Clutch assembly and integrated anti-rotation bracket / guard

Abstract

A clutch assembly (30; 130; 230) includes: a stationary journal support assembly (42; 142; 242) having a base (142-1; 242-1), a short shaft (142-2; 242-2) extending axially from the base, and a channel (142-3; 242-3); a threaded support journal (146; 246) coupled to the short shaft and accessible through the channel; pulley bearings (148; 248) supported on the threaded support journal; an integrated pulley / shaft (44; 144; 244) including a pulley (144-1; 244-1) and a central shaft (144-2; 244-2); and a clutch mechanism (140). The central shaft includes a cup-shaped hub (144-2H; 244-2H) and a distal portion (144-2D; 244-2D) extending axially from the cup-shaped hub. The cup-shaped hub is supported on pulley bearings, which are at least partially located within a blind, hollow internal region (144-2I; 244-2I) of the cup-shaped hub. The threaded support journal is at least partially located within the hollow internal region of the cup-shaped hub.

Description

[0001] This application is a divisional application of application number 202180008174.0 filed on January 19, 2021, entitled "Clutch Assembly and Integrated Anti-rotation Bracket / Protective Device". Technical Field

[0002] This invention generally relates to clutch assemblies and related manufacturing and usage methods. Additionally, this invention relates to an integrated anti-rotation bracket (ARB) and protective device that can be used with a variety of clutch mounting assemblies and methods. Background Technology

[0003] Clutches have been successfully configured in automotive applications to drive cooling fans and pumps. In particular, viscous clutches are desirable for many automotive and industrial equipment applications because they allow for controlled torque transmission over a relatively wide speed range. Viscous clutches are also desirable due to the use of shear fluids as torque transmission mechanisms, as shear fluids (e.g., silicone oils) have a relatively long service life and are typically maintenance-free.

[0004] There exists a segment of the automotive market that uses viscous clutches, which are mounted to drive hubs rather than directly to the engine crankshaft. These drive hubs are rigidly attached to the engine block and receive input speeds from the engine via a conveyor belt coupled to the viscous clutch shaft via pulleys (also called pulleys). The viscous clutch then supplies speeds to a fan or other output as needed or desired. Examples of such clutch assemblies include the clutch assembly disclosed in PCT International Patent Application Publication No. WO2011 / 062856A2 and those available from Horton, Inc. (Roseville, MN, USA). 250 fully variable fan driver.

[0005] However, direct-mount drive hubs present several challenges. For example, clutch assemblies with individual pulleys can have a relatively high number of parts, which can increase the number of steps in manufacturing the clutch assembly and lead to additional labor costs for installing and / or maintaining it. Furthermore, for example, PCT International Patent Application Publication No. WO2011 / 062856A2... Figure 1A prior art drive hub configuration is disclosed, in which a pulley bearing is secured to a stationary journal support shaft by a nut accessible only from the front, while the pulley and clutch shaft are connected together by other fasteners. In this prior art configuration, removing the pulley bearing from the journal support shaft first requires removing the pulley, which increases the overall workload for the mechanic. Fasteners oriented parallel to the axis of rotation are difficult to access and not easily seen by the mechanic, increasing maintenance time. Such fasteners for mounting the pulley are particularly difficult to access due to their location (typically at or near the rear of the clutch assembly, facing forward, the rear of which is behind and / or blocked by multiple components of the clutch assembly). To provide sufficient clearance for accessing such fasteners, components of the clutch assembly can be prevented from occupying space adjacent to such fasteners, thus limiting the range of configuration options for the clutch assembly and / or increasing the overall axial dimension of the assembly during installation.

[0006] Furthermore, when using a viscous clutch, it is necessary to functionally retain the coil / starter / control assembly and associated cables to prevent rotation. This anti-rotation function is typically achieved by connecting the cables and / or coil assembly to another resting point on the engine. Current can then be supplied to the coil / starter assembly, which selectively actuates the viscous clutch valve to control the amount of viscous shear fluid in the clutch's working chamber, and thus control the clutch's output speed.

[0007] Furthermore, when using a viscous clutch, its control is handled by the engine control unit or engine control module (ECU / ECM) or a separate clutch controller external to the ECU / ECM. When using an external controller, it converts the ECU / ECM signal into a usable signal to actuate the clutch valve. When using an external controller, it is necessary to fix the controller somewhere in the engine compartment (i.e., a non-rotating part). This external controller is operatively connected to the ECU / ECM and the clutch coil assembly.

[0008] However, conveyor belts located near external controllers (whether those belts are connected to the clutch or other components in the engine compartment) may break or "come off" during operation. A belt breakage or "coming off" event can cause the belt to come into contact with the external controller and / or cables or wires, which can damage the external controller and / or cables or wires. Summary of the Invention

[0009] In one aspect, the clutch assembly includes: a journal support assembly having a base, a short shaft extending axially from the base, and a channel extending through the base and the short shaft between opposing front and rear openings; a threaded support journal threadedly coupled to the short shaft, and the rear opening through the channel being accessible; pulley bearings supported radially on the threaded support journal; an integrated pulley / shaft including a pulley and a central shaft; and a clutch mechanism. The journal support assembly is rotationally stationary. The central shaft includes a cup-shaped hub and a distal portion extending axially from the cup-shaped hub. The cup-shaped hub is supported on the pulley bearings, which are at least partially located within a hollow internal region of the cup-shaped hub. The threaded support journal is at least partially located within the hollow internal region of the cup-shaped hub. The hollow internal region of the cup-shaped hub is blind when viewed from the front and radial directions. The clutch mechanism is supported on the distal portion of a central shaft, wherein the distal portion of the central shaft defines the axis of rotation of the clutch mechanism.

[0010] On the other hand, a method of manufacturing a clutch assembly includes: mounting a pulley bearing on a threaded bracket journal; mounting an integrated pulley / shaft on the pulley bearing, wherein the pulley bearing is at least partially positioned within a blind interior region of the cup-shaped hub of the integrated pulley / shaft; after mounting the integrated pulley / shaft on the integrated pulley / shaft, mounting a coil assembly on the integrated pulley / shaft; after mounting the coil assembly on the integrated pulley / shaft, mounting a housing base on the integrated pulley / shaft; after mounting the housing base on the integrated pulley / shaft, mounting a rotor assembly to the integrated pulley / shaft; after mounting the rotor assembly on the integrated pulley / shaft, mounting a housing cover on the integrated pulley / shaft; after mounting the housing cover on the integrated pulley / shaft, assembling a journal bracket assembly to the threaded bracket journal, engaging a tool with a torque feature of the threaded bracket journal to thread-couple the threaded bracket journal and the journal bracket assembly. The tool is inserted into the channel in the journal support assembly through the rear opening.

[0011] In another aspect, an integrated anti-rotation bracket (ARB) and protective device assembly suitable for use with a clutch includes: a body portion extending axially; a flange extending from the body portion; a stop extending from the body portion and axially spaced from the flange; a mounting extension extending from the body portion; and a device attached to the mounting extension at a position aligned with the stop in the axial direction.

[0012] This overview is provided by way of example only and not by way of limitation. Other aspects of the invention will be understood in light of the full scope of this disclosure, including the entire text, claims, and drawings. Attached Figure Description

[0013] Figure 1 This is a schematic diagram of a system including a clutch assembly according to an embodiment of the present invention.

[0014] Figure 2 This is a perspective view of a clutch assembly according to an embodiment of the present invention.

[0015] Figure 3 It is along Figure 2 The clutch assembly is shown in section 3-3.

[0016] Figure 4 This is a cross-sectional view of another embodiment of the clutch assembly.

[0017] Figure 5 This is a flowchart of an embodiment of a method for manufacturing a clutch assembly according to the present invention.

[0018] While the foregoing figures illustrate one or more embodiments of the invention, other embodiments are contemplated as noted in the discussion. In all instances, this disclosure presents the invention by way of illustration rather than limitation. It should be understood that those skilled in the art can devise many other modifications and embodiments that fall within the scope and spirit of the principles of the invention. The figures may not be drawn to scale, and applications and embodiments of the invention may include features, steps, and / or components not specifically shown in the figures. Detailed Implementation

[0019] In one aspect, the present invention relates to a clutch assembly adapted for mounting a clutch (e.g., a fan clutch) in a mounting location in an engine compartment. Embodiments of the clutch assembly may include a journal support (or simply "support") with a short shaft having a channel extending fully through it and having openings at opposing front and rear sides or ends; and a threaded support journal threadedly engaged with the short shaft to secure pulley bearings, integrated pulleys / shafts, and / or the like to the short shaft. The clutch mechanism may be supported by engagement with the shaft of the integrated pulley / shaft, wherein the integrated pulley / shaft provides torque input to the clutch mechanism via a "moving" central shaft portion of the integrated pulley / shaft. A tool may engage the threaded support journal through the channel in the short shaft of the journal support to apply torque to tighten the threaded engagement between components. The tool may be inserted from the rear opening of the channel, even if the current opening is blocked by other components (e.g., by the integrated pulley / shaft, the clutch mechanism, etc.). In this manner, the fastening connection between the integrated pulley / shaft and the short shaft can be performed blind or semi-blindly. Among other benefits, this configuration of the clutch assembly further allows the relatively heavy journal support component to be assembled near the end of the manufacturing process, so that in an assembly line-type manufacturing environment, only smaller and lighter workpieces (without heavy journal supports) need to be moved through most of the manufacturing and assembly stations. In some embodiments, the integrated pulley / shaft is a single integral piece, which helps to limit the total number of parts, reduce weight, and limit part clearance requirements. In other embodiments, the integrated pulley / shaft may consist of separate pulley and shaft components, such as those connected together with suitable fasteners, which helps to simplify the casting, machining, and / or other steps for manufacturing the integrated pulley / shaft while still allowing for limited part clearance requirements, among other benefits. Related methods for manufacturing and using the clutch assembly are also disclosed.

[0020] On the other hand, the present invention relates to an integrated anti-rotation bracket (ARB) and a protective device, which can be installed to engage both the journal bracket and the coil assembly of the clutch mechanism. Upon installation, the integrated ARB and protective device provide anti-rotation functionality to resist or prevent rotation of the coil assembly and further act as a protective device to shield and protect the controller, cables, wires, and / or other components from contact with the conveyor belt. Among other features and benefits, the integrated ARB and protective device can further be an optional external clutch controller (e.g., available from Horton, Inc., Roseville, MN, USA). The controller provides the mounting location. The integrated ARB and guard can be used with currently disclosed clutch mounting assemblies or in other applications.

[0021] This application claims priority to U.S. Provisional Patent Application Serial No. 62 / 963,599, filed January 21, 2020, the entire contents of which are incorporated herein by reference.

[0022] Figure 1 This is a schematic diagram of an embodiment of a cooling system 20, which includes an engine compartment 22, an internal combustion engine 24, a heat exchanger (H / X) 26, a fan 28, a clutch assembly 30, and a conveyor belt 32. The clutch assembly 30 of the illustrated embodiment includes a clutch mechanism 40, a journal bracket (or drive hub) assembly 42, and a pulley (also referred to as a pulley wheel) or an integrated pulley / shaft 44. The conveyor belt 32 transmits torque from the internal combustion engine 24 to the integrated pulley / shaft 44, which in turn transmits torque to the clutch mechanism 40. The clutch mechanism 40 selectively controls the torque transmission from the integrated pulley / shaft 44 to the fan 28. The fan 28 may be a cooling fan and may generate airflow around the heat exchanger 26 and / or the internal combustion engine 24. The journal bracket assembly 42 allows the clutch mechanism 40 to be mounted in a mounting location within the engine compartment 22, such as being mounted to the engine block of the internal combustion engine 24. The clutch mechanism 40 may be a viscous clutch, which can be controlled using an electromagnetic control scheme of a type known in the art.

[0023] Figure 2 and Figure 3 An embodiment of the clutch assembly 130 is shown. Figure 2 It is a perspective view of clutch assembly 130, and Figure 3 It is along Figure 2 The image shows a cross-sectional view of the clutch assembly 130 taken from line 3-3. The clutch assembly 130 of the illustrated embodiment includes a clutch (or clutch mechanism) 140, a journal support assembly 142, an integrated pulley / shaft 144, and a threaded support journal 146. The clutch mechanism 140 is rotatable about a rotation axis A.

[0024] The clutch mechanism 140 in the illustrated embodiment is configured as a viscous clutch having a coil (or control) assembly 140-1, a rotor assembly 140-2, and a housing assembly 140-3 having a housing base 140-3B and a housing cover 140-3C. Together with a suitable pump, the coil assembly 140-1 can electromagnetically control the operation of the clutch mechanism 140, for example, by generating a magnetic flux that actuates a valve assembly to control the amount of viscous shear fluid present in the working chambers adjacent to the rotor assembly 140-2 and the housing assembly 140-3. General operation of a viscous clutch is known. In the illustrated embodiment, the rotor assembly 140-2 serves as the torque input and the housing assembly 140-3 serves as the torque output, and the coil assembly 140-1 is axially located between the housing assembly 140-3 and the pulley 144-1. A reservoir for maintaining the shear fluid supply can be carried by the rotor assembly 140-2 so that it rotates whenever torque is input to the clutch mechanism 140. Fans or other output devices (in) Figure 2 and Figure 3 Not shown in the image, but see [link / reference]. Figure 1 The clutch mechanism 140 can be attached to the housing assembly 140-3 in a suitable manner (e.g., by bolts) to receive torque output from the clutch mechanism 140 during operation. As discussed further below, in the illustrated embodiment, the clutch mechanism 140 has an "active center" configuration and is supported and rests thereon by an integrated pulley / shaft 144. It should be further noted that the specific configuration of the clutch mechanism 140 is shown by way of example only and not as a limitation. As those skilled in the art will recognize, a variety of other viscous clutch configurations can be utilized in alternative embodiments, including different reservoir, valve, and control component configurations.

[0025] Journal support assembly 142 (or simply "support" or "journal bracket") has a generally radially extending base or flange 142-1 and a short shaft 142-2 extending axially from the base 142-1, the base or flange being attachable to a desired mounting position. Journal support assembly 142 is rotatably fixed relative to the mounting position so that it is stationary in rotation during use. In the illustrated embodiment, the base 142-1 is asymmetrical relative to the axis of rotation A. The short shaft 142-2 may have a generally cylindrical or sleeve shape and may be arranged coaxially with the axis of rotation A. A channel 142-3 extends through the short shaft 142-2 and the base 142-1 of journal support assembly 142, wherein a front opening 142-3F and a rear opening 142-3R are provided at opposite front and rear sides, respectively. In the illustrated embodiment, channel 142-3 extends axially. In this sense, the short shaft 142-2 is essentially hollow. Channel 142-3 may be aligned with the center of short shaft 142-2 and / or with the axis of rotation A. The rear opening 142-3R allows tools to be inserted into channel 142-3 (as discussed further below), and channel 142-3 may include threads at or near the front opening 142-3F. In the illustrated embodiment, short shaft 142-2 has internal threads along channel 142-3 at or near the front opening 142-3F. Short shaft 142-2 has a distal end 142-2D positioned substantially opposite to base 142-1.

[0026] The integrated pulley / shaft 144 includes a pulley 144-1 and a central shaft 144-2. Figure 2 and Figure 3In the illustrated embodiment, pulley 144-1 and central shaft 144-2 are connected together by fastener 144-3 to form discrete components of the unit. The clutch mechanism 140, including coil assembly 140-1, rotor assembly 140-2, and housing assembly 140-3, is supported by an integrated pulley / shaft 144. In the illustrated embodiment, rotor assembly 140-2 is rotatably fixed to central shaft 144-2, housing assembly 140-3 is rotatably supported on central shaft 144-2 via housing bearings, and coil assembly 140-1 is supported on central shaft 144-2 by coil bearings in a rotationally fixed manner as discussed further below. Furthermore, in the illustrated embodiment, central shaft 144-2 includes a distal portion 144-2D facing forward, a cup-shaped hub or spokes 144-2H facing rearward, and one or more flanges 144-2F. The distal portion 144-2D may have a generally solid (i.e., non-hollow) cylindrical shape and, in some embodiments, may be made of a flux-conducting material such as steel to form part of a flux loop for electromagnetically actuating the clutch mechanism 140. The distal portion 144-2D may extend axially from the cup-shaped hub 144-2H in a cantilever configuration. The cup-shaped hub 144-2H may have a generally cylindrical rear portion with a hollow internal region 144-2I, and a front connecting portion extending beyond a radial distance to connect with the central shaft 144-2. The outer race of the pulley bearing 148 may contact and engage the cup-shaped hub 144-2H at the hollow internal region 144-2I and may be held in place axially by a retainer 150 (such as a retainer ring). For example, the retainer 150 may engage with the cup-shaped hub 144-2H and be positioned adjacent to the pulley bearing 148 on the opposite rear side of the distal portion 144-2D of the central shaft 144-2. In the illustrated embodiment, the cup-shaped hub 144-2H surrounds the pulley bearing 148 on essentially three sides in such a manner that the front end of the journal support assembly 142 and the threaded support journal 146 are "blind," meaning they are inaccessible to the tool from the front and / or radial direction. Furthermore, the base 142-1 of the journal support assembly 142 and other components of the clutch assembly 130 restrict rearward access to the area where the pulley bearing 148 and the retainer 150 are located. A flange 144-2F extends radially outward from the cup-shaped hub 144-2H, and the pulley 144-1 can be attached to the flange 144-2F using fasteners 144-3. Fastener 144-3 may be arranged axially, but as will be clear from this disclosure, given other features of clutch assembly 130 (including threaded bracket journal 146), it is not necessary to access fastener 144-3 after the integrated pulley / shaft 144 has been initially assembled during the manufacture of clutch assembly 130.

[0027] The integrated pulley / shaft 144 can be adjusted for each application. For example, the pulley geometry, diameter, and overall shaft / pulley axial length can be adjusted according to the specific application requirements. Furthermore, the configuration of the integrated pulley / shaft 144 can be adjusted modularly, independently of the configuration of the journal support assembly 142.

[0028] The threaded bracket journal 146 is threadedly engaged with the short shaft 142-2 at or near the distal end 142-2D of the short shaft 142-2. As shown in the illustrated embodiment, a direct threaded connection is formed between the short shaft 142-2 and the threaded bracket journal 146 at or near the front opening 142-3F; however, in alternative embodiments, an indirect connection may be provided, such as with a centrally threaded sleeve. As further explained below, the threaded bracket journal 146 removably attaches the integrated pulley / shaft 144 to the short shaft 142-2 and the remainder of the journal bracket assembly 142. In the illustrated embodiment, the threaded bracket journal 146 is at least partially located within the hollow interior region 144-2I of the cup-shaped hub 144-2H, such that the threaded bracket journal 146 cannot be accessed from the front or radially when the integrated pulley / shaft 144 is installed.

[0029] exist Figure 2 and Figure 3In the illustrated embodiment, the threaded support journal 146 includes a generally cylindrical body 146-0 having one or more torque features 146-1, threads 146-2 at or near one end, and flanges 146-3 at opposite ends to serve as bearing stops. An integrated pulley / shaft 144 is rotatably supported on the threaded support journal 146 by a pulley (or grooved wheel) bearing 148. As shown in the illustrated embodiment, one or more races of the pulley bearing 148 can directly contact and rest on the body 146-0 of the threaded support journal 146. Furthermore, in the illustrated embodiment, the body 146-0 of the threaded support journal 146 has a slightly smaller diameter at the rear end of the threaded support journal 146 at the threaded 146-2 than at the axially central portion on which the pulley bearing 148 rests. The body 146-0 of the threaded bracket journal 146 may have an outer dimension (e.g., outer diameter) slightly smaller than the corresponding outer dimension (e.g., outer diameter) of the short shaft 142-2 at the portion on which the pulley bearing 148 rests, and the inner race of the pulley bearing 148 may have an inner diameter smaller than the outer diameter of the short shaft 142-2 at the distal end 142-2D, such that tightening the threaded engagement of the short shaft 142-2 and the threaded bracket journal 146 generates a generally axial clamping force to secure the pulley bearing 148. The clamping force generated by the threaded bracket journal 146 can be applied to the inner race of the pulley bearing 148 between the flange 146-3 of the threaded bracket journal 146 and the distal end 142-2D of the short shaft 142-2. In a further embodiment, in addition to or replacing the distal end 142-2D of the short shaft 142-2, a stop or flange may be provided on the short shaft 142-2, which contacts the pulley bearing 148 to act on the clamping load. The torque feature 146-1 may be a receiver for an Allen wrench, drill bit (e.g., The tool engagement surface of a Robertson drill bit, screwdriver, or other suitable tool. Figure 2 and Figure 3 In the illustrated embodiment, the torque feature 146-1 is arranged at the rear end of the body 146-0 and extends only partially into the interior of the body 146-0 in the axial direction, wherein the torque feature 146-1 is exposed to the channel 142-3. To secure the pulley bearing 148 in place, the threaded bracket journal 146 is threadedly engaged with the short shaft 142-2 of the journal bracket assembly 142. The threaded bracket journal 146 is screwed into (or alternatively screwed into) the short shaft 142-2, thereby securing the pulley bearing 148 in place by means of an axial clamping force.

[0030] In the illustrated embodiment, the journal support assembly 142 and the threaded support journal 146 are stationary, i.e., they do not rotate during use (even though they may be in a movable vehicle). During operation, the rotor assembly 140-2, which is fixedly attached to the integrated pulley / shaft 144 and clutch mechanism 140, can rotate at an input speed by torque supplied to the pulley 144-1 by a conveyor belt, which in turn is powered by an internal combustion engine or another prime mover (see [link to documentation]). Figure 1 Power is then provided. The clutch housing assembly 140-3 (including housing base 140-3B and cover 140-3C) and the attached output device (such as a fan) can then rotate at a commanded output speed according to the operation of the clutch mechanism 140 (e.g., according to the amount of viscous shear fluid present in the working chamber, wherein the clutch mechanism 140 is configured as a viscous clutch).

[0031] The pulley 144-1, cup hub 144-2H, fastener 144-3, body 146-0 of threaded bracket journal 146, and pulley bearing 148 can be axially aligned in the axial direction, or at least partially overlap each other. In this way, the force applied to the pulley 144-1 by the conveyor belt can be substantially aligned with the pulley bearing 148, which can help reduce the magnitude of the force and load that must be supported by the central shaft 144-2. When the clutch assembly 130 is installed and under load, some or all of the force applied to the pulley bearing 148 is transmitted through the threaded bracket journal 146. In this respect, the threaded journal 146 bears the suspended load transmitted through the pulley bearing 148, and the threaded journal 146 is not merely used to generate axial clamping forces such as those of a threaded nut. As shown in the illustrated embodiment, the rear opening 142-3R of the channel 142-3 through the base 142-1 and the short shaft 142-2 of the journal support assembly 142 allows for the insertion of a suitable tool from the rear to secure the threaded support journal 146 to the short shaft 142-2 (e.g., rotating the threaded support journal 146 relative to the short shaft 142-2 to tighten the threads 146-2). Simultaneously, the integrated pulley / shaft 144 can be configured as a unit, wherein the cup-shaped hub 144-2H (and the central shaft 144-1) surrounds the pulley bearing 148 on substantially three sides in such a manner that the front end of the sub-assembly including the threaded support journal 146 and the journal support assembly 142 is "blind," meaning it is inaccessible to the tool from the front and radial directions. This allows for an advantageous configuration of the integrated pulley / shaft 144 (and clutch mechanism 140), while also allowing the integrated pulley / shaft 144 to be rotatably fixed to and supported on the short shaft 142-2 via the pulley bearing 148.

[0032] The disclosed embodiments of the clutch assembly offer numerous features and benefits, including a relatively low number of parts and a relatively small axial length L from the first slot to the fan mount (e.g., Figure 3 As shown, this can be characterized as the axial projected distance from the first or last slot of the pulley to the fan mounting position. This avoids the need for clearance space between the pulley and the viscous clutch to place and attach coupling fasteners or to keep assembly tools in place at this location, and eliminates the need for accessible threaded hexagonal shafts or bolt flange joints during maintenance (after installation and use). Furthermore, the threaded bracket journal allows the journal bracket assembly to be attached to the rest of the clutch assembly last (or as one of the last few steps) during manufacturing, so that the relatively large and heavy journal bracket assembly does not need to be moved across the assembly line. This allows for greater assembly automation, standard fixing, and faster assembly, while also allowing for modular bracket and integrated pulley / shaft designs.

[0033] Figure 2 and Figure 3 An embodiment of an integrated anti-rotation bracket (ARB) and guard 160 mounted as part of clutch assembly 130 is also shown. In general, by providing a substantially rigid and rotatably fixed connection from coil assembly 140-1 to a stationary (i.e., non-rotating) journal support assembly 142, the integrated ARB and guard 160 provides an anti-rotation attachment / connection point for coil assembly 140-1 and also protects electrical components from conveyor belt breakage or "disengagement" events. As shown in the illustrated embodiment, the integrated ARB and guard 160 includes a flange 160-1, a base portion 160-2, a stop 160-3, a corner plate 160-4, and a mounting extension 160-5.

[0034] The flange 160-1 may extend radially or tangentially relative to the axis of rotation A and may be secured to the journal support assembly 142 by suitable fasteners or the like. In the illustrated embodiment, a portion of the flange 160-1 is at least partially positioned in a recess or notch in the base 142-1 of the journal support assembly 142 at a position radially outward from the short axis 142-2 by threaded fasteners and is secured to the recess or notch.

[0035] The base portion 160-2 may extend axially away from the flange 160-1 and may overlap with the pulley 144-1 of the integrated pulley / shaft assembly 144 in the axial direction. The stop member 160-3 may extend from the base portion 160-2 and may be aligned with or at least partially overlap with the pulley 144-1 at a location adjacent to and axially spaced from the flange 160-1. Figure 2As most clearly shown, the stop 160-3 can be configured to extend substantially perpendicularly to a side of the base portion 160-2, adjacent to the area of ​​the base portion 160-2, such that the stop 160-3 is generally (though not precisely) tangential to the pulley 144-1. The stop 160-3 helps provide rigidity for the integrated ARB and guard 160, and also provides a material subplate that helps physically isolate the conveyor belt (not shown) engaging with the pulley 144-1 from sensitive electrical components.

[0036] Angle plate 160-4 connects flange 160-1 and base portion 160-2 to help increase rigidity and structural strength. In the illustrated embodiment, a U-shaped groove separates stop 160-3 from angle plate 160-4 in the axial direction. Mounting extension 160-5 protrudes from base portion 160-2 at an angle; for example, mounting extension 160-5 may be angled to be arranged substantially radially relative to axis of rotation A. Mounting extension 160-5 provides anti-rotation attachment point for coil assembly 140-1, while integrated ARB and guard 160 as a whole provide a substantially rigid connection from coil assembly 140-1 to stationary (i.e., non-rotating) journal support assembly 142. This allows coil assembly 140-1 to resist rotation caused by friction in coil bearings, for example, those that rotatably support coil assembly 140-1 on rotatable central shaft 144-2. In addition, in this manner, the generally opposite ends of the integrated ARB and the protective device 160 can be connected to the journal bracket assembly 142 and the coil assembly 140-1.

[0037] A cable 162, including suitable wiring, can extend from the coil assembly 140-1 to a power supply, external clutch controller, engine controller, vehicle controller, etc. (not shown). The cable 162 can be secured to the integrated ARB and guard 160 via a fixture 164 located at or near the front end of the mounting extension 160-5 (and the front end of the base portion 160-2), wherein the cable 162 is protected by the stop 160-3 and the base portion 160-2. The mounting extension 160-5 may include fastener openings, clamping points, etc., to facilitate the attachment of electrical components. In the illustrated embodiment, the fixture 164 is attached to the mounting extension 160-5 at a position aligned axially with the stop 160-3.

[0038] In a further embodiment, the controller may be attached to the mounting extension 160-5. In some embodiments, the controller may function as an external electronic closed-loop clutch controller to translate control signals from the engine or vehicle controller into commands for operating the coil assembly 140-1, as well as other functions. For example, the controller may be or function similar to The controller (available from Horton, Inc., Roseville, MN, USA). Alternatively, the controller can be located away from the integrated ARB and guard 160.

[0039] Figure 2 and Figure 3 The specific shape and configuration of the integrated ARB and protective device 160 shown are merely examples and not limitations. In alternative embodiments, the integrated ARB and protective device 160 may have different configurations; for example, the mounting extension 160-5 may be received and may be a component directly connected to the base portion 160-2. Similarly, in a further embodiment, the corner plate 160-4 may be omitted.

[0040] The integrated ARB and guard 160 provides multiple functions and benefits. For example, the integrated ARB and guard 160 provides anti-rotation protection for the coil assembly 140-1 and associated cable 162. Furthermore, in the event of a sudden conveyor belt breakage or conveyor belt "disengagement" event, the integrated ARB and guard 160 provides protection for wires / cables and other electrical components, which can be achieved in part by positioning the base portion 160-2 and / or the stop 160-3 between the pulley 144-1 and the cable 162. This protection is also available when using a viscous clutch mechanism with a "moving center" configuration, which typically prevents wires or cables from passing through the interior of the rotatable "moving" central shaft 144-2. These benefits result in less maintenance and longer uptime for the clutch assembly 130. Additionally, the integrated ARB and protection device 160 provides locational and structural features for mounting an optional (external) clutch controller, which can be further protected by the base portion 160-2 and / or the stop 160-3. With a controller, such as one that is pre-attached, the integrated ARB and protection device 160 with a controller provides end users with a "plug-and-play" clutch solution, reducing installation work for the end user.

[0041] Figure 4 This is a cross-sectional view of another embodiment of the clutch assembly 230. The clutch assembly 230 has a configuration and function similar to that of the clutch assembly 130 described above. Therefore, in Figure 4 Similar figure labels are used, with Figure 2 and Figure 3 Compared to the reference numerals used in the accompanying drawings, in Figure 4Reference numerals used in the figures are increased by 100. For example, the clutch assembly 230 of the illustrated embodiment includes a clutch (or clutch mechanism) 240, a journal support assembly 242, an integrated pulley / shaft 244, and a threaded support journal 246. The clutch mechanism 240 is rotatable about a rotation axis A and includes a coil assembly 240-1, a rotor assembly 240-2, and a housing assembly 240-3 (having a housing base 240-3B and a housing cover 240-3C). The journal support assembly 242 includes a generally radially extending flange 242-1 and a short shaft 242-2 having a distal end 242-2D positioned generally opposite to the base 242-1. An axial channel 242-3 extends through the center of the base 242-1 and the short shaft 242-2, wherein a front opening 242-3F and a rear opening 242-3R are respectively provided at opposite front and rear sides. The rear opening 242-3R allows tools to be inserted into the channel 242-3, and the channel 142-3 may include threads at or near the front opening 242-3F. In the illustrated embodiment, the short shaft 142-2 has internal threads along the channel 142-3 at or near the front opening 142-3F. The integrated pulley / shaft 244 includes a pulley 244-1 with a "movable" configuration and a central shaft 244-2. The central shaft 244-2 includes a distal portion 244-2D facing forward and a cup-shaped hub or spokes 244-2H facing rearward. The distal portion 244-2D may have a generally solid (i.e., non-hollow) cylindrical shape. The cup-shaped hub 244-2H may have a generally cylindrical rear portion with a hollow internal region 244-2I and a front connecting portion extending beyond a radial distance to connect with the central shaft 244-2. The threaded support journal 246 is threadedly engaged with the short shaft 242-2 at or near the distal end 242-2D of the short shaft 142-2. As shown in the illustrated embodiment, a direct threaded connection is formed between the short shaft 242-2 and the threaded support journal 246 at or near the front opening 242-3F; however, in alternative embodiments, an indirect connection may be provided, for example, via a central threaded sleeve. Furthermore, in the illustrated embodiment, the threaded support journal 246 has a hollow cylindrical shape and a central opening that completely passes through the body 246-0. The threaded support journal 246 further includes a thread 246-2 and a flange 246-3. The outer race of the pulley bearing 248 may contact and engage the cup-shaped hub 244-2H at the hollow internal region 244-2I and may be held in place in the axial direction by a retainer 250 (such as a snap ring), wherein the inner race of the pulley bearing 248 is supported on the threaded support journal 246. In the illustrated embodiment, the cup-shaped hub 244-2H surrounds the pulley bearing 248 on essentially three sides in such a way that the front ends of the journal support assembly 242 and the threaded support journal 246 are "blind," meaning they are inaccessible to the tool from the front and radial directions.The threaded bracket journal 246 can axially clamp the pulley bearing 248, and at the same time provide support for the pulley bearing 248 in the radial direction.

[0042] exist Figure 4 In the illustrated embodiment, pulley 244-1 and central shaft 244-2 are integrated into a single integral component. In this respect, pulley 244-1 and central shaft 244-2 are inseparable in the illustrated embodiment. Figure 2 and Figure 3 Compared to the embodiment of integrated pulley / shaft 144, this configuration of integrated pulley / shaft 244 helps to further reduce the number of parts, but at the same time, as a trade-off, it reduces design modularity and increases application-specific design and manufacturing labor intensity.

[0043] The clutch assembly 230 also includes an integrated ARB and guard 260. As shown in the illustrated embodiment, the integrated ARB and guard 260 is a generally horizontal or axially extending structure that is fixed to both the coil assembly 240-1 and the journal support assembly 242 of the clutch mechanism 240 at a location radially outward from the pulley 244-1 (and the associated conveyor belt). In the illustrated embodiment, the integrated ARB and guard 260 includes a flange 260-1 and a base portion 260-2. By providing a substantially rigid connection from the coil assembly 240-1 and cable 262 to the stationary (i.e., non-rotating) journal support assembly 242, the front end of the base portion 260-2 (which may be radially inwardly stepped) provides an anti-rotation attachment / connection point for the coil assembly 240-1 and the associated cable 262. A mounting extension 260-5 may also be provided, providing space for mounting an optional external controller (not shown).

[0044] Figure 5This is a flowchart illustrating an embodiment of a method for manufacturing a clutch assembly (such as clutch assembly 30, 130, or 230). First, a pulley bearing 148 or 248 is placed on a threaded support journal 146 or 246, the pulley bearing 148 or 248 contacting a flange 146-3 or 246-3 that acts as a bearing stop to form a sub-assembly (step 300). Then, an integrated pulley / shaft 44, 144, or 244 is mounted (e.g., pressed) onto the sub-assembly of the pulley bearing 148 or 248 and the threaded support journal 146 or 246 (step 302). In embodiments where the integrated pulley / shaft 144 is configured as a unit made of separate pulley 144-1 and central shaft 144-2 sub-components, those sub-components (e.g., secured together with fasteners 144-3) form the integrated unit before mounting it onto the sub-assembly of pulley bearing 148 or 248 and threaded support journal 146 or 246, as part of step 302. Retainers 150 or 250 (such as snap rings) can then be installed to at least temporarily retain pulley bearing 148 or 248 relative to the integrated pulley / shaft 44, 144, or 244 (step 304). Next, coil assembly 140-1 or 240-1, including any associated spacers (if used), is mounted onto the central shaft 144-2 or 244-2 of the integrated pulley / shaft 44, 144, or 244 (step 306). Next, the housing base 140-3B or 240-3B, including any internal pole assembly for the flux circuit, is mounted on the central shaft 144-2 or 244-2 of the integrated pulley / shaft 44, 144, or 244, which transmits the flux generated by the coil assembly 140-1 or 240-1 via the clutch mechanism 40, 140, or 240 during use (step 308). Next, the rotor assembly 140-2 or 240-2 is mounted on the central shaft (step 310). As part of step 310, or as part of a related but separate step 312, the actuating feature can be used to apply assembly torque to the joint between the rotor assembly 140-2 or 240-2 and the central shaft 144-2 or 244-2 using suitable tools. Next, the housing cover 140-3C or 240-3C is installed onto the housing base 140-3B or 240-3B. The housing cover 140-3C or 240-3C encloses the rotor assembly 140-2 or 240-2 within the housing assembly 140-3 or 240-3 (step 314). Finally, the journal support assembly 42, 142 or 242 is assembled with the threaded support journal 146 or 246 (step 316).As part of step 316, or as part of a related but separate step 318, a suitable tool passes through the channel 142-3 or 242-3 in the base 142-1 or 242-1 and the short shaft 142-2 or 242-2 of the journal support assembly 142 or 242 to engage with the threaded support journal 146 or 246 to twist and tighten the threaded connection between these components. The threaded engagement between the threaded support journal 146 or 246 and the short shaft 142-2 or 242-2 of the journal support assembly 142 or 242 simultaneously generates a clamping force on the pulley bearing 148 or 248. During subsequent operation of the fully constructed clutch assembly 30, 130, or 230, the clamping force generated in the axial direction by the threaded support journal 146 or 246 can render the pulley bearing retainer 150 or 250 (such as a snap ring) redundant, or at least axially unloaded.

[0045] In embodiments using the integrated ARB and protective device 160 or 260, the method may further include attaching the integrated ARB and protective device 160 or 260 to the journal support assemblies 42, 142, 242, and securing the coil assembly 140-1 or 240-1 and / or the cable 162 or 262 to the integrated ARB and protective device 160 or 260 using a fixture 164 or the like. The integrated ARB and protective device 160 or 260 may be attached to the journal support assemblies 42, 142, or 242 before or after coupling the journal support assemblies 42, 142, or 242 to the threaded support journal 146 or 246. After coupling the journal support assemblies 42, 142, or 242 to the threaded support journal 146 or 246, the coil assembly 140-1 or 240-1 and / or the cable 162 or 262 are secured to the integrated ARB and protective device 160 or 260.

[0046] Because journal bracket assemblies 42, 142, or 242 are relatively heavy, the installation in step 316 at or near the end of the assembly process means that much smaller and lighter (i.e., lighter) workpieces are involved in the preceding steps 300 through 314. This facilitates manufacturing in an assembly line-type environment, although prior art clutch assemblies typically require earlier assembly of the journal brackets and necessitate the movement of such heavy workpieces through stations in the factory used for most or all assembly processes.

[0047] Given the whole of this disclosure, the method of using the disclosed clutch assembly will be clear to those skilled in the art.

[0048] Discussion of possible embodiments

[0049] The clutch assembly may include: a journal support assembly having a base, a short shaft extending axially from the base, and a channel extending through the base and the short shaft between opposing front and rear openings, wherein the journal support assembly is stationary in terms of rotation; a threaded support journal threadedly coupled to the short shaft such that the rear opening through the channel is accessible to the threaded support journal; pulley bearings radially supported on the threaded support journal; and an integrated pulley / shaft assembly. The shaft includes a pulley and a central shaft, wherein the central shaft includes a cup-shaped hub and a distal portion extending axially from the cup-shaped hub, the cup-shaped hub being supported on the pulley bearing, the pulley bearing being at least partially located within a hollow internal region of the cup-shaped hub, the threaded support journal being at least partially located within the hollow internal region of the cup-shaped hub, and the hollow internal region of the cup-shaped hub being blind when viewed from the front and radial directions; and a clutch mechanism supported on the distal portion of the central shaft, wherein the distal portion of the central shaft defines the rotation axis of the clutch mechanism.

[0050] Additionally and / or alternatively, the clutch assembly described in the preceding paragraph may optionally include any one or more of the following features, configurations, and / or additional components:

[0051] The threaded bracket journal may include a flange configured as a bearing stop;

[0052] The pulley bearing can be axially clamped against the short shaft by the threaded bracket journal;

[0053] The threaded bracket journal may include a torque feature exposed in the channel, such that a tool inserted into the channel from the rear of the base can engage the torque feature;

[0054] The threaded support journal may include threads that engage with internal threads on the short shaft along the channel;

[0055] The pulley can overlap with the pulley bearing in the axial direction;

[0056] A retainer that engages with the cup-shaped hub and is positioned near the pulley bearing opposite the distal portion of the central shaft;

[0057] The clutch mechanism can be a viscous clutch;

[0058] The viscous clutch may include a coil assembly that is axially supported on a distal portion of a central shaft between the pulley and the housing assembly of the viscous clutch.

[0059] An integrated anti-rotation bracket (ARB) and protective device are attached to the journal support assembly;

[0060] The coil assembly can be rotatably fixed to the integrated ARB and protective device;

[0061] Integrated ARBs and protective devices may include a flange, an axially extending body portion, and a stop extending from the body portion and positioned adjacent to the pulley.

[0062] The integrated ARB and protective device may further include a mounting extension, wherein a fixture is attached to the mounting extension and the fixture secures a cable electrically connected to the coil assembly;

[0063] A fan attached to the clutch mechanism; and / or

[0064] The clutch assembly may be part of a cooling system in the engine compartment, which may be part of the vehicle.

[0065] A method of manufacturing a clutch assembly includes: mounting a pulley bearing on a threaded bracket journal; mounting an integrated pulley / shaft on the pulley bearing, wherein the pulley bearing is at least partially positioned within a blind interior region of a cup-shaped hub of the integrated pulley / shaft; after mounting the integrated pulley / shaft, mounting a coil assembly on the integrated pulley / shaft; after mounting the coil assembly on the integrated pulley / shaft, mounting a housing base on the integrated pulley / shaft; after mounting the housing base on the integrated pulley / shaft, mounting a rotor assembly on the integrated pulley / shaft; after mounting the rotor assembly on the integrated pulley / shaft, mounting a housing cover on the integrated pulley / shaft; after mounting the housing cover on the integrated pulley / shaft, assembling a journal bracket assembly to the threaded bracket journal; and engaging a tool with a torque feature of the threaded bracket journal to thread-couple the threaded bracket journal and the journal bracket assembly. The tool is inserted into a channel in the journal bracket assembly through a rear opening.

[0066] Additionally and / or alternatively, the method described in the preceding paragraphs may optionally include any one or more of the following features, configurations, and / or additional steps:

[0067] Prior to the step of assembling the journal support assembly onto the threaded support journal, the clutch assembly components are moved between multiple workstations in the factory.

[0068] The retainer is mounted on the integrated pulley / shaft to axially retain the pulley bearing, at least temporarily.

[0069] The pulley bearing is axially clamped between the journal support assembly and the threaded support journal;

[0070] The race of the pulley bearing can be axially clamped between the distal end of the short shaft of the journal support assembly and the flange of the threaded support journal.

[0071] Apply torque to secure the rotor assembly to the central axis of the integrated pulley / shaft;

[0072] Attach the integrated anti-rotation bracket (ARB) and guard to the journal bracket assembly and secure the coil assembly to the integrated ARB and guard; and / or

[0073] After coupling the threaded bracket journal to the journal bracket assembly, the coil assembly can be secured to the integrated ARB and protective device.

[0074] An integrated anti-rotation bracket (ARB) and protective device assembly for use with a clutch includes: a body portion extending axially; a flange extending from the body portion; a stop extending from the body portion and axially spaced from the flange; a mounting extension extending from the body portion; and a device attached to the mounting extension at a position aligned with the stop in the axial direction.

[0075] Additionally and / or alternatively, the integrated ARB and protective device assembly described in the preceding paragraphs may optionally include any one or more of the following features, configurations, and / or additional components:

[0076] A journal support assembly includes a base, wherein the flange is fixed to the base, and wherein the journal support is stationary in terms of rotation.

[0077] A cable, which includes wires, wherein the device is attached to the cable;

[0078] pulley;

[0079] A central shaft, which is rotatably fixed to the pulley and defines the axis of rotation;

[0080] A clutch mechanism supported on the central shaft, the clutch mechanism including a coil assembly supported on the central shaft;

[0081] The coil assembly is rotatably fixed to the mounting extension;

[0082] The mounting extension may extend at a certain angle relative to the main body in the radial direction; and / or

[0083] The blocking element can extend vertically from the body portion.

[0084] Summarize

[0085] Any relative or degree terms used herein, such as “substantially,” “truly,” “approximately,” etc., shall be interpreted and governed by any applicable limitations or restrictions expressly stated herein. In all cases, any relative or degree terms used herein shall be construed as broadly covering any embodiments of the relevant disclosure and such scope or variations, as would be understood by one of ordinary skill in the art in light of the whole of this disclosure, such as covering common manufacturing tolerance variations, incidental alignment variations, transient alignment or shape variations caused by thermal, rotational, or vibratory operating conditions. Furthermore, any relative or degree terms used herein shall be construed as encompassing a range that expressly includes the specified quality, characteristic, parameter, or value, without variation as if no defined relative or degree terms were used in a given disclosure or description.

[0086] While the invention has been described with reference to preferred embodiments, those skilled in the art will recognize that changes in form and detail may be made without departing from the spirit and scope of the invention. For example, although the threaded connection between the short shaft and the threaded support journal is shown as being positioned internally along a channel in the short shaft, in alternative embodiments, the threaded connection may be located externally or at an external portion of the short shaft. Furthermore, in alternative embodiments, bayonet, spline, and pin connections or other types of attachments may be used instead of the threaded connection, in which case the threaded support journal does not need to be threaded.

Claims

1. An integrated anti-rotation bracket and protective device assembly for use with a clutch, the assembly comprising: The body portion extends axially; A flange that extends from the body portion; A blocking member extending from the body portion and axially spaced from the flange; The mounting extension extends from the body portion; as well as A fixture that is attached to the mounting extension in the axial direction at a position aligned with the blocking member.

2. The component according to claim 1, further comprising: A journal support assembly, the journal support assembly including a base, wherein the flange is secured to the base, and wherein the journal support assembly is stationary in terms of rotation; and A cable, the cable including wires, wherein the device is attached to the cable.

3. The component according to claim 2, further comprising: pulley; A central shaft, which is rotatably fixed to the pulley and defines an axis of rotation; as well as A clutch mechanism supported on the central shaft, the clutch mechanism including a coil assembly supported on the central shaft, wherein the coil assembly is rotatably fixed to the mounting extension.

4. The component according to claim 1, wherein, The mounting extension extends in a radial direction at a certain angle relative to the body portion, and wherein the blocking member extends vertically from the body portion.

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