High-Speed, Overrunning Coupling and Control Assembly, Coupling Assembly and Locking Member which Pivotally Moves with Substantially Reduced Friction

Abstract

A high-speed overrunning coupling and control assembly, coupling assembly and locking member which pivotally moves with substantially reduced friction are provided. At least one pivot projects from a main body portion of the locking member and enables pivotal motion of the locking member. The at least one pivot is sized, shaped and located with respect to the main body portion so that the at least one pivot makes contact with at least one bearing located between a pocket surface of a pocket and an outer surface of the at least one pivot to reduce friction during pivotal motion.

Claims

1. A locking member for controllably transmitting torque between first and second coupling members of a coupling assembly, the first coupling member rotating about a rotational axis of the assembly and including a centerline through the axis and a coupling face having a pocket which is at least partially defined by a pocket surface, the pocket being sized and shaped to receive and nominally retain the locking member and at least one bearing, the locking member pivoting down into the pocket during an overrunning condition of the assembly, the locking member comprising: a member-engaging first end surface; a member-engaging second end surface; a main body portion between the end surfaces; and at least one pivot which projects from the main body portion, the at least one pivot enabling pivotal motion of the locking member and being sized, shaped and located with respect to the main body portion so that the at least one pivot makes contact with the at least one bearing located between the pocket surface and an outer surface of the at least one pivot to reduce friction during the pivotal motion.

2. The locking member as claimed in claim 1, wherein the at least one pivot has a generally cylindrical end portion for contacting the at least one bearing and wherein the at least one bearing comprises a thrust bearing which reacts centrifugal forces generated from the locking member at high speeds about the rotational axis.

3. The locking member as claimed in claim 1, wherein the end surfaces of the locking member are movable between engaged and disengaged positions with respect to the coupling members during the pivotal motion whereby one-way torque transfer may occur between the coupling members.

4. The locking member as claimed in claim 1, wherein the at least one pivot comprises at least one projecting ear which extends laterally from the main body portion and wherein the at least one bearing comprises a thrust bearing which reacts centrifugal forces generated from the locking member at high speeds about the rotational axis.

5. The locking member as defined in claim 1, wherein the at least one pivot comprises inner and outer projecting ears which extend laterally from the main body portion and wherein the at least one bearing includes a roller bearing on each ear.

6. The locking member as claimed in claim 1, wherein the at least one pivot comprises a convex upper pivot which extends upwardly from the main body portion and wherein the at least one bearing includes a roller bearing on opposite sides of the upper pivot.

7. The locking member as claimed in claim 1, wherein the locking member is a planar or radial locking strut.

8. The locking member as claimed in claim 7, wherein the locking strut is an active locking strut.

9. The locking member as claimed in claim 1, wherein the locking member is a metal injection molded locking member.

10. The locking member as claimed in claim 1, wherein the locking member includes inner and outer pivots which extend laterally from the main body portion for enabling pivotal motion of the locking member about an axis which intersects the pivots.

11. The locking member as claimed in claim 1, wherein each pocket has an inner pocket wall and an outer pocket wall, the inner pocket wall being parallel to a normal to the centerline and the outer pocket wall being angled with respect to the normal of the centerline to improve locking member dynamics.

12. An engageable coupling assembly comprising: first and second coupling members, the first coupling member rotating about a rotational axis of the assembly and including a centerline through the axis and a coupling face having a pocket which is at least partially defined by a pocket surface, the pocket being sized and shaped to receive and nominally retain a locking member and at least one bearing, the locking member pivoting down into the pocket during an overrunning condition of the assembly, the locking member including: a member-engaging first end surface; a member-engaging second end surface; a main body portion between the end surfaces; and at least one pivot which projects from the main body portion, the at least one pivot enabling pivotal motion of the locking member and being sized, shaped and located with respect to the main body portion so that the at least one pivot makes contact with the at least one bearing located between the pocket surface and an outer surface of the at least one pivot to reduce friction during the pivotal motion.

13. The assembly as claimed in claim 12, wherein the at least one pivot comprises a convex upper pivot which extends upwardly from the main body portion and wherein the at least one bearing includes a roller bearing on opposite sides of the upper pivot.

14. The assembly as claimed in claim 12, wherein the at least one pivot has a generally cylindrical end portion for contacting the at least one bearing and wherein the at least one bearing comprises a thrust bearing which reacts centrifugal forces generated from the locking member at high speeds about the rotational axis.

15. The assembly as claimed in claim 12, wherein the end surfaces of the locking member are movable between engaged and disengaged positions with respect to the coupling members during the pivotal motion whereby one-way torque transfer may occur between the coupling members.

16. The assembly as claimed in claim 12, wherein the at least one pivot comprises at least one projecting ear which extends laterally from the main body portion and wherein the at least one bearing comprises a thrust bearing which reacts centrifugal forces generated from the locking member at high speeds about the rotational axis.

17. The assembly as defined in claim 12, wherein the at least one pivot comprises inner and outer projecting ears which extend laterally from the main body portion and wherein the at least one bearing includes a roller bearing on each ear.

18. The assembly as claimed in claim 12, wherein the locking member is a planar or radial locking strut.

19. The assembly as claimed in claim 18, wherein the locking strut is an active locking strut.

20. The assembly as claimed in claim 12, wherein the locking member is a metal injection molded locking member.

21. The assembly as claimed in claim 12, wherein the locking member includes inner and outer pivots which extend laterally from the main body portion for enabling pivotal motion of the locking member about an axis which intersects the pivots.

22. The assembly as claimed in claim 12, wherein each pocket has an inner pocket wall and an outer pocket wall, the inner pocket wall being parallel to a normal to the centerline and the outer pocket wall being angled with respect to the normal of the centerline to improve locking member dynamics.

23. An overrunning coupling and control assembly comprising: first and second coupling members, the first coupling member rotating about a rotational axis of the assembly and including a centerline through the axis and a first coupling face having a pocket which is at least partially defined by a pocket surface, the pocket being sized and shaped to receive and nominally retain a locking member and at least one bearing and a second face spaced from the first coupling face and having a passage in communication with the pocket to communicate an actuating force to the locking member to actuate the locking member within the pocket so that the locking member moves between engaged and disengaged positions, the locking member pivoting down into the pocket during an overrunning condition of the assembly, the locking member including: a member-engaging first end surface; a member-engaging second end surface; a main body portion between the end surfaces; and at least one pivot which projects from the main body portion, the at least one pivot enabling pivotal motion of the locking member and being sized, shaped and located with respect to the main body portion so that the at least one pivot makes contact with the at least one bearing located between the pocket surface and an outer surface of the at least one pivot to reduce friction during the pivotal motion.

24. The assembly as claimed in claim 23, wherein the at least one pivot has a generally cylindrical end portion for contacting the at least one bearing and wherein the at least one bearing comprises a thrust bearing which reacts centrifugal forces generated from the locking member at high speeds about the rotational axis.

25. The assembly as claimed in claim 23, wherein the end surfaces of the locking member are movable between engaged and disengaged positions with respect to the coupling members during the pivotal motion whereby one-way torque transfer may occur between the coupling members.

26. The assembly as claimed in claim 23, wherein the at least one pivot comprises at least one projecting ear which extends laterally from the main body portion and wherein the at least one bearing comprises a thrust bearing which reacts centrifugal forces generated from the locking member at high speeds about the rotational axis.

27. The assembly as defined in claim 23, wherein the at least one pivot comprises inner and outer projecting ears which extend laterally from the main body portion and wherein the at least one bearing includes a roller bearing on each ear.

28. The assembly as claimed in claim 23, wherein the locking member is a planar or radial locking strut.

29. The assembly as claimed in claim 28, wherein the locking strut is an active locking strut.

30. The assembly as claimed in claim 23, wherein the locking member is a metal injection molded locking member.

31. The assembly as claimed in claim 23, wherein the at least one pivot comprises a convex upper pivot which extends upwardly from the main body portion and wherein the at least one bearing includes a roller bearing on opposite sides of the upper pivot.

32. The assembly as claimed in claim 23, wherein the locking member includes inner and outer pivots which extend laterally from the main body portion for enabling pivotal motion of the locking member about an axis which intersects the pivots.

33. The assembly as claimed in claim 23, wherein each pocket has an inner pocket wall and an outer pocket wall, the inner pocket wall being parallel to a normal to the centerline and the outer pocket wall being angled with respect to the normal of the centerline to improve locking member dynamics.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0076] FIG. 1 is a top plan view, partially broken away, of a prior art locking member or strut located in a pocket of a rotating pocket plate together with a pivot axis of the strut, different reactive forces, F.sub.R1 and F.sub.R2, and a centrifugal force Fc at a center of gravity of the strut;

[0077] FIG. 2 is a view similar to the view of FIG. 1 of a different prior art locking member and different moment arms and forces;

[0078] FIG. 3 is an exploded perspective view of an overrunning active coupling and control assembly constructed in accordance with at least one embodiment of the invention;

[0079] FIG. 4 is a view similar to the view of FIG. 3 but from a reverse angle;

[0080] FIG. 5 is an end perspective view of the assembly of FIGS. 3 and 4 in its assembled condition;

[0081] FIG. 6 is a view similar to the view of FIG. 5 but with the notch plate removed to show the locking members and the cover plate;

[0082] FIG. 7 is a side view, partially broken away and in cross-section, of a pair of roller bearings on opposite sides of a convex, upper pivot of a radial strut;

[0083] FIG. 8 is a side view, partially broken away and in cross-section, of a roller bearing on an ear of a radial strut;

[0084] FIG. 9 is a side schematic view, partially broken away and in cross-section, of the radial strut of FIG. 8 but now showing a roller bearing on each ear of the radial strut;

[0085] FIG. 10 is a top plan view, partially broken away, of a prior art locking member or strut located within the pocket of a rotating pocket plate wherein dashed circles indicate areas of friction at the walls of the pocket caused by centrifugal force which can approach 200 lbs. at the outer pocket wall;

[0086] FIG. 11 is a side view, partially broken away and in cross-section, showing a bearing on an ear of the locking member and various biasing members or springs with an actuation system to control movement of the locking member;

[0087] FIG. 12 is a top plan view, partially broken away, of a locking member, its bearing, and springs within a pocket of a pocket plate together with a retainer plate;

[0088] FIG. 13 is a view similar to the view of FIG. 12 but with the retainer plate removed;

[0089] FIG. 14 is a view similar to the view of FIG. 11 but showing an apply plate as part of the actuation system and the locking member in its retracted, uncoupling position;

[0090] FIG. 15 is a view similar to the view of FIG. 14 but showing the locking member in its extended, coupling position;

[0091] FIG. 16 is a top plan view, partially broken away, of a locking member of a different embodiment within a pocket of a pocket plate together with a retainer plane;

[0092] FIG. 17 is view similar to the view of FIG. 16 but with the retainer plate removed to reveal a return spring in the form of a leaf spring and a thrust bearing for the locking member;

[0093] FIG. 18 is a view similar to the views of FIGS. 16 and 17 but with the locking member and the retainer plate removed to particularly show the leaf spring, the bearing and an axial apply spring for the locking member;

[0094] FIG. 19 is a view similar to the view of FIG. 14 and showing the locking member, the leaf spring and actuating spring of FIGS. 16-18, with the locking member in its retracted, uncoupling position;

[0095] FIG. 20 is a side perspective view of the locking member or strut of FIGS. 16, 17 and 19;

[0096] FIG. 21 is an exploded perspective view of an overrunning coupling and control assembly constructed in accordance with an embodiment of the present invention and with the components of FIGS. 16-20;

[0097] FIG. 22 is a top perspective view, partially broken away, of a locking member similar to the locking member of FIGS. 16, 17 and 20 within a pocket of a pocket plate together with a rotary selector plate which allows the locking member to rise into a notch of a notch plate;

[0098] FIG. 23 is a view similar to the view of FIG. 22 but with the selector plate removed to reveal a spring and a thrust bearing for the locking member;

[0099] FIG. 24 is a view similar to the views of FIGS. 22 and 23 but with the locking member and the selector plate removed to particularly show the spring and the thrust bearing for the locking member;

[0100] FIG. 25 is a view similar to the view of FIG. 19 with the locking member and spring of FIGS. 22 and 23 and the selector plate of FIG. 22 and with the locking member in its extended, coupling position;

[0101] FIG. 26 is a side perspective view of the locking member or strut of FIGS. 22, 23 and 25;

[0102] FIG. 27 is an exploded perspective view of an overrunning coupling and control assembly constructed in accordance with another embodiment of the present invention with the components of FIGS. 22-26;

[0103] FIGS. 28 is a view similar to the view of FIG. 17 but with the pocket of the pocket plate rotated outwardly;

[0104] FIG. 29 is a view similar to the views of FIGS. 17 and 28 but with no pocket rotation; and

[0105] FIG. 30 is a view similar to the views of FIGS. 17, 28 and 29 but with inward pocket rotation.

DETAILED DESCRIPTION

[0106] As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention.

[0107] In general, a locking member or strut, generally indicated at 102, is disclosed herein which can be used in its respective coupling and control assembly 100 (FIGS. 3 and 4). Different embodiments of the locking member 102 are specifically shown in drawing FIGS. 7-9 and 11-15.

[0108] The active rotating or pivoting strut 102 is actuated to move into its up or coupling position (FIGS. 11 and 15) so that a lock can occur between a pocket plate 106 and a notch plate 110. This occurs when an actuation system 104 (FIG. 11) including an apply plate, generally indicated at 105, and actuating or apply springs 115 are commanded to move the strut 102. The centrifugal force generated by the rotating strut 102 can hold the strut 102 in the notch plate 110 and prevent disengagement from occurring due to friction. To overcome this issue, a return spring 114 with more force can be used. With at least one embodiment of the invention, the strut 102 can be disengaged with a relatively small return spring. The apply springs 115 are designed to ride on the outside wall of the pockets to reduce the effects of centrifugal force. If this was not designed this way, the springs 115 could get caught between the strut and pocket which could cause damage to the spring or not allow the spring to push the strut in the engaged position. This could also be done with the return spring when coil springs are used as shown in FIG. 11. A torsion spring 114 is used in FIG. 13 on the strut inside ear which has little change in function with centrifugal force (this spring is used in this configuration due to packing also).

[0109] In at least one embodiment of the invention, at least one bearing in the form of a thrust bearing 126 (i.e., FIGS. 3, 4, 6 and 11-15) is used for the actively controlled strut 102 with a dynamic clutch where the active strut 102 is actuated to move into its up position so that a lock can occur between the pocket plate 106 and notch plate 110. When the actuation system is commanded so the strut 102 can disengage itself, the centrifugal force generated by the rotating strut 102 can hold itself in the pocket plate 106 and prevent disengagement from occurring due to the friction. The force to actuate also becomes too large to manage. To overcome this issue, the return spring 114 and the apply spring 115 with more force can be used.

[0110] With this embodiment of the invention, the strut 102 can be disengaged with either a small return spring 114, or no return spring depending on how the strut 102 needs to behave at lower speeds, and the force to apply becomes much lower. The thrust bearing 126 is used in between the pocket plate 106 and the strut 102 so that all the force generated by the strut 102 is acted directly onto the bearing 126. This strut 102 is in the planer direction which allows the center of mass of the strut 102 does not affect the function of engaging or disengaging. The insensitivity of the center of mass of the strut 102 is due to the orientation of the planer configuration which is important since a strut in the radial direction (i.e. FIGS. 7-9) will always have the center of mass affecting the engagement and disengagement forces. The bearing 126 is used since the friction to rotate is called rolling friction which tends to have a frictional coefficient of 0.0015 compared to a static frictional coefficient of 0.2 of lubricated steel on steel. A frictional coefficient between 0.0015 and 0.2 calculates to the bearing 126 resisting 0.8% of the force compared to that of lubricated steel on steel interface.

[0111] The assembly 100 includes the backing or apply plate 105, the pocket plate 106, a cover or retainer plate, generally indicated at 108, the notch plate 110, and a snap ring, generally indicated at 112, which holds all of the plates 105, 106, 108 and 110 together. The biasing members or springs 115 bias their respective struts 102 within their respective pockets 113.

[0112] The apply plate 105 supports dowels 117 and the pocket plate 106 supports bushings 118 in holes 119 in which the dowels 117 are supported by the bushings 118. In this way, the plates 106 and 105 are connected. The retainer plate 108 has a plurality of passages 111 through which the struts 102 can extend so that the struts 102 can perform their locking function.

[0113] Each strut 102 includes a member-engaging first end surface 120, a member-engaging second end surface 122 and an elongated main body portion 124 between the end surfaces 120 and 122. At least one and preferably two (so that each strut 102 can be used as either a forward or a reverse strut) projecting ears 130 extends laterally from the main body portion 124. The end surfaces 122 and 120 of the locking member 102 are moveable between engaged and disengaged positions with respect to the coupling members 106 and 110 during pivotal motion whereby one-way torque transfer may occur between the coupling members 106 and 110.

[0114] The biggest force that exists in this design is a stabilizing force that wants to keep the strut 102 in the down position caused by high rotational speeds. This force gets bigger as speed in the clutch increases. This force does not exist in the radial style strut of FIGS. 7-9.

[0115] In the embodiments of FIGS. 7-9, the bearing takes the form of roller bearings 128 and 128. The strut or locking member is a radial strut 102 having end surfaces 120 and 122 and a main body portion 124. The radial strut 102 of FIG. 7 includes a convex upper pivot 126 wherein the roller bearings 128 are positioned in bearing contact on opposite sides of the pivot 126.

[0116] The radial strut 102 of FIGS. 8 and 9 includes a pair of ears 130 which extend laterally from the main body portion 124. Roller bearings 128 are positioned about the ears 130 to rotationally support the radial strut 102.

[0117] The design of the bearings 128 and 128 for the radial strut 102 of FIGS. 7-9 is similar to the design of the bearings 126 for the planar strut 102. The radial strut 102 is sensitive to the center of mass location which will need to be slightly shifted to the disengaged position to prevent an unintentional engagement. There is no stabilizing force with a radial strut which means that the largest force in this system would be the center of mass relative to the pivot point of the strut 102. Two designs (FIGS. 7-9) could use roller bearings to maintain the centrifugal forces that are created with high rotational speeds. The first design (FIG. 7) would have two bearings 128 on the top of the strut 102 (further to the outside diameter) which would require more radial packaging. The second design (FIGS. 8 and 9) would have a bearing 128 in the middle on each of the ears 130 of the strut 102 requiring more axial packaging. The bearings 128 help manage the centrifugal forces, so the largest force in the system would be the moment that is created by the center of mass of the strut 102 not being at the center of rotation. The center of mass of the strut 102 should be biased to the strut-disengaged direction to prevent an unintended actuation. The centrifugal forces can force the rollers within the bearings 128 to be pushed to the OD of the bearing 128 which could cause some issues. This would have to be taken under consideration when designing this option.

[0118] Each of the pockets 113 in the pocket plate 106 provides sufficient clearance to allow sliding movement of its locking member 102 during movement of the locking member 102 between engaged and disengaged positions. Each locking member 102 may be an injection molded locking member such as a metal injection molded locking member or strut. Alternatively, the struts may be made via additive manufacturing such as 3D printing. By using additive manufacturing one can vary the density in the struts which would help the stabilizing moment from centrifugal forces.

[0119] The first coupling member or pocket plate 106 also has a face with a plurality of passages 140 spaced about the rotational axis 142 (FIG. 5) of the assembly 100 and including a passage 142 in communication with each pocket 113. The passages 140 communicate actuating forces (typically via the actuating springs 115) to their respective locking members 102 within their respective pockets 113. The faces of the pocket plate 106 are generally annular and extend generally radially with respect to the rotational axis 142 of the assembly 100. Actuators, such as the spring actuators 115, may be received within the passages 140 to provide the actuating forces to actuate the locking members 102 within their respective pockets 113 so that the locking members 102 move between their engaged and disengaged positions. Other types of actuators besides the spring actuators 115 may be used to provide the actuating forces. Also, pressurized fluid may be used to provide the actuating forces.

[0120] Biasing members such as the coiled return springs 114 bias the locking members 102 against pivotal motion of the locking members 102 towards their engaged positions. The spring actuators 115 pivot their locking members 102 against the bias of the spring biasing members 114. Each pocket 113 may have an inner recess 144 for receiving its respective biasing spring 114 wherein the pockets 113 are spring pockets.

[0121] Referring now to FIGS. 16-21, a locking member or strut, generally indicated at 202, is disclosed herein which can be used in its respective coupling and control assembly 200 (FIG. 21). The shape of the strut 202 is optimized to lower the stabilizing force that occurs at high rotational speeds.

[0122] The active rotating or pivoting strut 202 is actuated to move into its up or coupling position (not shown) so that a lock can occur between a pocket plate 206 and a notch plate 210. This occurs when an actuation system such as the actuation system 104 (FIG. 11) including an apply plate, (not shown), and actuating or apply springs 215 are commanded to move the strut 202. The centrifugal force generated by the rotating strut 202 can hold the strut 202 in the notch plate 210 and prevent disengagement from occurring due to friction. To overcome this issue, a return spring such as a leaf spring 214 with more force can be used. With at least one embodiment of the invention, the strut 202 can be disengaged with a relatively small return spring. The apply springs 215 are designed to ride on the outside wall of the pockets to reduce the effects of centrifugal force. If this was not designed this way, the springs 215 could get caught between the strut and pocket which could cause damage to the spring or not allow the spring to push the strut into the engaged position.

[0123] In at least one embodiment of the invention, at least one rotary bearing in the form of a thrust bearing 226 (i.e., FIGS. 17, 18, and 21) is used for the actively controlled strut 202 with a dynamic clutch where the active strut 202 is actuated to move into its up position so that a lock can occur between the pocket plate 206 and the notch plate 210. When the actuation system is commanded so the strut 202 can disengage itself, the centrifugal force generated by the rotating strut 202 can hold itself in the pocket plate 206 and prevent disengagement from occurring due to the friction. The force to actuate also becomes too large to manage. To overcome this issue, the return spring 214 and the apply spring 215 with more force can be used.

[0124] With this embodiment of the invention, the strut 202 can be disengaged with either a small return spring 214, or no return spring depending on how the strut 202 needs to behave at lower speeds, and the force to apply becomes much lower. The thrust bearing 226 is used in between the outer side wall of a pocket 213 in the pocket plate 206 and the strut 202 so that all the force generated by the strut 202 is acted directly onto the bearing 226. This strut 202 is in the planer direction so that the center of mass of the strut 202 does not affect the function of engaging or disengaging. The insensitivity of the center of mass of the strut 202 is due to the orientation of the planer configuration which is important since a strut in the radial direction (i.e. FIGS. 7-9) will always have the center of mass affecting the engagement and disengagement forces. The bearing 226 is used since the friction to rotate is called rolling friction which tends to have a frictional coefficient of 0.0015 compared to a static frictional coefficient of 0.2 of lubricated steel on steel. A frictional coefficient between 0.0015 and 0.2 calculates to the bearing 226 resisting 0.8% of the force compared to that of lubricated steel on steel interface.

[0125] The assembly 200 includes the backing or apply plate (not shown), the pocket plate 206, a cover or retainer plate, generally indicated at 208, the notch plate 210, and a snap ring, generally indicated at 212, which holds all of the plates 206, 208 and 210 together. The biasing members or springs 215 bias their respective struts 202 within their respective pockets 213. The leaf or biasing spring 214 is located in a groove 203 formed in a lower surface of the strut 202.

[0126] As in the first embodiment, the apply plate supports dowels (not show) and the pocket plate 206 supports bushings (not shown) in holes in which the dowels are supported by the bushings.

[0127] In this way, the plates are connected. The retainer plate 208 has a plurality of passages 211 through which the struts 202 can extend so that the struts 202 can perform their locking function.

[0128] Each strut 202 includes a member-engaging first end surface 220, a member-engaging second end surface 222 and a lobed main body portion 224 between the end surfaces 220 and 222. At least one and preferably two (so that each strut 202 can be used as either a forward or a reverse strut) projecting lobes or ears 230 extends laterally from the main body portion 224. The ears 230 have substantially flat parallel ends, one of which engages an inner end surface 225 of the thrust bearing 226. The end surfaces 222 and 220 of the locking member 202 are moveable between engaged and disengaged positions with respect to the coupling members 206 and 210 during pivotal motion whereby one-way torque transfer may occur between the coupling members 206 and 210.

[0129] The biggest force that exists in this design is a stabilizing force that wants to keep the strut 202 in the down position caused by high rotational speeds. This force gets bigger as speed in the clutch increases. This force does not exist in the radial style strut of FIGS. 7-9.

[0130] Each of the pockets 213 in the pocket plate 206 provides sufficient clearance to allow sliding movement of its locking member 202 during movement of the locking member 202 between engaged and disengaged positions. Each locking member 202 may be an injection molded locking member such as a metal injection molded locking member or strut. Alternatively, the struts 202 may be made via additive manufacturing such as 3D printing. By using additive manufacturing one can vary the density in the struts 202 which would help the stabilizing moment from centrifugal forces.

[0131] The first coupling member or pocket plate 206 also has a face with a plurality of passages 240 spaced about the rotational axis of the assembly 200 and including a passage in communication with each pocket 213. The passages 240 communicate actuating forces (typically via the actuating springs 215) to their respective locking members 202 within their respective pockets 213. The faces of the pocket plate 206 are generally annular and extend generally radially with respect to the rotational axis of the assembly 200. Actuators, such as the spring actuators 215, may be received within the passages 240 to provide the actuating forces to actuate the locking members 202 within their respective pockets 213 so that the locking members 202 move between their engaged and disengaged positions. Other types of actuators besides the spring actuators 215 may be used to provide the actuating forces. Also, pressurized fluid may be used to provide the actuating forces.

[0132] Biasing members such as the leaf springs 214 bias the locking members 202 against pivotal motion of the locking members 202 towards their engaged positions. The spring actuators 215 pivot their locking members 202 against the bias of the spring biasing members 214. Each pocket 213 may have an inner recess 244 for receiving its respective biasing leaf spring 214 wherein the pockets 213 are spring pockets.

[0133] Referring now to FIGS. 22-27, a lobed locking member or strut, generally indicated at 302, is disclosed herein which can be used in its respective coupling and control assembly 300 (FIG. 27). The strut 302 is similar in size and shape to the strut 302. The assembly 300 includes a selector plate, generally indicated at 301, including apertures 311 which allow the struts 302 to rise or pivot into notches of a notch plate 310. Alternatively, a fixed cover plate can be used for a passive one-way clutch function.

[0134] The active rotating or pivoting strut 302 is actuated to move into its up or coupling position (FIGS. 22, 23 and 25) so that a lock can occur between a pocket plate 306 and the notch plate 310. This occurs when the selector plate 301 is commanded to rotate in a first direction so that the strut 302 can extend through an aperture 311 in the selector plate 301 as shown in FIGS. 22 and 25. The centrifugal force generated by the rotating strut 302 can hold the strut 302 in the notch plate 310 and prevent disengagement from occurring due to friction. With at least one embodiment of the invention, the strut 302 can be disengaged by again rotating the selector plate 302 but in the opposite direction.

[0135] In at least one embodiment of the invention, at least one rotary bearing in the form of a thrust bearing 326 (i.e., FIGS. 23 and 24) is used for the strut 302 where the strut 302 is actuated to move into its up position so that a lock can occur between the pocket plate 306 and notch plate 310. When the selector plate 301 is commanded to rotate so the strut 302 can disengage, the centrifugal force generated by the rotating strut 302 can hold itself in the pocket plate 306 and prevent disengagement from occurring due to the friction. The force to actuate may become too large to manage. To overcome this issue, the apply spring 315 with more force can be used.

[0136] With this embodiment of the invention, the strut 302 can be disengaged from the outer side wall of the pocket with the thrust bearing 326 used in between the outer side wall of a pocket in the pocket plate 306 and the strut 302 so that all the force generated by the strut 302 is reacted directly into the bearing 326. As in the embodiment of FIGS. 16-21, the thrust bearing 326 reacts the centrifugal forces generated from the strut 302 at high speeds. The strut 302 is in the planer direction which means the center of mass of the strut 302 does not affect the function of engaging or disengaging. The insensitivity of the center of mass of the strut 302 is due to the orientation of the planer configuration which is important since a strut in the radial direction (i.e. FIGS. 7-9) will always have the center of mass affecting the engagement and disengagement forces. The thrust bearing 326 is used since the friction to rotate is called rolling friction which tends to have a frictional coefficient of 0.0015 compared to a static frictional coefficient of 0.2 of lubricated steel on steel. A frictional coefficient between 0.0015 and 0.2 calculates to the bearing 326 resisting 0.8% of the force compared to that of lubricated steel on steel interface.

[0137] The assembly 300 includes the pocket plate 306, the selector plate 301 (or possibly a cover or retainer plate), the notch plate 310, and a snap ring, generally indicated at 312, which holds all of the plates 301, 306, and 310 together. The biasing members or springs 315 bias their respective struts 302 within their respective pockets 313.

[0138] Each strut 302 includes a member-engaging first end surface 320, a member-engaging second end surface 322 and an elongated main body portion 324 between the end surfaces 320 and 322. At least one and preferably two (so that each strut 302 can be used as either a forward or a reverse strut) projecting lobes or ears 330 extends laterally from the main body portion 324. The ears 330 have substantially flat parallel ends, one of which engages an inner end surface 325 of the thrust bearing 326. The end surfaces 322 and 320 of the locking member 302 are moveable between engaged and disengaged positions with respect to the coupling members 306 and 310 during pivotal motion whereby one-way torque transfer may occur between the coupling members 306 and 310.

[0139] The biggest force that exists in this design is a stabilizing force that wants to keep the strut 302 in the down position caused by high rotational speeds. This force gets bigger as speed in the clutch increases. This force does not exist in the radial style strut of FIGS. 7-9 as previously mentioned.

[0140] Each of the pockets 313 in the pocket plate 306 provides sufficient clearance to allow sliding movement of its locking member 302 during movement of the locking member 302 between engaged and disengaged positions. Each locking member 302 may be an injection molded locking member such as a metal injection molded locking member or strut. Alternatively, the struts 302 may be made via additive manufacturing such as 3D printing. By using additive manufacturing one can vary the density in the struts 302 which would help the stabilizing moment from centrifugal forces.

[0141] The first coupling member or pocket plate 306 includes an aperture 342 in communication with each pocket 313. Biasing members, such as coiled springs 315, may be received within the apertures 342 to provide the biasing forces to bias the locking members 302 within their respective pockets 313 so that the locking members 302 move between their engaged and disengaged positions. Other types of biasing members besides the springs 315 may be used to provide the biasing forces.

[0142] The non-apertured portions of the selector plate 301 prevent pivotal motion of the locking members 302 towards their engaged positions. The springs 315 pivot their locking members 302 when the apertures 311 are aligned with the locking members 302.

[0143] Referring now to FIGS. 28 through 30 (which correspond to FIG. 17) besides the many previously described factors effecting the laydown or lockdown speed of a strut, the inventors of this application have discovered that pocket rotation (i.e. the angle of the pocket outer wall 225 relative to a line (or centerline) 227 running through the center of the clutch) is another factor that affects the amount of actuation force needed to rotate the strut 202. Counter-clockwise (i.e. outward) pocket rotation as shown in FIG. 28 lowers actuation force for a rotating pocket plate thereby allowing or compensating for relatively large draft angles which lowers manufacturing costs. Clockwise (i.e. inward), pocket rotation as shown in FIG. 30 raises laydown speed. The desired speed (i.e. RPM) at which struts laydown determines the clutches ability to engage. Therefore, if it is desired that the clutch engages at a relatively high speed (i.e. RPM), then inward pocket rotation would be used.

[0144] As described in U.S. publication application 2017/0343060 assigned to the same assignee as the assignee of the present application, with the addition of a pocket rotation, the geometric composition of the strut and its pocket change, resulting in the generation of a new moment due to the centrifugal force now acting on the strut. Centrifugal force is the physical force causing the strut/lock wall dynamics as described herein. This new moment arises from the relative change of point of rotation about which the strut rises or descends.

[0145] The largest force acting on the strut 202 while at high rotational speeds is the Euler torque (also known as the stabilizing torque). If the strut 202 is rotated inwards (i.e. FIG. 30), the moment due to the center 229 of the mass of the strut 202 when the strut 202 is pitched in the engaged position cancels out the Euler torque. The bearing 226 removes the friction, and the inward rotation cancels the Euler torque. This allows the strut 202 to pitch in and out of the notch plate 210 at high rotational speeds with small amount of actuation force. This can be applied to all of the different struts disclosed herein whether actively applied or passively applied.

[0146] While exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention. Additionally, the features of various implementing embodiments may be combined to form further embodiments of the invention.