologies, Inc., Troy, MI
(US)
(*) Notice: Subject to any disclaimer, the term of this
patent is extended or adjusted under 35 (Continued)
U.S.C. 154(b) by 398 days. FOREIGN PATENT DOCUMENTS
(21) Appl. No.: 11/535,545 WO 2005.002957 A1 1, 2005
(22) Filed: Sep. 27, 2006
(65) Prior Publication Data Primary Examiner Ruth Ilan
US 2007/00755.17 A1 Apr. 5, 2007 Attorney, Agent, or Firm Michael Best & Friedrich
Related U.S. Application Data
57 ABSTRACT
(60) Provisional application No. 60/722,114, filed on Sep. (57)
30, 2005.
(51) Int. Cl A vehicle including a frame, left and right wheels, and a
we6L/06
B62D (2006.01) leaning Suspension system. The frame defines a longitudinal
B60G 2L/00 (2006.01) vehicle axis. The leaning suspension system includes a trans
(52) U.S. Cl. ...................... 180/210; 180/41; 280/5.509; n al left and Egy taping obse, and right
280/615s. 280/615. 280/124,103.
58) Field of Classification S h
280/124135
280/124.103
control arms and a least one lean actor, Ineransverse
beam is coupled to the frame and pivotable about the vehicle
(58) Field of Classi ise a .......... • us - s axis. The left and right damping members are pivotally
2 6. 2it. :1. . So... coupled to the left and right sides of the transverse beam. The
f s Cross. 7. • al- w s left control arm is pivotally coupled to the left wheel and to
S licati i 5.508, 5. s 80/210, 41 the frame, and the right control arm is pivotally coupled to the
ee application file for complete search history. right wheel and to the frame. The lean actuator is pivotally
(56) References Cited connected between the frame and the transverse beam. The
lean actuator is configured to extend and retract to tilt the left
U.S. PATENT DOCUMENTS and right wheels and to lean the vehicle while cornering.
1975,117 A 10/1934 Millington
2,279,120 A 4/1942 Hurley 21 Claims, 6 Drawing Sheets
 US 7,591.337 B2
Page 2

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U.S. Patent Sep. 22, 2009 Sheet 1 of 6 US 7,591,337 B2
U.S. Patent Sep. 22, 2009 Sheet 2 of 6 US 7,591,337 B2

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U.S. Patent Sep. 22, 2009 Sheet 3 of 6 US 7,591,337 B2

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U.S. Patent Sep. 22, 2009 Sheet 4 of 6 US 7,591,337 B2
U.S. Patent Sep. 22, 2009 Sheet 5 of 6 US 7,591,337 B2
U.S. Patent Sep. 22, 2009 Sheet 6 of 6 US 7,591,337 B2

F.G. 6
 US 7,591,337 B2
1. 2
LEANING SUSPENSION MECHANCS BRIEF DESCRIPTION OF THE DRAWINGS

RELATED APPLICATIONS FIG. 1 is a perspective view of a three-wheeled motorcycle

including a leaning front Suspension embodying the present
Priority is hereby claimed to U.S. Provisional Patent Appli invention.
cation No. 60/722,114 filed on Sep. 30, 2005, the entire FIG. 2 is a side view of the three-wheeled motorcycle of
contents of which are incorporated herein by reference. FIG 1.
FIG. 3 is a front view of the three-wheeled motorcycle of
BACKGROUND FIG. 1, illustrating the three-wheeled motorcycle in an
10 upright position.
The present invention relates to vehicles with leaning Sus FIG. 4 is a front view of the three-wheeled motorcycle of
pension systems. In particular, the present invention relates to FIG. 1, illustrating the three-wheeled motorcycle in a leaning
three-wheeled vehicles with leaning Suspension systems. position.
FIG. 5 is an enlarged perspective view of the front suspen
SUMMARY 15 sion of the three-wheeled motorcycle of FIG. 1.
FIG. 6 is an exploded perspective view of the front suspen
The present invention relates to a suspension system for a sion of the three-wheeled motorcycle of FIG. 1.
three-wheeled vehicle. The suspension system permits the DETAILED DESCRIPTION
vehicle to leanwhile cornering, much like a motorcycle. This
is accomplished via hydraulic actuators that force the bike Before any embodiments of the invention are explained in
into a leaning position while turning, and back to an upright detail, it is to be understood that the invention is not limited in
position while tracking a straight line. A transverse beam is its application to the details of construction and the arrange
coupled to the hydraulic actuators and to spring dampers to ment of components set forth in the following description or
allow the Suspension to operate independently, even while the 25 illustrated in the following drawings. The invention is capable
vehicle is cornering. of other embodiments and of being practiced or of being
In one embodiment of the invention, a vehicle includes a carried out In various ways. Also, it is to be understood that
frame, left and right wheels, and a leaning Suspension system. the phraseology and terminology used herein is for the pur
The frame defines a longitudinal vehicle axis. The left wheel pose of description and should not be regarded as limiting.
is disposed on the left side of the vehicle axis, and the right 30 The use of “including.” “comprising,” or “having and varia
wheel is disposed on the right side of the vehicle axis. The tions thereof herein is meant to encompass the items listed
leaning Suspension system includes a transverse beam, left thereafter and equivalents thereofas well as additional items.
and right damping members, left and right control arms, and Unless specified or limited otherwise, the terms “mounted.”
at least one lean actuator. The transverse beam is coupled to “connected,” “supported,” and “coupled' and variations
the frame and pivotable about the vehicle axis. The left damp 35 thereof are used broadly and encompass both direct and indi
ing member is pivotally coupled to a left side of the transverse rect mountings, connections, Supports, and couplings. Fur
beam, and the right damping member is pivotally coupled to ther, “connected and “coupled are not restricted to physical
a right side of the transverse beam. The left control arm has a or mechanical connections or couplings.
first end pivotally coupled to the left wheel and an opposite FIGS. 1 and 2 illustrate a three-wheeled motorcycle or trike
end coupled to the frame, and the right control arm has a first 40 10 having an engine 12, handlebars 14, a frame 16, a single
end pivotally coupled to the right wheel and an opposite end rear wheel 20, and first and second front wheels 22, 24. The
coupled to the frame. The lean actuator is pivotally connected rear wheel 20 is mounted to a rear portion of the frame 16, and
between the frame and the transverse beam. The lean actuator the front wheels 22, 24 are coupled to the frame 16 via a
is configured to extend and retract to tilt the left and right leaning Suspension system 18. The frame 16 includes a front
wheels and to lean the vehicle while cornering. 45 bulkhead 40 and a main bulkhead 42 defining the front por
In another embodiment of the invention, a vehicle includes tion of the frame 16. The front bulkhead 40 is connected to the
a frame, left and right wheels, and a leaning Suspension sys main bulkhead 42 to stiffen and strengthen the entire Suspen
tem. The frame defines a longitudinal vehicle axis. The left sion system 18 The engine 12 is coupled to the rear wheel 20
wheel is disposed on the left side of the vehicle axis, and the through a drive assembly (not shown) to propel the trike 10.
right wheel is disposed on the right side of the vehicle axis. 50 The handlebars 14 are pivotally coupled to the front portion of
The leaning Suspension system includes a transverse beam, the frame 16 and coupled to the front wheels 22, 24 through a
left and right control arms, and at least one lean actuator. The steering system to turn the front wheels 22, 24.
transverse beam is coupled to the frame and is pivotable about The illustrated embodiment is for a trike 10 having two
the vehicle axis. The left control arm has an end pivotally steerable front wheels 22, 24 and a single, driven rear wheel
coupled to the left wheel and an opposite end coupled to the 55 20. It should be noted that it is within the scope of the inven
frame. The right control arm has an end pivotally coupled to tion to employ the Suspension of the present invention in a
the right wheel and an opposite end coupled to the frame. The vehicle having two rear wheels and a single front wheel. Also,
opposite ends of the right and left upper control arms are in other embodiments, the suspension can be used for both the
forked. At least a portion of the transverse beam is disposed front and rear wheels in a vehicle having four wheels, such as
between the forked ends of the right and left control arms. The 60 an ATV.
lean actuator is pivotally connected between the frame and FIG. 3 illustrates the orientation of the suspension system
the transverse beam, and is configured to extend and retract to 18 while the trike 10 tracks a straight line on a flat surface.
tilt the left and right wheels and to lean the vehicle while FIG. 4 illustrates the same front view of the trike 10 as FIG.3,
cornering. but in a leaning configuration. This view shows how the
Other aspects of the invention will become apparent by 65 suspension system 18 is oriented when the trike 10 is turning,
consideration of the detailed description and accompanying or tracking an arcuate path. It should be noted that in order to
drawings. highlight the different positions of the suspension system 18
 US 7,591,337 B2
3 4
between FIGS. 3 and 4, the handlebar 14 and wheel 22, 24 tion of the transverse beam 30. In other embodiments, the
positions are illustrated in the same, center, straight-forward transverse beam 30 could be positioned in front of the front
position for both FIGS. 3 and 4. Although this position is pivots 90, behind the rear pivots 92, or coupled to a different
correctly illustrated in FIG. 3, the handlebar 14 position and location than the upper control arms 32 (i.e. coupled to a
the wheel 22, 24 positions in FIG. 4 normally would be different bulkhead).
pivoted and turned, respectively, toward or into the direction As mentioned above, the spring dampers 36 include upper
of the turn. and lower pivot points 70, 72 connecting the transverse beam
Referring to FIGS. 5 and 6, the leaning suspension system 30 to the lower control arms 34. The spring dampers 36
18 includes a transverse beam 30, upper control arms 32. include a shock absorbing member Surrounded by a biasing
lower control arms 34, spring dampers 36, hydraulic actuators 10 member. This style of spring damper 36 is well known to
38, and spindles 44. The spindles 44 each include upper and those skilled in the art, and will not be discussed in further
lower pins 102, 100, as well as means for coupling to one of detail. Alterative embodiments may utilize a different method
the front wheels 22, 24, such as a hole 101 for receiving a of biasing and shock absorbing, such as leaf springs, coil
wheel axle 103. The structure of the spindle 44 is well known Springs, or air springs.
to those skilled in the art. 15 The hydraulic actuators 38 include upper and lower pivot
The transverse beam 30 is rigid and remains substantially points 110, 112. The illustrated embodiment shows the upper
horizontal during operation of the trike 10. The transverse pivot points 110 of the hydraulic actuators 38 are pivotally
beam 30 has a center pivot point 60, end pivot points 62, and coupled to the intermediate pivot points 64 on the transverse
intermediate pivot points 64. The transverse beam 30 is piv beam 30 at a location between the center pivot point 60 and
otally coupled to the main bulkhead 42 at the center pivot 60. one of the end pivot points 62. Other embodiments could
The center pivot 60 is positioned to coincide with the longi include the hydraulic actuators 38 pivotally coupled to the
tudinal centerline of the trike 10 and defines a pivot axis that end pivot points 62 and the spring dampers 36 pivotally
is parallel to the vehicle centerline. The end pivot points 62 coupled to the transverse beam 30 at a location between the
are pivotally coupled to upper pivots 70 on the spring dampers center pivot point 60 and one of the end pivot points 62. The
36. 25 hydraulic actuators 38 and spring dampers can also be pivot
With reference to FIGS. 3 and 4, the vehicle lean angle A ally coupled to other points along the transverse beam 30.
and the pivot angle B of the substantially horizontal trans The hydraulic actuators 38 in the illustrated embodiment
verse beam 30 are illustrated. As shown in FIG. 4, the trans include a cylinder having top and bottom fluid ports 114,116.
verse beam 30 defines a line between its pivot points 62, and A piston (not shown) exists at the end of a shaft 118 within
this line defines the pivot angle B relative to the horizontal 30 each cylinder. When hydraulic fluid is forced into the top fluid
riding surface. In FIG. 3, the vehicle is upright (i.e., a lean port 114 by a hydraulic pump (not shown), the internal piston
angle A of 0 degrees) and the transverse beam 30 is horizontal is forced down, and the shaft 118 retracts. While this is hap
(i.e., parallel to the horizontal riding Surface with a pivot pening, hydraulic fluid is being forced out of the bottom fluid
angle B of 0 degrees). In FIG. 4, the vehicle is leaning port 116 and into a reservoir (not shown). When hydraulic
approximately 30 degrees with respect to Vertical (i.e., a lean 35 fluid is forced into the bottom fluid port 116, the internal
angle A of 30 degrees), and the transverse beam 30 remains piston is forced up, and the shaft 118 extends. While this is
Substantially horizontal while pivoting only approximately 5 happening, hydraulic fluid is being forced out of the top fluid
degrees in the opposite direction relative to horizontal (i.e., port 114 and into the reservoir.
pivot angle B of 5 degrees). As used herein, the transverse The hydraulic actuators 38 act to control the orientation of
beam 30 is said to be substantially horizontal when the pivot 40 the trike 10. When entering a turn, one of the hydraulic actua
angle B is less than 10 degrees relative to horizontal, more tors 38 extends in length while the other retracts, moving the
specifically less than 5 degrees relative to horizontal, and even trike 10 into a leaning position as illustrated in FIG. 4. When
more specifically less than 3 degrees relative to horizontal. the trike 10 is leaving the turn, the hydraulic actuators 38 act
The lower control arms 34 have trunnions 80 coupled to to bring the trike 10 back to a vertical orientation as illustrated
one end and adapted to receive the lower pin 100 on the 45 in FIG. 3. The hydraulic actuators are controlled by a leaning
spindles 44. These trunnions 80 allow the suspension to oper Suspension control system that monitors at least one charac
ate independent of wheel steering by permitting the spindles teristic of the trike Such as handlebar position (i.e., steering
44 to pivot and turn regardless of the position of the lower angle), speed, acceleration, etc. Safety features can be present
control arms 34. The two remaining ends of the lower control to ensure the trike 10 is returned to the vertical orientation
arms 34 include front and rear pivot points 82, 84 that are 50 when the engine 12 is turned off, or if there is a malfunction
pivotally connected to the main bulkhead 42. A central pivot in the control of the hydraulic system.
86 is located centrally on the lower control arms 34 and is The substantially horizontal orientation of the transverse
adapted to pivotally couple to lower pivot points 72 on the beam 30 is maintained by the Influence of the spring dampers
spring dampers 36. 36. The lower control arms 34 are connected to the front
The upper control arms 32 also have trunnions 80 rotatably 55 wheels 22, 24 through the spindles 44 and to the transverse
coupled to one end and adapted to rotatably receive the upper beam 30 by the spring dampers 36. The front wheels 22, 24,
pin 102 on the spindles 44. These trunnions 80 allow the and thus the lower control arms 34, remain substantially
Suspension to operate independent of wheel steering. The two parallel to the road during normal operation. The road is
remaining ends of the upper control arms 32 include front and generally substantially planar for the width of the trike 10
rear pivot points 90, 92 that are pivotally connected to the 60 meaning that as long as both front wheels 22, 24 are in contact
main bulkhead 42. with the road, whether cornering or tracking a straight line,
In the illustrated embodiment, the transverse beam 30 is the spring dampers 36 will bias the transverse beam 30 to a
positioned between the front and rear pivots 90, 92 on the position that is substantially parallel to the road. The hydrau
upper control arms 32. At least a portion of the transverse lic actuators 38 connect the frame 16 to the transverse beam
beam 30 is disposed and substantially centered between the 65 30, and control the lean of the trike 10. As a hydraulic actuator
forked ends of the control arms 32. The control arms 32 define 38 extends. it pushes the frame 16 away from the transverse
a Substantially horizontal plane that intersects at least a por beam 30, initiating lean. The biasing force from the spring
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dampers 36 acting on the transverse beam creates a larger 4. The vehicle of claim 3, wherein the transverse beam is
moment about the central pivot 86 than the hydraulic actua substantially centered between the forked ends of the right
tors 38, so extension of the hydraulic actuators 38 moves the and left upper control arms.
frame 16 with respect to the beam 30. 5. The vehicle of claim 1, wherein the left damping mem
The steering system includes spindles 44, tie rods 46, and ber is pivotally coupled between the left lower control arm
the steering box 48. The handlebars 14 are coupled to the and the left side of the transverse beam, and the right damping
steering box 48 such that when an operator turns the handle member pivotally coupled between the right lower control
bars 14, an output shaft (not shown) on the steering box 48 arm and the right side of the transverse beam.
rotates. The output shaft is pivotally coupled to a first end of 6. The vehicle of claim 5, wherein the left damping mem
each tie rod 46. The second end of each tie rod 46 is pivotally 10 ber is pivotally coupled to a left end of the transverse beam at
coupled to a bracket secured to one of the spindles 44. As the a left pivot point, and the right damping member is pivotally
output shaft on the steering box 48 rotates, the tie rods 46 coupled to a right end of the transverse beam at a right pivot
follow, pulling one spindle 44 and pushing the other. The point.
spindles 44 are rotatably coupled to the upper and lower 7. The vehicle of claim 6, wherein the at least one lean
control arms 32, 34 by upper and lower pins 102, 100. Thus 15 actuator includes one end pivotally coupled to the frame and
the pushing or pulling action initiated by the tie rods 46 causes an opposite end pivotally coupled to the transverse beam
the spindles 44, and thus the front wheels 22, 24, to rotate between the vehicle axis and one of the right or left pivot
about the upper and lower pins 102, 100. points.
Using hydraulic actuators 38 as discussed affords some 8. The vehicle of claim 1, wherein the at least one lean
major advantages to trikes. First, since the lean of the trike 10 actuator includes a left lean actuator pivotally coupled
is controlled by the hydraulic actuators 38, the upper and between the frame and a left side of the transverse beam and
lower control arms 32, 34, spring dampers 36, and steering a right lean actuator pivotally coupled between the frame and
components are free to act normally, regardless of the trike's a right side of the transverse beam.
10 lean. This allows the trike 10 to absorb bumps while 9. The vehicle of claim 1, further comprising handlebars
tracking an arcuate path in the same manner it would if it were 25 pivotally coupled to the frame, a left tie rod coupled between
tracking a straight line, making for a consistent Suspension the handlebars and the left wheel, and a right tie rod coupled
action, even while turning. between the handlebars and the right wheel.
10. The vehicle of claim 1, wherein the transverse beam
What is claimed is: remains substantially horizontal when the wheels tilt and the
1. A vehicle comprising: 30 vehicle leans.
a frame defining a longitudinal vehicle axis; 11. The vehicle of claim 1, further comprising a left spindle
a left wheel disposed on the left side of the vehicle axis; coupled between the left upper control arm and the left wheel,
a right wheel disposed on the right side of the vehicle axis; and a right spindle coupled between the right upper control
a leaning Suspension system including arm and the right wheel.
a transverse beam coupled to the frame and pivotable 35 12. A vehicle comprising:
about the vehicle axis, a frame defining a longitudinal vehicle axis;
a left damping member pivotally coupled to a left side of a left wheel disposed on the left side of the vehicle axis;
the transverse beam, a right wheel disposed on the right side of the vehicle axis;
a right damping member pivotally coupled to a right side a leaning Suspension system including
of the transverse beam, 40 a transverse beam coupled to the frame and pivotable
a left upper control arm having a first end pivotally about the vehicle axis,
coupled to the left wheel and an opposite end coupled a left upper control arm having an end pivotally coupled
to the frame, to the left wheel and an opposite end coupled to the
a right upper control arm having a first end pivotally frame,
coupled to the right wheel and an opposite end 45 a right upper control arm having an end pivotally
coupled to the frame, coupled to the right wheel and an opposite end
a left lower control arm having a first end pivotally coupled to the frame, wherein the opposite ends of the
coupled to the left wheel and an opposite end pivotally right and left upper control arms are forked, and
coupled to the frame, wherein at least a portion of the transverse beam is
50 disposed between the forked ends of the right and left
a right lower control arm having a first end pivotally upper control arms,
coupled to the right wheel and an opposite end pivot a left lower control arm having an end pivotally coupled
ally coupled to the frame, and to the left wheel and an opposite end coupled to the
at least one lean actuator pivotally connected between frame,
the frame and the transverse beam, the lean actuator 55 a right lower control arm having an end pivotally
configured to extend and retract to tilt the left and right coupled to the right wheel and an opposite end
wheels and to lean the vehicle while cornering, such coupled to the frame, and
that the left and right wheels tilt substantially the same at least one lean actuator pivotally connected between
amount as a lean angle of the vehicle. the frame and the transverse beam, the lean actuator
2. The vehicle of claim 1, wherein ends of the right and left 60 configured to extend and retract to tilt the left and right
upper control arms are forked, and wherein at least a portion wheels and to lean the vehicle while cornering, such
of the transverse beam is disposed between the forked ends of that the left and right wheels tilt substantially the same
the right and left upper control arms. amount as a lean angle of the vehicle.
3. The vehicle of claim 2, wherein at least a portion of the 13. The vehicle of claim 12, wherein at least a portion of the
transverse beam is located within a substantially horizontal 65 transverse beam is located within a substantially horizontal
plane defined by one of the left upper control arm and the right plane defined by one of the left upper control arm and the right
upper control arm. upper control arm.
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14. The vehicle of claim 13, wherein the transverse beam is 18. The vehicle of claim 12, wherein the at least one lean
substantially centered between the forked ends of the right actuator includes a left lean actuator pivotally coupled
and left upper control arms. between the frame and a left side of the transverse beam and
15. The vehicle of claim 14, further comprising a left a right lean actuator pivotally coupled between the frame and
damping member pivotally coupled between the left lower 5 a right side of the transverse beam.
control arm and the left side of the transverse beam, and a 19. The vehicle of claim 12, further comprising handlebars
right damping member pivotally coupled between the right pivotally coupled to the frame, a left tie rod coupled between
lower control arm and the right side of the transverse beam. the handlebars and the left wheel, and a right tie rod coupled
16. The vehicle of claim 15, wherein the left damping between the handlebars and the right wheel.
member is pivotally coupled to a left end of the transverse 10 20. The vehicle of claim 12, wherein the transverse beam
beam at a left pivot point, and the right damping member is remains substantially horizontal when the wheels tilt and the
pivotally coupled to a right end of the transverse beam at a vehicle leans.
right pivot point. 21. The vehicle of claim 12, further comprising a left
17. The vehicle of claim 16, wherein the at least one lean spindle coupled between the left upper control arm and the
actuator includes one end pivotally coupled to the frame and 15 left wheel, and a right spindle coupled between the right
an opposite end pivotally coupled to the transverse beam upper control arm and the right wheel.
between the vehicle axis and one of the right or left pivot
points. k k k k k