Includes an axially oriented linear actuator with a single stator coil and a clutch assembly having the actuator.

Abstract

An axially oriented dual-position linear actuator includes a linearly movable transducer and a fixed stator having a single stator coil. The linear actuator is axially oriented because the stator and transducer are axially offset from each other, and the transducer is axially movable toward and away from the stator between a first end position and a second end position. To move the transducer between the end positions, the stator coil attracts or repels the transducer according to the polarity of the current in the stator coil. The linear actuator can be part of a clutch assembly, such as a dynamically controllable clutch, for controlling the coupling member of the clutch assembly.

Description

[0001] Cross-reference to related applications

[0002] This application is a continuation of U.S. Application No. 17 / 480,512, filed September 21, 2021, which claims the benefit of U.S. Provisional Application No. 63 / 083,194, filed September 25, 2020, the disclosure of which is incorporated herein by reference in its entirety. Technical Field

[0003] This invention relates to automotive clutch assemblies, and more particularly to linear actuators for controlling and operating coupling members of such clutch assemblies. Background Technology

[0004] A one-way clutch (“OWC”) includes a first coupling (or clutch) member, a second coupling member, and at least one locking element (or locking member) between opposing surfaces of the coupling members. The locking element is movable between (i) an engaged (or disengaged) position and (ii) a disengaged (or disengaged) position, in which the locking element extends from the first coupling member and engages the second coupling member, and in the disengaged position, the locking element does not extend from the first coupling member and does not engage the second coupling member. When the locking element is in the engaged position and engages the second coupling member, the OWC is locked in one rotational direction but has free rotation in the opposite direction. Two types of OWCs commonly used in vehicles and automatic transmissions include roller clutches and wedge clutches. A roller clutch may include spring-loaded rollers between an inner and outer race of the OWC, and a wedge clutch may include an asymmetrically shaped wedge located between the inner and outer races of the OWC.

[0005] The selectable OWC (“SOWC”) (also known as a two-way clutch) further includes a second set of locking elements that, in conjunction with the selector plate, add multiple functions to the OWC. The SOWC can create a mechanical connection in one or both directions between rotating or stationary input / output power flow components (e.g., input / output shafts respectively connected to the coupling member) and can overspeed in one or both directions. The SOWC includes an externally controlled selection mechanism that is movable between positions for adjusting the selector plate to different corresponding operating modes of the SOWC.

[0006] A dynamic clutch is a clutch assembly in which both the first and second coupling members are rotatable. A dynamically controllable clutch (or dynamically selectable clutch) (“DCC”) is packaged in a dynamic clutch position, typically containing a jaw clutch, synchronizer, and wet friction assembly. Using electro-actuation, DCC eliminates the need for a hydraulic system and yields significant packaging and system efficiency benefits. In particular, as discussed herein, DCC uses an actuation system comprising a linear actuator that controls the locking element as either or both coupling members rotate.

[0007] See now Figure 1A , Figure 1B Figure 1C , Figure 1D and Figure 1E (Collectively referred to as “Figure 1”), a DCC 12 according to the prior art will be described. The DCC 12 is a component of a system (not shown), such as an automotive transmission, and further has an input power flow component (e.g., a drive gear) and an output power flow component (e.g., a driven shaft).

[0008] The DCC 12 has a radially inner rotating race (i.e., a first coupling member in the form of a bag-shaped plate 13) and a radially outer rotating race (i.e., a second coupling member in the form of a notch plate 16). The bag-shaped plate 13 is fixedly connected to the first power flow component of the system, and the notch plate 16 is fixedly connected to the second power flow component of the system. Therefore, when the bag-shaped plate 13 and the notch plate 16 are connected respectively, the first power flow component and the second power flow component are connected.

[0009] The pocket plate 13 includes a first set and a second set of radial locking elements 26 for clockwise (“CW”) and counterclockwise (“CCW”) engagement, respectively. During engagement, at least one of the locking elements 26 simultaneously contacts the pocket portion and the notch engagement surface of the pocket plate 13 and the notch plate 16, respectively, thereby connecting the pocket plate and the notch plate together. The connection of the pocket plate 13 and the notch plate 16 connects the first power flow component and the second power flow component together. Therefore, in each locked rotational direction, the DCC 12 can transmit torque between the power flow components, which are connected together via the connected pocket plate 13 and the notch plate 16.

[0010] The DCC 12 is electrically actuated by an actuation system in the form of a linear motor (“linear actuator”) 14. The linear actuator 14 includes a stator 22 and a transducer 20. The stator 22 is fixed in place, such as via a mounting member 47, to a transmission housing (not shown). The stator 22 includes a pair of copper wire induction coils 44, 46. Steel plates 48, 50, and 52 provide housings for the stator coils 44, 46. The stator coils 44, 46 are wound in series with opposite polarities relative to each other (anti-series).

[0011] The converter 20 is capable of linear movement between lateral (i.e., axial) positions. The converter 20 is fixedly connected to and rotates with the bag-shaped plate 13. The converter 20 includes an annular ring of segmented permanent magnet 21, steel plates 23 and 25, and a rigid plunger 30. The plunger 30 operates a locking element 26. The plunger 30 extends through a hole formed by a bracket of the converter 20 and is biased by an applied spring 34. The plunger 30 is threaded at its end and secured within its hole by an internally threaded nut 35. The tapered end of the plunger 30 extends through a hole in the ring 55.

[0012] Figure 1B Figure 1C , Figure 1D and Figure 1E The linear actuator 14 controls the locking element 26 in detail. As the bag-shaped plate 13 and the notch plate 16 rotate, the linear actuator 14 controls the locking element 26. The plunger 30 within the converter 20 directly contacts the locking element 26 and causes it to tilt upwards or downwards depending on the actuation direction. The linear actuator 14 has an "off" position (shown in Figures 1B and 1D) and an "on" position (in...). Figure 1C (as shown in IE). In this case, the linear actuator 14 moves the converter 20 to the rightmost position (in Figure 1B and Figure 1D (shown in) and the leftmost position (in) Figure 1C and Figure 1E (As shown in the image) Move horizontally between the "disconnected" and "connected" positions.

[0013] When the converter 20 moves from "disengaged" to "engaged", each plunger 30 contacts the lower face or surface of its locking element 26, thus engaging the locking element into the recessed plate 16. When the locking element 26 is engaged with the recessed plate 16, the DCC 12 can transmit torque in each locking rotational direction. The return spring 28 beneath each locking element 26 is compressed during engagement. When the command is given to "disengage", the converter 20 moves back towards the "disengaged" position, and the plunger 30 loses contact with the locking element 26. The compressed return spring 28 generates a force that causes the locking element 26 to pitch downwards or disengage. Once the torque reversal occurs, the locking element 26 can disengage and the DCC 12 can rotate freely.

[0014] To change the state from "off" to "on", the current excites the stator coil 46 closest to the converter 20. The energized induction coil 46 generates a magnetic field that repels the steady-state field generated by the permanent magnet 21, while the stator coil 44 further away generates an attractive magnetic field. The combination of repulsive and attractive forces caused by the stator coils 44 and 46 causes the converter 20 to move.

[0015] Once the converter 20 passes the central stator plate 50, the permanent magnet 21 attempts to align perfectly with the leftmost stator plate 48. However, the mechanical stop 53 ( Figure 1D and Figure 1E To prevent perfect alignment, a bias force is applied to hold the converter 20 in the "on" position. The converter 20 is magnetically latched in the "on" position.

[0016] To disengage DCC 12, current is applied to the stator coil 44 closest to converter 20 (previously away from stator coil 46), and linear actuator 14 moves from “on” stop 53 to a ring that serves as “off” stop 42 in a similar manner to that described above. The “off” mechanical stop 42 prevents complete alignment of permanent magnet 21 and rightmost stator plate 52, maintaining a magnetic latch in the “off” position.

[0017] As described, the linear actuator 14 is a dual-position linear actuator with a pair of radially oriented stator coils 44, 46. The linear actuator 14 is radially oriented, wherein the stator 22 and the transducer 20 are radially offset from each other, wherein the stator 22 is an outer radial component and the transducer 20 is an inner radial component. Summary of the Invention

[0018] The object of this invention is an axially oriented linear actuator.

[0019] Another object of the present invention is an axially oriented linear actuator having a single stator coil.

[0020] Another object of the present invention is a linear actuator having a single stator coil.

[0021] Another object of the present invention is a clutch assembly having a linear actuator for controlling and operating the coupling member of the clutch assembly with axial orientation.

[0022] Another object of the present invention is a clutch assembly that includes a linear actuator having a single stator coil.

[0023] In performing at least one of the above and / or other purposes, a linear actuator is provided for controlling a coupling member of a clutch assembly. The linear actuator includes: (i) a stator having stator coils and (ii) a transducer axially offset from the stator. Depending on the polarity of the current in the stator coils, the transducer can move axially between a first position adjacent to the stator and a second position distant from the stator.

[0024] In this embodiment, the stator coil is a single stator coil and the stator does not have other stator coils.

[0025] After the converter has moved to the first position adjacent to the stator, the converter can be magnetically latched in the first position adjacent to the stator by a magnetic circuit extending through the stator core and the permanent magnet of the converter. After the converter has moved to the second position away from the stator coils, the converter can be magnetically latched in the second position away from the stator by a magnetic circuit extending through the stator latch plate and the permanent magnet of the converter.

[0026] Permanent magnets can include multiple segmented permanent magnets.

[0027] The stator may encapsulate the transducer. The stator may further include (i) a stator core having stator coils, (ii) a stator latch plate, and (iii) a stator connector connecting the stator core and the stator latch plate. The stator core and stator latch plate may be ferromagnetic and the stator connector may be nonmagnetic. In other embodiments, the stator does not include a stator connector, and the stator core and stator latch plate are directly connected to each other.

[0028] In this embodiment, the stator and / or converter has a ring-shaped form.

[0029] The converter may include a radially outer ferromagnetic converter ring and a radially inner ferromagnetic converter ring, as well as a permanent magnet extending radially between the radially outer ferromagnetic converter ring and the radially inner ferromagnetic converter ring.

[0030] Furthermore, a clutch assembly is provided for performing at least one of the above and / or other purposes. The clutch assembly includes: (i) a first coupling member and a second coupling member, the first and second coupling members being supported for rotation relative to each other about a rotational axis; (ii) a locking element; and (iii) a linear actuator having a stator and a transducer axially oriented relative to each other. The transducer is axially movable relative to the stator to a first position away from the stator, such that the locking element moves to a deployed position, in which the locking element mechanically couples the coupling members together to prevent relative rotation of the coupling members about the rotational axis in at least one direction.

[0031] The converter can be further axially moved relative to the stator to a second position adjacent to the stator, such that the locking element is moved to a non-deployed position in which the coupling members are not mechanically coupled together by the locking element, thereby allowing the coupling members to rotate relative to each other in at least one direction about the axis of rotation.

[0032] The first coupling member can be a bag-shaped plate and the second coupling member can be a notched plate.

[0033] Similarly, a system is provided to achieve at least one of the above and / or other objectives. The system includes a clutch assembly and a first power flow component and a second power flow component. The first power flow component may be a drive or input component, and the second power flow component may be a driven or output component. The first and second power flow components are respectively fixedly connected to a first coupling member and a second coupling member, whereby when a locking element mechanically couples the coupling members together, torque flow between the power flow components via the coupling members can be realized to prevent relative rotation of the coupling members about a rotation axis in at least one direction.

[0034] The converter is further axially movable relative to the stator to a second position adjacent to the stator, such that the locking element is moved to a non-deployed position, in which the coupling members are not mechanically coupled together by the locking element, thereby allowing the coupling members to rotate relative to each other about the axis of rotation in at least one direction and disabling torque flow between the power flow components.

[0035] According to an embodiment of the invention, the axially oriented linear actuator includes (i) a fixed stator having a single stator coil, and (ii) a linearly movable transducer. The stator coil attracts or repels the transducer according to the polarity of the current in the stator coil. Thus, the transducer is movable relative to the stator between a first position and a second position.

[0036] The prior art linear actuator 14 described herein further includes a fixed stator and a linearly movable transducer. However, the linear actuator 14 is radially oriented (i.e., the stator and transducer are radially oriented relative to each other). Conversely, an axially oriented linear actuator is axially oriented (i.e., the stator and transducer are axially oriented relative to each other). Furthermore, the linear actuator 14 has a pair of stator coils. In contrast, an axially oriented linear actuator may include only a single stator coil.

[0037] An axially oriented linear actuator is used in a clutch assembly to control and operate the coupling member of the clutch assembly. The axially oriented linear actuator is axially oriented because the stator and the transducer are axially offset from each other relative to the coupling member of the clutch assembly. The transducer is capable of axial movement toward and away from the stator between a first end position and a second end position. The first end position and the second end position correspond to a first operating mode and a second operating mode of the clutch assembly.

[0038] Axially oriented linear actuators can be used to control or operate any clutch assembly that requires a dual-position linear actuator, such as dynamically controllable clutches, including the DCC 12 clutch described herein.

[0039] Compared to currently available linear actuators (such as linear actuator 14), the axially oriented linear actuator according to embodiments of the invention can provide higher actuation force and higher latching force, can be designed for smaller package space in both the radial and axial directions, requires only one stator coil, and requires less copper material for the coil winding because the coil winding consists of only one stator coil. Attached Figure Description

[0040] Figure 1A This is an exploded view of a dynamically controllable clutch (“DCC”) based on existing technology;

[0041] Figure 1B is A partial cutaway view of the DCC, shown in a cross-section, in which the linear actuator of the DCC is in the "disconnected" position, thus putting the DCC in freewheel mode;

[0042] Figure 1C This is a partial cross-section of the DCC and a perspective view shown in cross-section, where the linear actuator is in the "on" position, thus putting the DCC in locked mode;

[0043] Figure 1D This is a partial section and side view of the DCC, shown in cross-section, where the linear actuator converter is magnetically latched in the "disconnected" position. Figure 1B and Figure 1D The same state involving DCC;

[0044] Figure 1E This is a partial section and side view of the DCC, shown in cross-section, where the linear actuator converter is magnetically latched in the "on" position, wherein... Figure 1C and Figure 1E The same state involving DCC;

[0045] Figure 2 A partially cutaway perspective view of an axially oriented linear actuator according to an embodiment of the present invention is shown.

[0046] Figure 3 A quarter-section view of an axially oriented linear actuator is shown.

[0047] Figure 4 A perspective view of the converter for an axially oriented linear actuator is shown.

[0048] Figure 5 A cross-sectional view depicting the magnetization of the segmented permanent magnet of the converter is shown;

[0049] Figure 6A shows a schematic cross-sectional view of an axially oriented linear actuator, wherein the converter is controlled to move laterally from left to right (i.e., the linear actuator of the present invention switches from an "on" position to an "off" position) (in this document, the leftmost position is considered the "on" position and the rightmost position is considered the "off" position; of course, depending on the function of the clutch assembly, the required force, and the structure, the roles can be reversed, wherein the leftmost position is the "off" position and the rightmost position is the "on" position);

[0050] Figure 6B shows a schematic cross-sectional view of an axially oriented linear actuator, in which the converter is in the rightmost position and magnetically latched (i.e., the linear actuator is magnetically latched in the "off" position).

[0051] Figure 7A A schematic cross-sectional view of an axially oriented linear actuator is shown, in which the converter is controlled to move laterally from right to left (i.e., the linear actuator switches from the "off" position to the "on" position).

[0052] Figure 7B A schematic cross-sectional view of an axially oriented linear actuator is shown, in which the converter is in the leftmost position and magnetically latched (i.e., the linear actuator is magnetically latched in the "on" position);

[0053] Figure 8 A quarter-section view of a model depicting an alternative stator core design / modification for an axially oriented linear actuator is shown.

[0054] Figure 9 A perspective view of a converter for an axially oriented linear actuator according to another embodiment of the present invention is shown;

[0055] Figure 10 Showing Figure 9 A cross-sectional view of the converter of the axially oriented linear actuator shown; and

[0056] Figure 11 An exploded view of DCC according to an embodiment of the present invention is shown. Detailed Implementation

[0057] This document discloses detailed embodiments of the invention; however, it should be understood that the disclosed embodiments are merely exemplary embodiments of the invention, which may be implemented in different and alternative forms. The drawings are not necessarily drawn to scale; some features may be enlarged or minimized to show details of specific components. Therefore, the specific structural and functional details disclosed herein should not be construed as limiting, but merely as a representative basis for teaching those skilled in the art to employ the invention in different ways.

[0058] See now Figure 2 and Figure 3 A linear actuator 100 according to an embodiment of the present invention is shown. As will be described, in this embodiment, the linear actuator 100 is an axially oriented, two-position electromagnetic linear actuator with a single stator coil. The linear actuator 100 can be used to control or operate the coupling member of any clutch assembly that requires a two-position linear actuator, such as a DCC 12, etc.

[0059] The linear actuator 100 has a fixed stator 110 and a linearly movable transducer 112. Both the stator 110 and the transducer 112 are annular in shape. The stator 110 and the transducer 112 are axially offset from each other along the axial direction. Figure 2 As shown, the converter 112 is at least partially encapsulated by the stator 110. The converter 112 is capable of linear movement relative to the stator 110 between at least a first position adjacent to the stator and a second position distant from the stator.

[0060] Stator 110 includes an induction or stator coil 101, a stator coil package 102, a stator core 103, a stator connector 104, and a latch plate 105. In these embodiments, stator coil 101 is a single stator coil and stator 110 does not have other stator coils. Stator coil 101 may include copper. Stator coil package 102 encapsulates stator coil 101 and may be a molded overlay and / or may include epoxy resin. Stator core 103 includes a ferromagnetic material. Stator connector 104 may be nonmagnetic or include a ferromagnetic material. Latch plate 105 includes a ferromagnetic material. Any ferromagnetic material may include ferromagnetic steel. In some embodiments, stator core 103 and latch plate 105 include ferromagnetic steel.

[0061] The converter 112 includes radially outer and inner converter rings 106, a segmented permanent magnet 107, and a magnet package 108. The converter ring 106 comprises a ferromagnetic material such as ferromagnetic steel. The magnet package 108 encapsulates the permanent magnet 107 and is nonmagnetic.

[0062] like Figure 2 and Figure 3As shown and described, stator 110 includes stator core 103, stator coil 101, stator coil package 102, stator connector 104, and latch plate 105. Stator connector 104 can be made of magnetic or non-magnetic materials. Using non-magnetic materials (aluminum, stainless steel, etc.) in this area improves the performance of the linear actuator 100, but magnetic materials (steel) can also be used here to simplify the assembly process if the application allows for lower actuation forces. When both stator core 103 and stator connector 104 are made of the same material such as steel, stator connector 104 can be part of stator core 103 as a single component.

[0063] like Figure 2 and Figure 3 As further shown and described, the converter 112 includes a converter ring 106, a segmented permanent magnet 107, and a non-magnetic material 108 to secure and assemble the permanent magnet to the converter assembly. When current flows through the stator coil 101, the converter 112 moves to either end by magnetic attraction or repulsion. This attraction or repulsion depends on the polarity of the actuating current. Once the converter movement to either end is complete, the converter 112 is secured in place by a magnetic latching force at either end.

[0064] See now Figure 4 and Figure 5 And continue to see Figure 2 and Figure 3 The converter 112 will be described in further detail. Figure 4 A perspective view of converter 112 is shown. Preferably, converter 112 is shown in the form of a ring. Figure 4 As further shown, the converter 112 includes a converter ring 106, which is connected to each other as a portion of a segmented permanent magnet 107 (in Figure 4 Nine sections are shown in the diagram) and non-magnetic encapsulation material 108 (in Figure 4 Only one of the three transparent sections is shown in the image, so the corresponding permanent magnet 107 can be seen. The permanent magnet 107 is held in place by any non-magnetic material (molded, epoxy, aluminum, stainless steel, etc.) capable of fixing the permanent magnet in place.

[0065] Figure 5 A cross-sectional view illustrating the magnetization of permanent magnet 107 is shown. As shown, permanent magnet 107 is magnetized radially outward as indicated by the arrow. Of course, permanent magnet 107 can also be magnetized radially inward. In this alternative case, the attraction and repulsion effects will be opposite to those described herein for the case of permanent magnet 107 being magnetized radially outward.

[0066] The converter 112 is capable of linearly moving between a first position adjacent to the stator 110 and a second position away from the stator 110, depending on the polarity of the current in the stator coil 101. More specifically, the converter 112 is capable of laterally moving between the "disengaged" and "engaged" positions of the linear actuator 100 along the axial direction of the coupling member of the clutch assembly (not shown) operated relative to the linear actuator 100. For example, for the linear actuator 100 operating the pocketplate 13 and notch plate 16 of the DCC 12, when the linear actuator 100 is in the "disengaged" position, the DCC is in freewheel mode, and when the linear actuator 100 is in the "engaged" position, the DCC is in locked mode.

[0067] Referring now to Figures 6A and 6B, the operation of switching the linear actuator 100 from the "on" position to the "off" position will be described. In Figure 6A, the transducer 112 is controlled to move laterally from left to right. The actuation event includes a current flowing through a single stator coil 101 (as indicated by symbol 120 in the page of Figure 6A). A magnetic loop 122 is generated in the magnetization direction of the permanent magnet 107. The magnetic loop 122 attracts the transducer 112 toward the stator coil 101. Therefore, the transducer 112 moves from left to right toward the stator coil 101, as indicated by arrow 124.

[0068] Once the left-to-right movement is complete, the transducer 112 is in the right-end position adjacent to the stator coil 101, as shown in Figure 6B. The actuation current is disconnected, and the transducer 112 is latched in the right-end position and held in place by the force generated by the magnetic circuit 122. Thus, the linear actuator 100 is magnetically latched in the "off" position.

[0069] See now Figure 7A and Figure 7B This will describe the operation of switching the linear actuator 100 from the "off" position to the "on" position. Figure 7A In this configuration, converter 112 is controlled to move laterally from right to left. Actuation events include the current flowing through a single stator coil 101 (from...) Figure 7A The page appears as shown by symbol 130. Magnetic circuit 132 is generated in the opposite direction to the magnetization direction of permanent magnet 107. Magnetic circuit 132 repels transducer 112 away from stator coil 101. Therefore, transducer 112 moves from right to left from stator coil 101, as shown by arrow 134.

[0070] Once the right-to-left movement is complete, the converter 112 is positioned at the left end adjacent to the stator latch plate 105, as... Figure 7BAs shown. The actuation current is disconnected, and the converter 112 is latched in the left-end position and held in place by the force generated by the magnetic circuit 132. Thus, the linear actuator 100 is magnetically latched in the "on" position.

[0071] See now Figure 8 Alternative stator core design / modification for linear actuator 100. The stator core can be modified by reducing one of the magnetic poles, thereby producing... Figure 8 The geometry modification shown is within the region enclosed by loop 140. This modification alters the performance of the linear actuator 100, resulting in lower actuation force, but simplifies the manufacturing process. Therefore, applications allowing for lower forces can be considered.

[0072] See now Figure 9 and Figure 10 The diagram illustrates a converter 112 based on an alternative design. This alternative design of converter 112 can help reduce the amount of permanent magnet material, thus reducing the overall cost. Figure 10 As shown, reducing the amount of brittle permanent magnet material and making changes to the converter ring 106 can increase the overall structural integrity of the converter assembly and make the assembly less sensitive to stress caused by centrifugal force at high angular velocities.

[0073] This alternative design change includes radially reducing the size of the permanent magnet segment 107 to thereby reduce the amount of permanent magnet material, and for example... Figure 10 The converter ring 106 shown is modified. In summary, as shown in the figure, some permanent magnet materials are basically replaced with steel.

[0074] In other embodiments, the coil and magnet arrangements described herein are reversed compared to the stator and transducer. That is, the coil arrangement described herein as part of the stator is instead arranged as part of the transducer; and the magnet arrangement described herein as part of the transducer is instead arranged as part of the stator.

[0075] The linear actuator 100 may be part of a clutch assembly having a first coupling member and a second coupling member (e.g., a pocket plate and a notch plate) supported for rotation relative to each other in a first and a second direction about a rotational axis. The linear actuator 100 is part of a clutch assembly for controlling the coupling members. Specifically, the transducer 112 may be axially moved relative to the stator 110 to a first position away from the stator, such that the locking element of the clutch assembly moves to a deployed position, in which the locking element mechanically couples the coupling members together to prevent relative rotation of the coupling members about the rotational axis in at least one direction. Conversely, the transducer 112 may be axially moved relative to the stator 110 to a second position adjacent to the stator, such that the locking element moves to a non-deployed position, in which the coupling members are not mechanically coupled together by the locking element, thereby allowing the coupling members to rotate relative to each other in the first and a second direction about the rotational axis.

[0076] The clutch assembly may be part of a system further comprising a first power flow component and a second power flow component respectively fixedly connected to the first coupling component and the second coupling component. In this case, when the locking element mechanically couples the coupling components together, a torque flow is achieved between the power flow components via the coupling components to prevent relative rotation of the coupling components about a rotation axis in at least one direction.

[0077] See now Figure 11 And continue to see Figure 1A and Figure 2 An exploded view of a DCC 212 according to an embodiment of the present invention is shown. The DCC 212 differs from the DCC 12 shown in FIG. 1 in that the DCC 212 includes a linear actuator 100 instead of the prior art linear actuator 14. Apart from this, the DCC 212 has the same components as the DCC 12, and these components are... Figure 11 Used in Figure 1A The same reference numerals are used in the accompanying drawings.

[0078] The transducer 112 of the linear actuator 100 is fixedly connected to and rotates with the pouch plate 13. Specifically, the transducer 112 is fixedly connected to the outer circumferential surface of the pouch plate 13 via the inner diameter of the transducer ring 106. As described, the transducer 112 is capable of linearly moving relative to the pouch plate 13 between an axial "on" and "off" position. In the "on" position, the transducer 112 causes the plunger 30 to contact the lower face or surface of its locking element 26, causing the locking element to engage in the recessed plate 16. In the "off" position, the transducer 112 causes the plunger 30 to lose contact with its locking element 26, thereby allowing the locking element to disengage from the recessed plate 16.

[0079] DCC 212 is an example of a clutch assembly in which a linear actuator 100 can be used to control or operate the coupling member of the clutch assembly. As indicated, the linear actuator 100 can be used to control or operate the coupling member of any type of clutch assembly that requires a dual-position linear actuator. Furthermore, the connection of the converter 112 of the linear actuator 100 from the inner diameter of the converter 112 to the pocket plate 13 is an example of how the converter 112 can be connected to a clutch assembly component. Of course, as those skilled in the art will understand, there are many ways in which the converter 112 can be connected to a clutch assembly component.

[0080] While exemplary embodiments have been described above, these embodiments are not intended to describe all possible forms of the invention. Rather, the terminology used herein is descriptive rather than restrictive, and it should be understood that various changes can be made without departing from the spirit and scope of the invention. Furthermore, features of different embodiments may be combined to form other embodiments of the invention.

Claims

1. A linear actuator for controlling a coupling member of a clutch assembly, comprising: Stator, the stator having stator coils and stator core; A converter, the converter having a direction of motion; The stator coils generate a first magnetic circuit; The converter is movable along the axial direction, between a position adjacent to the stator and a position away from the stator, depending on the polarity of the current in the stator coil, wherein the first magnetic loop generated by the stator coil extends between the stator and the converter in a direction substantially parallel to the direction of movement; The converter includes a permanent magnet; and The converter is magnetically latched in a position adjacent to the stator by extending a second magnetic loop through the stator core and the permanent magnet.

2. The linear actuator according to claim 1, wherein: The stator coil is a single stator coil, and the stator does not have other stator coils.

3. The linear actuator according to claim 1, wherein: The stator further includes a stator latch plate; and After the converter has been moved to a position away from the stator, the converter is magnetically latched in the position away from the stator by extending a third magnetic loop through the stator latch plate and the permanent magnet.

4. The linear actuator according to claim 1, wherein: The permanent magnet comprises multiple segmented permanent magnets.

5. The linear actuator according to claim 1, wherein: The stator encapsulates the converter.

6. The linear actuator according to claim 1, wherein: The stator also includes a stator connector and a stator latch plate, wherein the stator connector connects the stator core to the stator latch plate.

7. The linear actuator according to claim 6, wherein: Both the stator core and the stator latch plate are ferromagnetic.

8. The linear actuator according to claim 1, wherein: The stator has a ring-shaped form; and The converter has a ring-shaped form.

9. A linear actuator for controlling a coupling member of a clutch assembly, comprising: Stator, the stator having stator coils; The converter is offset from the stator axis; The converter is capable of moving along the axial direction, between a first position adjacent to the stator and a second position away from the stator, depending on the polarity of the current in the stator coil; as well as The stator further includes (i) a stator core having the stator coils, (ii) a stator latch plate, and (iii) a stator connector connecting the stator core and the stator latch plate; as well as Both the stator core and the stator latch plate are ferromagnetic, and the stator connector is non-magnetic.

10. A linear actuator for controlling a coupling member of a clutch assembly, comprising: Stator, the stator having stator coils; The converter is offset from the stator axis; The converter is capable of moving along the axial direction, between a first position adjacent to the stator and a second position away from the stator, according to the polarity of the current in the stator coils; and The converter includes a radially outer ferromagnetic converter ring and a radially inner ferromagnetic converter ring, and a permanent magnet extending radially between the radially outer ferromagnetic converter ring and the radially inner ferromagnetic converter ring.

11. A clutch assembly, comprising: A first coupling member and a second coupling member are supported for rotating relative to each other about a rotation axis; Locking element; as well as A linear actuator having a stator, a latch plate, and a transducer axially oriented relative to each other in the direction of a rotation axis, the transducer being movable in the direction of the rotation axis between a position adjacent to the stator and a position adjacent to the latch plate; A stator coil that generates a first magnetic circuit; the first magnetic circuit extends between the stator and the transducer in a direction generally parallel to the axis of rotation; The converter includes a permanent magnet; The converter is magnetically latched in a position adjacent to the latch plate by extending a second magnetic circuit through the latch plate and the permanent magnet. The linear actuator causes the locking element to move to a deployment position, in which the locking element mechanically couples the first coupling member and the second coupling member together to prevent relative rotation of the first coupling member and the second coupling member about the rotation axis in at least one direction.

12. The clutch assembly according to claim 11, wherein: The linear actuator causes the locking element to move to a non-deployed position, in which the first coupling member and the second coupling member are not mechanically coupled together via the locking element, thereby enabling the first coupling member and the second coupling member to rotate relative to each other about the rotation axis in at least one direction.

13. The clutch assembly according to claim 12, wherein: The stator and the converter each have a ring-shaped form.

14. The clutch assembly of claim 12, wherein: The first coupling member is a bag-shaped plate and the second coupling member is a notched plate.

15. The clutch assembly according to claim 11, wherein: The stator has a single stator coil and no other stator coils; as well as The converter is capable of moving along the direction of the rotation axis and between the stator and the latch plate, depending on the polarity of the current in the stator coil.

16. A system comprising: A clutch assembly comprising (i) a first coupling member and a second coupling member supported for rotation relative to each other about a rotation axis, (ii) a locking element, and (iii) a linear actuator having a stator and a transducer axially oriented relative to each other, the transducer being axially movable relative to the stator in the direction of the rotation axis to a position adjacent to the stator and a position away from the stator; A stator coil that generates a first magnetic loop that extends between the stator and the transducer in a direction generally parallel to the axis of rotation; Stator core; The converter includes a permanent magnet; and the converter is magnetically latched in a position adjacent to the stator by extending a second magnetic loop through the stator core and the permanent magnet; Stator latch plate; as well as The converter is magnetically latched in a position away from the stator by a third magnetic loop extending through the stator latch plate and the permanent magnet; as well as The linear actuator causes the locking element to move to a deployment position, in which the first coupling member and the second coupling member are mechanically coupled together via the locking element; the linear actuator causes the locking element to move to a non-deployment position, in which the first coupling member and the second coupling member are not mechanically coupled together via the locking element. as well as A first power flow component and a second power flow component are fixedly connected to a first coupling member and a second coupling member, respectively. When the locking element mechanically couples the first and second coupling members together, torque flow through the first and second coupling members is realized between them to prevent relative rotation of the first and second coupling members about the rotation axis in at least one direction. Conversely, when the locking element moves to a non-deployment position where the first and second coupling members are not mechanically coupled together, torque flow through the first and second coupling members is not realized between them, thereby allowing the first and second coupling members to rotate relative to each other about the rotation axis in at least one direction.

17. The system according to claim 16, wherein: The stator has a single stator coil and no other stator coils; and The transducer can be moved axially relative to the stator depending on the polarity of the current in the individual stator coil.

18. The system according to claim 16, wherein: The first coupling member is a bag-shaped plate and the second coupling member is a notched plate.

19. The system according to claim 16, wherein: The axial space between the converter and the stator in the direction of movement of the converter at a position away from the stator is greater than the axial space between the converter and the stator at a position adjacent to the stator.

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