Actuator with potting compound

Abstract

An actuator includes a housing defining a cavity. The actuator also includes a hub disposed in the cavity. The actuator also includes a controller disposed in the cavity and supported by the hub. The actuator also includes a potting compound surrounding the controller within the cavity.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 346,356 filed on May 27, 2022 and U.S. Non-Provisional Application No. 18 / 201,423 filed on May 24, 2023, the entire disclosures of which are incorporated herein by reference. Technical Field

[0003] The present disclosure relates generally to actuators, and more particularly to actuators including a controller surrounded by a potting compound. Background Art

[0004] The actuator may include a controller disposed within a housing. A potting compound may be inserted into the housing to cover the controller. The potting compound may protect the controller from adverse environmental conditions such as liquids, debris, vibration effects, thermal effects, etc. Due to the relative motion between other components in the actuator and the housing, it may be desirable to have alternative designs and configurations to reduce undesirable relative motion between the housing and other components of the actuator. Summary of the invention

[0005] According to one embodiment, the actuator includes a housing defining a cavity. The actuator also includes a hub disposed in the cavity. The actuator also includes a controller disposed in the cavity and supported by the hub. The actuator also includes a potting compound surrounding the controller in the cavity.

[0006] In embodiments, a potting compound may fill the cavity around the controller.

[0007] In an embodiment, the hub may include a first portion configured to radially constrain the hub in the cavity and a second portion radially spaced from the housing and supporting the controller. A potting compound may fill the cavity between the second portion and the housing. The potting compound may be configured to radially constrain the second portion in the cavity. The second portion may include a groove extending radially inward from an outer surface of the second portion. The potting compound may fill the groove. The potting compound may be configured to axially constrain the hub in the cavity via the groove. The potting compound may be configured to prevent movement of the hub relative to the housing.

[0008] In an embodiment, the actuator may include a cable gland extending through an opening in the housing and a portion of the cable extending through the cable gland into the cavity. A potting compound may cover the cable gland and the portion of the cable in the cavity. The potting compound may be configured to seal the cable gland to the housing and seal the cable within the cavity. The potting compound may be configured to retain the portion of the cable in the cavity.

[0009] In an embodiment, the actuator may include a shaft extending outward from the cavity. The potting compound may be spaced apart from the shaft. The actuator may include an encoder magnet supported by the shaft. The potting compound may be radially spaced apart from the encoder magnet. The potting compound may be axially spaced apart from the encoder magnet. The controller may include a sensor. The potting compound may cover the sensor, and the sensor may be configured to detect a position of the shaft through the potting compound.

[0010] In an embodiment, the potting compound may be configured to adhere to the hub. In an embodiment, the controller may include a plurality of circuit boards axially spaced apart from each other. The potting compound may fill the cavity between the circuit boards. In an embodiment, the potting compound may be configured to seal the cavity around the controller.

[0011] According to an exemplary embodiment of the present disclosure, a method for potting an actuator housing is provided. The method includes inserting a circuit board having a sensor into the housing. The method also includes filling the housing with a potting compound. The method also includes inserting a tool configured to direct the potting compound away from a portion of the circuit board including the sensor. The method also includes removing the tool after curing the potting compound.

[0012] In an embodiment, the tool may be configured not to adhere to the potting compound.In an embodiment, the thickness of the potting compound covering the portion of the circuit board including the sensor may be less than the thickness of the potting compound covering the rest of the circuit board. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Figure 1 A cross-sectional view along the axis of an actuator according to an embodiment of the present disclosure is shown.

[0014] Figure 2 Shows Figure 1 An enlarged cross-sectional view of the housing of the actuator is shown in FIG.

[0015] Figure 3 Shows Figure 1 An enlarged cross-sectional view of another portion of the actuator is shown in FIG.

[0016] Figure 4 Shows Figure 1 An enlarged cross-sectional view of another portion of the actuator.

[0017] Figure 5 Shows Figure 1 An enlarged cross-sectional view of another portion of the actuator is shown in FIG.

[0018] Figure 6 A flow chart of an exemplary process for potting a portion of a cavity of an actuator is shown. DETAILED DESCRIPTION

[0019] Embodiments of the present disclosure are described herein. It should be understood that the same reference numerals appearing in different figures identify the same or functionally similar structural elements. In addition, it should be understood that the disclosed embodiments are examples only, and other embodiments may take various alternative forms. The drawings are not necessarily drawn to scale; some features may be enlarged or minimized to show the details of a particular component. Therefore, the specific structural and functional details disclosed herein should not be interpreted as being restrictive, but only as a representative basis for teaching those skilled in the art to utilize the embodiments in various ways. As will be understood by those of ordinary skill in the art, the various features illustrated and described with reference to any of the drawings in the drawings may be combined with the features illustrated in one or more other drawings to produce embodiments that are not explicitly illustrated or described. The combination of the illustrated features provides representative embodiments for typical applications. However, for specific applications or implementations, various combinations and modifications of features consistent with the teachings of the present disclosure may be desired.

[0020] The terms used herein are only for the purpose of describing specific aspects and are not intended to limit the scope of the present disclosure. Unless otherwise specified, all technical terms and scientific terms used herein have the same meaning as those generally understood by those of ordinary skill in the art to which the present disclosure belongs. The following example methods, devices and materials are now described, but any method, device or material similar or equivalent to those methods, devices or materials described herein can be used in the practice or testing of the present disclosure.

[0021] Some actuators may include a controller disposed in a housing. These actuators may also include a potting compound covering the controller within the housing. However, the potting compound may only cover a portion of the controller, for example due to a gap between the controller and the housing, thereby exposing the remainder of the controller to adverse environmental conditions. In addition, undesirable movement of other components relative to the housing may occur, for example due to manufacturing tolerances. In this case, the components may separate from the controller and / or the controller may move relative to the potting compound, thereby deforming the potting compound. This relative movement may prevent the actuator from operating in a desired manner.

[0022] Advantageously, in one embodiment of the present disclosure, the actuator includes a housing defining a cavity. A hub is disposed in the cavity. A controller is disposed in the cavity and supported by the hub. A potting compound surrounds the controller within the cavity. Surrounding the controller within the cavity protects the entire controller from adverse environmental conditions, which can increase the likelihood that the actuator will operate in a desired manner. In addition, the potting compound can adhere to other components surrounding the controller, which can reduce the likelihood of relative movement between the components and the controller or the housing.

[0023] Reference Figures 1 to 5 , generally showing an actuator 100. The actuator 100 includes a housing 102 and a plurality of components. The housing 102 houses the plurality of components of the actuator 100. The housing 102 may extend in an annular manner about an axis A. The housing 102 includes a first end 104 and a second end 106 spaced apart from the first end 104 along the axis A. The housing 102 includes a wall 108 extending from the first end 104 to the second end 106 along the axis A. In addition, the wall 108 extends in an annular manner about the axis A. The wall 108 defines a cavity 110 extending circumferentially about the axis A and axially along the axis A.

[0024] The wall 108 may include an opening 122 extending radially through the wall 108. The opening 122 may be designed, i.e., sized and shaped, to receive a cable 124. The cable 124 may include one or more wires configured to provide power to one or more components of the actuator 100, such as sensors 414a, 414b, the motor 300, the controller 400, etc. The cable 124 may extend through the opening 122 into the cavity 110. A cable gland 126 may be configured to seal the cable 124 to the housing 102 in the opening 122. The cable gland 126 may extend through the opening 122. For example, a portion of the cable gland 126 may be disposed in the cavity 110.

[0025] The actuator 100 includes a hub 352 disposed in the cavity 110. The hub 352 may extend in an annular manner around the axis A. The hub 352 includes an outer surface 358 extending circumferentially around the axis A. The outer surface 358 includes a first portion 360 and a second portion 362. The first portion 360 of the outer surface 358 is disposed radially outward of the second portion 362. The first portion 360 is engaged with the housing 102. For example, the first portion 360 may be non-rotatably connected to the housing 102, such as via a press-fit connection.

[0026] The second portion 362 is radially spaced from the housing 102 . The second portion 362 may include a groove 364 extending circumferentially about the axis A. The groove 364 may extend radially inward from the second portion 362 toward the axis A. The groove 364 may be axially spaced from the first portion 360 .

[0027] The controller 400 disposed in the cavity 110 includes a plurality of circuit boards 412a, 412b, 412c and a plurality of supports 402 supporting the plurality of circuit boards 412a, 412b, 412c. The controller 400 may be disposed between two encoder magnets 368a, 368b, which are supported by respective shafts 308, 154 that can rotate around the axis of rotation. For example, the encoder magnet 368b may be connected to the shaft 154 in a non-rotatable manner, and the encoder magnet 368a may be connected to the shaft 308 in a non-rotatable manner. The encoder magnets 368a, 368b may be spaced apart from each other along the axis of rotation. The encoder magnets 368a, 368b may face each other, i.e., each facing the controller 400. Each encoder magnet 368a, 368b has exactly opposite polarity, i.e., the magnetic poles are exactly oppositely spaced apart from each other on the respective encoder magnets 368a, 368b. The encoder magnets 368a, 368b can be arranged coaxially with the axis A.

[0028] The controller 400 may include a computer 416 and one or more sensors 414a, 414b supported by circuit boards 412a, 412b, 412c. Sensors 414a, 414b may be angular position sensors. For example, each sensor 414a, 414b may be configured to detect the angular position of the corresponding encoder magnet 368a, 368b relative to the axis of rotation. Sensors 414a, 414b may be angular position sensors of any suitable type. For example, sensors 414a, 414b may be Hall effect sensors configured to output a unique angular position within a 360° rotation range around the axis of rotation. In this example, the Hall effect sensor may determine the angular position of the corresponding encoder magnet 368a, 368b based on, for example, detecting the position of the magnetic pole relative to the axis of rotation according to known techniques.

[0029] The computer 416 includes a processor and a memory such as is known. The memory includes one or more forms of computer-readable media and stores instructions that can be executed by the processor to perform various operations including those disclosed herein. The computer 416 is generally arranged to communicate with various components in the actuator 100, such as sensors 414a, 414b, motor 300, etc., and / or communicate with devices external to the actuator 100, such as via known wired mechanisms and / or wireless mechanisms.

[0030] The actuator 100 may include a plurality of supports 402 configured to support circuit boards 412a, 412b, 412c. The supports 402 may be configured to hold the sensors 414a, 414b within a predetermined range of the respective encoder magnets 368a, 368b. The predetermined range may be specified by the manufacturer of the sensor, for example, based on empirical testing to determine that the sensor output meets a specified range of measurement accuracy and / or precision.

[0031] Each support 402 may be mounted to the hub 352, for example, via a press-fit connection. For example, the hub 352 may have a plurality of recesses spaced circumferentially from one another about the axis A, and each support 402 may be press-fit into a corresponding recess. The support 402 may be any suitable material, such as plastic.

[0032] The actuator 100 may include any suitable number of circuit boards. For example, the actuator 100 may include a plurality of circuit boards 412a, 412b, 412c. In this example, the circuit boards 412a, 412b, 412c may be axially spaced apart from each other. That is, the support 402 may be configured to support each circuit board 412a, 412b, 412c and to space the circuit boards 412a, 412b, 412c axially apart from each other.

[0033] For example, the controller 400 may be programmed to detect, for example, via a sensor, an angular position of the shaft 308 relative to the axis A. Additionally, or alternatively, for example, the controller 400 may be programmed to update the angular position of the shaft 308. For example, the controller 400 may be programmed to actuate a motor, for example, an electric motor such as a permanent magnet synchronous motor, to rotate about the axis A. In such an example, the rotation of the motor may cause the shaft 308 to rotate.

[0034] The potting compound 182 surrounds the controller 400 within the cavity 110. For example, the potting compound 182 can fill the cavity 110 around the controller 400. That is, the potting compound 182 can fill the axial and radial spaces of the components of the controller 400 and the components of the actuator 100. By filling the cavity 110 around the controller 400, the potting compound 182 can protect the controller 400 and, in particular, the circuit boards 412a, 412b, 412c and their components from possible debris and / or fluids entering the cavity 110. In addition, the potting compound 182 can provide thermal and vibration isolation for the controller 400. The potting compound 182 can be any suitable material, such as epoxy, urethane, silicone, etc.

[0035] In addition, the potting compound 182 can contact the hub 352. The potting compound 182 can be configured to prevent movement of the hub 352 relative to the housing 102. For example, the potting compound 182 can fill a gap between the second portion 362 of the hub 352 and the wall 108. Filling the gap can help to radially constrain the hub 352 relative to the housing 102. In addition, the potting compound 182 can fill the groove 364, which can help to axially constrain the hub 352, such as by not applying sufficient shear force to the potting compound 182 at the groove 364 to prevent axial movement of the hub 352.

[0036] Additionally, or alternatively, the potting compound 182 can cover the cable gland 126 in the cavity 110, which can further help seal the opening 122. The opening 122 can be axially disposed between the hub 352 and the shaft 154. Moreover, covering the cable gland 126 allows the potting compound 182 to adhere to the cable 124, which can help prevent the cable 124 from being removed from the cable gland 126, such as by pulling along the axis R.

[0037] The potting compound 182 can be configured to be radially spaced from the encoder magnet 368b. In addition, the potting compound 182 can be configured to be axially spaced from the encoder magnet 368b. For example, during the curing process, a tool that guides the potting compound 182 away from the axis A can be inserted into the potting compound 182. The tool can be configured not to adhere to the potting compound 182, so that the tool can be removed from the potting compound 182 after curing without compromising the adhesion of the potting compound 182 to other components of the actuator 100.

[0038] After the potting compound 182 is cured and the tool is removed, the potting compound 182 defines a recess 140. The recess 140 can be arranged coaxially with the axis A. The recess 140 can be configured to receive a portion of the shaft 154 that supports the encoder magnet 368b. In this embodiment, the shaft 154 can rotate freely within the recess 140, i.e., without contacting the potting compound 182.

[0039] The potting compound 182 can cover the sensor 414b. The sensor 414b can be configured to detect the encoder magnet 368b through the potting compound 182. For example, the axial thickness of the potting compound 182 covering the sensor 414b can be controlled, for example, via a tool, so that the potting compound 182 does not interfere with the sensor 414b detecting the encoder magnet 368b. The axial thickness of the potting compound 182 covering the sensor 414b is less than the axial thickness of the potting compound 182 covering the rest of the circuit boards 412a, 412b, 412c.

[0040] Reference Figure 6 , Figure 6is a diagram of an example process 600 for potting a cavity 110 including a controller 400. The process 600 disclosed herein includes exemplary steps performed in an exemplary order. However, it should be understood that the process 600 may include fewer steps and / or the steps may be performed in a different order. The process 600 may be performed by an operator during a manufacturing process.

[0041] The process 600 begins in block 602. In block 602, the housing 102 of the actuator 100 is provided. The hub 352 is inserted into the cavity 110, and the controller 400 is inserted into the cavity 110. As described above, the controller 400 is supported by the hub 352 in the cavity 110. The process 600 continues in block 604.

[0042] In block 604, potting compound 182 is inserted into cavity 110. A predetermined volume of potting compound 182 may be inserted into cavity 110. The predetermined volume may be determined to correspond to a desired volume of the portion to be filled of cavity 110. Process 600 continues in block 606.

[0043] In block 606, a tool is inserted into the cavity 110. The tool may be arranged coaxially with the axis A. The tool may be inserted until the tool contacts the circuit board 412c around the sensor 414b. The tool is configured to circumferentially surround the sensor 414b on the circuit board 412c. As described above, the tool is configured to direct the potting compound 182 away from the sensor 414b. The process 600 continues in block 608.

[0044] In block 608 , the potting compound 182 is cured, for example, according to known techniques. The process 600 continues in block 610 .

[0045] In block 610 , the tool is removed from the cavity 110 . For example, the shaft 154 supporting the encoder magnet 368 b may be inserted by the tool into the recess 140 formed in the potting compound 182 . The process 600 ends after block 610 .

[0046] Although exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms covered by the claims. The words used in the specification are descriptive rather than restrictive, and it should be understood that various changes can be made without departing from the spirit and scope of the present disclosure. As previously described, the features of various embodiments can be combined to form other embodiments of the present disclosure that may not be explicitly described or illustrated. Although various embodiments may have been described as providing advantages or being superior to other embodiments or prior art implementations in terms of one or more desired characteristics, it is recognized by those of ordinary skill in the art that one or more features or characteristics can be compromised to achieve the desired overall system properties, depending on the specific application and implementation. These properties may include, but are not limited to, cost, strength, durability, life cycle cost, marketability, appearance, packaging, size, applicability, weight, manufacturability, ease of assembly, etc. Therefore, to some extent, any embodiment is described as being less ideal than other embodiments or prior art implementations in terms of one or more characteristics, which are not outside the scope of the present disclosure and may be ideal for a particular application.

[0047] Reference numerals list

[0048] 100 Actuator

[0049] 102 Housing

[0050] 104 First end

[0051] 106 Second End

[0052] 108 wall

[0053] 110 cavity

[0054] 122 Opening

[0055] 124 Cables

[0056] 126 Cable gland

[0057] 140 recess

[0058] 154 Axis

[0059] 182 Potting Compound

[0060] 300 Motor

[0061] 308 Axis

[0062] 352 Hub

[0063] 358 External surface

[0064] 360 Part 1

[0065] 362 Part 2

[0066] 364 Grooves

[0067] 400 Controller

[0068] 402 Support

[0069] 416 Computer

[0070] 368a Encoder Magnet

[0071] 368b Encoder Magnet

[0072] 412a, 412b, 412c circuit boards

[0073] 414a, 414b sensors

[0074] A, R axis

Claims

1. An actuator, comprising: a housing defining a cavity; a hub disposed in the cavity; a controller disposed in the cavity and supported by the hub; as well as A potting compound surrounds the controller within the cavity.

2. The actuator according to claim 1, wherein: The potting compound fills the cavity around the controller.

3. The actuator according to claim 1, wherein: The hub includes a first portion configured to radially constrain the hub in the cavity and a second portion radially spaced from the housing and supporting the controller, the potting compound filling the cavity between the second portion and the housing.

4. The actuator according to claim 3, wherein: The potting compound is configured to radially constrain the second portion in the cavity.

5. The actuator according to claim 3, wherein: The second portion includes a groove extending radially inward from an outer surface of the second portion, and the potting compound fills the groove.

6. The actuator according to claim 5, wherein: The potting compound is configured to axially constrain the hub in the cavity via the groove.

7. The actuator according to claim 3, wherein: The potting compound is configured to prevent movement of the hub relative to the housing.

8. The actuator of claim 1 further comprising a cable gland extending through the opening in the housing and a portion of a cable extending through the cable gland into the cavity, wherein The potting compound covers the cable gland and the portion of the cable in the cavity.

9. The actuator according to claim 8, wherein: The potting compound is configured to seal the cable gland to the housing and seal the cable within the cavity.

10. The actuator according to claim 8, wherein: The potting compound is configured to retain the portion of the cable within the cavity.

11. The actuator of claim 1 further comprising a shaft extending outwardly from the cavity, wherein: The potting compound is spaced apart from the shaft.

12. The actuator of claim 11 further comprising an encoder magnet supported by the shaft, wherein: The potting compound is radially spaced apart from the encoder magnet.

13. The actuator according to claim 12, wherein: The potting compound is axially spaced from the encoder magnet.

14. The actuator according to claim 11, wherein: The controller includes a sensor, the potting compound covers the sensor, and the sensor is configured to detect a position of the shaft through the potting compound.

15. The actuator according to claim 1, wherein: The potting compound is configured to adhere to the hub.

16. The actuator according to claim 1, wherein: The controller includes a plurality of circuit boards axially spaced apart from one another, the potting compound filling the cavity between the circuit boards.

17. The actuator according to claim 1, wherein: The potting compound is configured to seal the cavity around the controller.

18. A method for potting an actuator housing, comprising: inserting a circuit board having a sensor into the housing; filling the housing with a potting compound; inserting a tool configured to direct potting compound away from a portion of the circuit board including the sensor; as well as The tool is removed after the potting compound is cured.

19. The method according to claim 18, wherein: The tool is configured not to adhere to the potting compound.

20. The method according to claim 18, wherein: The thickness of the potting compound covering the portion of the circuit board including the sensor is less than the thickness of the potting compound covering the rest of the circuit board.

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