Overrunning coupling and control assembly and system to prevent the inadvertent engagement of the assembly

Abstract

Overrunning coupling and control assembly and control system for use therein are provided. The system includes a control member mounted for controlled shifting movement between the coupling faces of first of second coupling members. A one-way locking member such as a pawl is pivotally connected to the control member for movement between a disengaged position in which the control member is permitted to shift or rotate relative to the second coupling member and an engaged position between the control member and a locking member engaging portion of the second coupling member to lock the control member and the second coupling member together to prevent the control member from inadvertently shifting in a first direction relative to the second coupling member in the absence of an actuator command signal received by a bi-directional actuator subassembly including an output member connected to the control member.

Claims

1. A system for controlling operating modes of an overrunning coupling assembly including first and second coupling members having first and second coupling faces, respectively, in close-spaced opposition with one another, the first coupling member being mounted for rotation about a rotary axis, the system comprising: a control member mounted for controlled shifting movement between the coupling faces; a bi-directional actuator assembly including an output member connected to the control member for selective, small-displacement, control member shifting movement relative to the second coupling member between a first position which corresponds to a first operating mode of the coupling assembly and a second position which corresponds to a second operating mode of the coupling assembly in response to an actuator command signal; and a one-way locking member pivotally connected to the control member for movement between a disengaged position in which the control member is permitted to shift relative to the second coupling member and an engaged position between the control member and a locking member engaging portion of the second coupling member to lock the control member and the second coupling member together to prevent the control member from inadvertently shifting in a first direction relative to the second coupling member in the absence of the actuator command signal received by the actuator assembly.

2. The system as claimed in claim 1, wherein the control member is a control or selector plate rotatable about the axis between different angular positions.

3. The system as claimed in claim 1, wherein the output member includes an actuator arm.

4. The system as claimed in claim 1, wherein the coupling assembly is a clutch assembly, the coupling members are clutch members and the coupling faces are clutch faces.

5. The system as claimed in claim 4, wherein the clutch assembly is a selectable, one-way clutch assembly and wherein the first clutch member is a notch plate, the second clutch member is a pocket plate and the control member is a selector plate rotatable about the axis.

6. The system as claimed in claim 1, wherein the system is an electromechanical system and wherein the actuator assembly includes an electrically-powered device for driving the control member in response to an electrical actuator command signal.

7. The system as claimed in claim 6, wherein the device comprises a solenoid having an armature configured to move between extended and retracted positions and wherein the output member is connected to the armature so that the output member is allowed to rotate a predetermined amount before the output member begins to shift the control member.

8. The system as claimed in claim 1, further comprising a biasing member which exerts a biasing force on the locking member to bias the locking member into the engaged position, the locking member and the output member being pivotally connected together.

9. The system as claimed in claim 1, wherein the locking member is spring-biased into the engaged position.

10. The system as claimed in claim 1, wherein the locking member is integrally formed with the output member.

11. The system as claimed in claim 1, wherein the locking member and the output member are rotatably connected to the control member via a slip fit connection.

12. The system as claimed in claim 11, wherein the control member has a hole formed therein and the output member has a pivot pin projecting therefrom, the pin having the slip fit connection with the hole in the control member so that the pivot pin rotates within the control member.

13. The system as claimed in claim 1, wherein the output member extends through a slot formed in a wall of the second coupling member and wherein the locking member engaging portion at least partially defines the slot.

14. The system as claimed in claim 1, wherein the locking member engaging portion is formed on the second coupling face.

15. An overrunning coupling and control assembly comprising: a coupling subassembly including first and second coupling members having first and second coupling faces, respectively, in close-spaced opposition with one another, the first coupling member being mounted for rotation about a rotary axis and the second coupling member including a pawl-engaging portion; a control member mounted for controlled shifting movement between the coupling faces; a bi-directional actuator subassembly including an output member connected to the control member for selective, small-displacement, control member shifting movement relative to the second coupling member between a first position which corresponds to a first operating mode of the coupling subassembly and a second position which corresponds to a second operating mode of the coupling subassembly in response to an actuator command signal; and a one-way locking member pivotally connected to the control member for movement between a disengaged position in which the control member is permitted to shift relative to the second coupling member and an engaged position between the control member and the locking member engaging portion of the second coupling member to lock the control member and the second coupling member together to prevent the control member from inadvertently shifting in a first direction relative to the second coupling member in the absence of the actuator command signal received by the actuator subassembly.

16. The assembly as claimed in claim 15, wherein the control member is a control or selector plate rotatable about the axis between different angular positions.

17. The assembly as claimed in claim 15, wherein the output member includes an actuator arm.

18. The assembly as claimed in claim 15, wherein the coupling subassembly is a clutch subassembly, the coupling members are clutch members and the coupling faces are clutch faces.

19. The assembly as claimed in claim 18, wherein the clutch subassembly is a selectable, one-way clutch subassembly and wherein the first clutch member is a notch plate, the second clutch member is a pocket plate and the control member is a selector plate rotatable about the axis.

20. The assembly as claimed in claim 15, wherein the actuator subassembly includes an electrically-powered device for driving the control member in response to an electrical actuator command signal.

21. The assembly as claimed in claim 20, wherein the device comprises a solenoid having an armature configured to move between extended and retracted positions and wherein the output member is connected to the armature so that the output member is allowed to rotate a predetermined amount before the output member begins to shift the control member.

22. The assembly as claimed in claim 15, further comprising a biasing member which exerts a biasing force on the locking member to bias the locking member into the engaged position, the locking member and the output member being pivotally connected together.

23. The assembly as claimed in claim 15, wherein the locking member is spring-biased into the engaged position.

24. The assembly as claimed in claim 15, wherein the locking member is integrally formed with the output member.

25. The assembly as claimed in claim 15, wherein the locking member and the output member are pivotally connected to the control member via a slip fit connection.

26. The assembly as claimed in claim 25, wherein the control member has a hole formed therein and the output member has a pivot pin projecting therefrom, the pin having the slip fit connection with the hole in the control member so that the pivot pin rotates within the control member.

27. The assembly as claimed in claim 15, wherein the output member extends through a slot formed in a wall of the second coupling member and wherein the locking member engaging portion at least partially defines the slot.

28. The assembly as claimed in claim 15, wherein the locking member engaging portion is formed on the second coupling face.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a top plan view of a pocket plate having pockets for locking struts;

(2) FIG. 2 is a perspective view of a selector plate or control member for use in a coupling and control assembly constructed in accordance with at least one embodiment of the present invention;

(3) FIG. 3 is a side elevational view, partially broken away, showing the interconnection between a two-piece actuator arm and spring-biased locking member or pawl and the pocket plate of FIG. 1;

(4) FIG. 4 is a back view of the two-piece actuator arm and spring-biased pawl of FIG. 3;

(5) FIG. 5 is a view, similar to the view of FIG. 3, but also showing an actuator assembly and forces or loads represented by arrows;

(6) FIG. 6 is a top perspective view of the actuator arm of FIGS. 3-5;

(7) FIG. 7 is a perspective view, similar to the view of FIG. 6, but from a reverse direction;

(8) FIG. 8 is a top perspective of the pawl of FIGS. 3-5;

(9) FIG. 9 is a perspective view, similar to the view of FIG. 8, but from a reverse direction;

(10) FIG. 10 is a front view of an actuator arm and locking member or pawl formed as a single piece;

(11) FIG. 11 is a view, similar to the view of FIG. 5, but showing the one-piece design of FIG. 10;

(12) FIG. 12 is a perspective view, similar to the view of FIG. 6, but of the one-piece design;

(13) FIG. 13 is a perspective view, similar to the view of FIG. 7, but of the one-piece design; and

(14) FIGS. 14-18 are side schematic views, partially broken away, of a one-piece actuator arm and locking member, a selector plate and a pocket plate wherein the direction of actuation is reversed with respect to the previous embodiments.

DETAILED DESCRIPTION

(15) 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.

(16) An overrunning coupling and control assembly typically includes a coupling subassembly such as a selectable one-way clutch (SOWC) subassembly. The subassembly includes first and second coupling members having first and second coupling faces, respectively, in closed-spaced opposition with one another.

(17) As shown in FIG. 1, the first coupling member may be a notch plate (not shown) which is mounted for rotation about a rotary axis 21 of the subassembly and the second coupling member may be a pocket plate, generally indicated at 20, which is stationary relative to the notch plate. The pocket plate 20 has a coupling face 22 with pockets 23.

(18) As shown in FIG. 2, the SOWC subassembly also typically includes a control member or selector plate, generally indicated at 30 in the first embodiment of the invention, (not shown for the second embodiment) and 30 in the third embodiment, mounted for controlled shifting or rotational movement between the coupling faces of the notch and pocket plates. The selector plate 30 includes a plurality of spaced apertures 32 to allow locking members or struts to extend therethrough. The selector plate 30 also includes a hole 34 which extends therethrough to allow a slip-fit pivotal connection with an actuator arm and a one-way locking member or pawl as described hereinbelow.

(19) Referring to FIGS. 5 and 11, the coupling and control assembly also includes a bi-directional actuator subassembly, generally indicated at 40 (40 in FIG. 11), including an output member or actuator arm (42 in the first embodiment, 42 in the second embodiment and 42 in the third embodiment) pivotally connected to the selector plate 30 via a pivot pin 43 and connected to an armature or plunger 46 of an actuator or solenoid by collars 47 on opposite sides of a head portion 48 of the arm 42. (Opposite side surfaces of the head portion 48 are angled to provide the proper motion of the output member 42 and the locking member 50 during linear movement of the armature 46).

(20) A biasing spring 49 biases the armature 46 for selective, small-displacement, control member shifting or pivotal movement relative to the pocket plate 20 between a first position which corresponds to a first operating mode of the coupling subassembly and a second position which corresponds to a second operating mode of the coupling subassembly in response to an actuator command signal received by the actuator of the subassembly 40.

(21) The coupling and control assembly also includes a one-way locking member or a pawl (50 in the first embodiment of FIGS. 3-5, 8 and 9; 50 in the second embodiment of FIGS. 12 and 13; and 50 in the third embodiment of FIGS. 14-18). The pawl 50 is also pivotally connected to the selector plate 30 via the pin 43 (which extends into the hole 34) for movement between a disengaged position in which the selector plate 30 is permitted to shift or rotate relative to the pocket plate 20 and an engaged position between the selector plate 30 and a locking member engaging portion 24 of the pocket plate 20 to lock the selector plate 30 and the pocket plate 20 together to prevent the selector plate 30 from inadvertently shifting or rotating in a first direction about the axis 21 relative to the pocket plate 20 in the absence of the actuator command signal received by the actuator of the subassembly 40.

(22) The assembly may further comprise one or more locking members or struts (not shown) disposed between the coupling faces of the coupling members and moveable between the first and second positions. Shifting movement of the selector plate 30 causes the locking member to change position. The selector plate 30 has at least one opening, and preferably, a plurality of the openings 32, which extends completely therethrough and through which the locking struts extend between the notch and pocket plates.

(23) The actuator of the actuator subassembly 40 may be an electrically-powered device such as a solenoid for driving the selector plate 30 in response to an electrical actuator command signal from a controller (not shown) which, in turn, may be electrically coupled to a TECU of a vehicle. The solenoid provides a substantially equally distributed load or force as indicated by the arrows 45 in FIG. 5 during covering of the struts by the selector plate 30.

(24) The assembly of the first embodiment may further comprise a biasing member such as a torsion spring, generally indicated at 60, which exerts a biasing force on the pawl 50 to bias the pawl 50 into an engaged position with the pawl-engaging portion 24. The pawl 50 and the arm or output member 42 are pivotally connected together. One end 62 of the spring 60 is positioned in an elongated slot 44 formed in the back surface of the arm 42 and a second end 64 of the spring 60 is positioned in an elongated slot 52 (FIG. 9) formed in the back surface of the pawl 50. The load or force (indicated by arrow 63) of the spring 60 is provided between the arm 42 and a free end or locking portion 65 of the pawl 50 during covering of the struts by the selector plate 30. In this way, the pawl 50 is spring-biased into the engaged position with the pawl-engaging portion 24 which is integrally formed on the face 22 of the pocket plate 20.

(25) In the second embodiment, a locking member or pawl 50 is integrally formed with an arm or output member 42 as shown in FIGS. 10-13 (first embodiment shown in FIGS. 3-9).

(26) The locking member 50, 50 or 50 and the output member 42, 42 or 42 may both be pivotally connected to the control member 30 or 30 via a slip fit connection provided by the pivot pin (43, 43 or 43) which extends into and is retained within the hole 34 or 34 of the selector plate 30 or 30 to allow the pivotal motion.

(27) The actuator arm or output member 42, 42 or 42 extends through a slot 26, 26 or 26 formed in its respective cylindrical wall 28, 28 or 28 of the pocket plate 20, 20 or 20. In the third embodiment of FIGS. 14-18, the locking member engaging portion 24 of the pocket plate 20 at least partially defines the slot 26.

(28) The pawl-engaging portion 24 is integrally formed on the second coupling face 22 of the pocket plate 20 in the first embodiment and the pawl-engaging portion 24 is integrally formed on the second coupling face 22 of the pocket plate 20 in the second embodiment.

(29) The solenoid of the actuator subassemblies 40 and 40 typically have the armatures 46 and 46, respectively, configured to linearly move between extended and retracted positions wherein the output members 42 and 42 are connected to their respective armatures 46 and 46 so that the output members 42 and 42 are allowed to rotate a predetermined amount before the output members 42 and 42 begin to shift their respective selector plates 30 and 30.

(30) The actuation systems 40 and 40 may be either hydraulic or electric systems. Each actuation system can be forced to a selector plate open orientation if forces get high. These high forces can be from cold oil drag during notch plate rotation. At least one embodiment of the invention creates a lock so that when the actuator is in its struts-covered position, a force generated at the selector plate cannot disengage the lock. The lock can only be disengaged by the actuator when commanded to go into its struts-covered position.

(31) During cold temperature notch plate rotation, forces are generated at the selector plate causing the return spring 49 or 49 of the actuation system to be overcome and the struts to be uncovered by selector plate movement. This would cause an engagement of the struts with the notch plate when the actuator was not commanded to uncover the struts. This invention prevents this from occurring. Without this invention, the actuation system would have to be built stronger to prevent the selector plate 30, 30 or 30 from moving or shifting when not commanded, or the clutch would have to be designed so that less unintended force would be generated.

(32) In general, the first embodiment of FIGS. 3-9, there is disclosed, a two-piece actuator arm, one member is connected to the actuator armature and solenoid (called the actuator arm), and one member connected to the actuator arm that acts as the locking member (called locking member or pawl). These two members are connected to each other and are allowed to pivot relative to each other. The actuator arm is designed to rotate to a fixed location during both the on and off states and can freely rotate within the selector plate. There is a torsional spring between the actuator arm and the pawl so that the pawl can be forced into the lock position. The pocket plate has a small ledge or portion to interface with the pawl to allow the locking action to occur. When the actuator commands the struts to be uncovered, the actuator armature begins to move which makes the actuator arm rotate to its allowable rotation allowing the pawl to be lifted from the locked position. Once the pawl is lifted from its locked position the actuator arm moves tangentially and uncovers the struts.

(33) In general, the second embodiment of FIGS. 10-12 is similar to the first embodiment except the actuator arm and pawl are a solid, one-piece design. This simplifies the function and assembly of the parts. This design functions very similar to that of the first design, but the load path during the actuator off/strut covered action can cause binding and wear issues. If the conditions exist that a solid one-piece actuator arm can be used, money can be saved from part and assembly cost.

(34) In general, the third embodiment of FIGS. 14-18 utilizes a one-piece actuator arm and locking member or pawl and can freely rotate between its connection to its selector plate. This design differentiates from the first two designs since the direction of actuation is reversed. The actuator arm pivots about the pocket plate so that when the actuation system commands a movement, the opposite side of the actuator moves in the opposite direction of the actuation system. This design works since the unintended force from the selector plate pushes in the opposite direction of the actuation. When the force comes from the selector plate (from drag) the selector pushed on the actuator arm which locks into the pocket plate when a small return spring is used to push on the actuator arm in the lock direction.

(35) FIG. 14 shows the struts covered and the solenoid off. A small spring force keeps the actuator arm from disengaging from a lock condition.

(36) FIG. 15 shows the struts covering, solenoid off.

(37) FIG. 16 shows the struts uncovering, solenoid on.

(38) FIG. 17 shows the struts uncovering, solenoid on.

(39) FIG. 18 shows the struts uncovered, solenoid on.

(40) In at least one of the above-noted embodiments (i.e. the first and second), the angle on the actuator arm that interfaces with the solenoid armature is designed so that the actuator arm can rotate a specific amount before the actuator arms begins to move the selector plate. When uncovering the struts, the rotation of the actuator arm allows the locking feature to clear the lock feature on the pocket plate. When covering the struts in the first embodiment, the rotation of the actuator arm allows to compress the small torsion spring (and keep forces low to prevent wear) so when the selector plate is completely covered, the lock can occur. The above-noted angles are relatively important and without them the lock may not function properly.

(41) 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.