Multiple-input multiple-output actuator and assembly using same

Abstract

An exemplary actuator includes a motor, a transmission, and a support structure. The motor includes two torque sources that apply respective input torque to a rotor that rotates about an axis of rotation in response to a net input torque. The torque sources are arranged such that the input torques are summed, resulting in a vector summed torque output. The torque source also generates respective reaction torques applied to the first stator and the second stator. The transmission couples and constrains the first stator and the second stator such that rotational movement of one stator causes counter-rotation of the other stator. Thus, the reaction torques are subtracted, resulting in a differential torque output. In some applications, the differential torque output is used to actuate a suspension of a vehicle. The actuator is also coupled to the vehicle via the support structure that also reflects a reaction force or torque to actuate other subsystems (e.g., anti-dive, anti-squat).

Description

[0001] This application is a divisional application of the patent application with the application date of December 03, 2019, the application number of 201980080200.3, and the invention title of "Multi-Input Multi-Output Actuators and Assemblies Using the Same". Background Art

[0002] Electric motors are used to convert electrical power into mechanical force and / or motion in household appliances, power tools, and motor vehicles. The cost of a typical electric motor mainly depends on the cost of the raw materials used to manufacture the electric motor. For example, rare earth magnets and copper used in the coils of electric motors are usually the largest contributors to the total cost of the motor. To reduce the cost of mechanical systems, it is generally desirable to use a single motor to power multiple subsystems.

[0003] A common method of driving multiple subsystems with one motor is to use gears and / or switches to control which subsystem is driven by the motor. For example, a gearbox coupled to the motor may have multiple gears, where the output of each gear is coupled to a different subsystem. In this way, a single motor can drive two or more subsystems, although there is usually a constraint that these subsystems cannot be used simultaneously if the gearbox can only transfer power to only one function at a time.

[0004] Figures 1A to 1C Kinematically equivalent actuator assemblies 100a - 100c are shown, which can be used to perform two functions simultaneously in a wheeled vehicle: propulsion and active suspension. Figure 1A The actuator assembly 100a in includes an axial flux motor coupled to a support structure 150

[0005] 120. The axial flux motor 120 includes a rotor 121 mounted to a main shaft 124. The rotor 121 rotates in response to a torque input applied to the first stator 122 and the second stator 123 by a torque source.

[0006] The main shaft 124 is coupled to a reference ground 11 (e.g., via a wheel in contact with the road). The main shaft 124 is also coupled to the support structure 150. The support structure 150 is directly coupled to a chassis 12, which includes a joint housing 142 mounted on an arm 144a. The joint housing 142 is slidably adjustable relative to the support structure 150. Additionally, a spring 152 is coupled to the joint housing 142 and the support structure 150 to provide a restoring force as a suspension.

[0007] The first stator 122 is coupled to the joint housing 142 via a link 145a at node 146, and the second stator 123 is coupled to the joint housing 142 via a link 145b at node 147. The links 145a and 145b are coupled to the joint housing 142 at node 143. To actuate the suspension, a reaction torque is applied to the first stator 122 and / or the second stator 123. This, in turn, results in a force being applied to the chassis 12 that causes the motor 120 to translate relative to the chassis 12 along the support structure 150 (e.g., move up and down in Figure 1A ).

[0008] Figure 1B Another actuator assembly 100b is shown that both propels the vehicle and provides an active suspension for the vehicle. Again, the chassis 12 is directly coupled to the axial flux motor 120 via slots 149a and 149b in the arm 144b. The slots 149a and 149b are coupled to pins that are mounted to the first stator 122 at node 146 and to the second stator 123 at node 147.

[0009] Figure 1C Another actuator assembly 100c is shown that provides propulsion and an active suspension. The chassis 12 includes arms 144c that are coupled to the links 145a and 145b at nodes 148a and 148b, respectively, rather than to the joint housing 142. The links 145a and 145b are coupled to the first stator 122 and the second stator 123 at nodes 146 and 147, respectively, as shown in FIG. 1. SUMMARY OF THE INVENTION

[0010] Figures 1A to 1C The actuator assemblies 100a - 100c (collectively referred to as actuator assembly 100) in Figures 1A to 1C are capable of rotating the rotor 121 and translating the suspension. The actuator assemblies 100 are used primarily because of their integrated simplicity, since the output of the motor 120 is directly coupled to the chassis 12. However, these actuator assemblies 100 have several drawbacks. First, the actuator assemblies 100 cannot reflect the force / torque between the support structure 150 and the chassis 12 because the reaction torque applied to the first stator 122 and the second stator 123 is dissipated by the chassis 12. In other words, the support structure constrains the translational movement of the main shaft 124 relative to the chassis. Neither the first stator 122 nor the second stator 123 applies a torque load to the support structure in the actuator assemblies 100 shown.

[0011] This prevents the actuator assemblies 100 from providing additional output. Second, the actuator assemblies 100 are not self - contained mechanisms; they rely on integration with the chassis 12 to provide the desired actuation. This, in turn, means that the chassis 12 should have certain structural features to enable the actuator assemblies 100 to operate correctly.

[0012] Accordingly, the present disclosure relates to actuators that can reflect force / torque and / or be compatible with a variety of chassis or other reference structures. Example actuators can include motors, transmissions, and support structures (suspensions). The motor can include one or more torque sources to provide an input torque for actuation. The transmission can couple and constrain the torque source(s) so as to modify the resulting output force / torque provided by the actuator. For example, the actuator can provide a summed torque output based on the superposition of one or more input torques. The transmission can in turn couple and constrain the torque source(s) to produce reverse rotational motion. In this way, the actuator can also provide a differential torque output based on the subtraction of one or more input torques.

[0013] The force / torque output from the actuator can be further divided into various component forces / component torques that are applied at one or more nodes that connect the actuator to other subsystems. For example, the output force / torque can include a reflected force / torque applied between the support structure of the actuator and the chassis, the reflected force / torque being generated in response to an imbalance of other output forces / torques from the actuator. The reflected force / torque can provide yet another output to actuate a subsystem. For example, the reflected force / torque can be used for anti-dive and / or anti-squat functions in a suspension (e.g., preventing the front of the vehicle from moving downward during forward deceleration and / or preventing the rear of the vehicle from moving downward during forward acceleration).

[0014] Additionally, the actuator can also provide a mixed output of different magnitudes and / or directions based on one or more input torques and / or reaction torques. For example, the transmission can constrain the range of motion and / or the motion ratio of one or more torque sources, thereby changing the dependence of each output force / torque on the input torque / reaction torque. The actuator can also incorporate mechanisms that create an asymmetric response between the inputs (e.g., a first torque source moves a second torque source, but the second torque source cannot move the first torque source).

[0015] In one exemplary application, the actuator can be used as part of an active suspension system of a vehicle. The actuator can be part of an actuator assembly that includes a chassis coupled to the actuator via a MacPherson strut and a wheel coupled to the motor in the actuator. The wheel is an unsprung mass and the chassis is a sprung mass. The actuator can include a rocker joint mechanism or a sliding joint mechanism that directly couples the motor and / or the transmission to the chassis via components that are capable of moving the sprung mass relative to the unsprung mass.

[0016] In one example, an actuator for a vehicle includes a support structure connected to the vehicle's chassis via a suspension, a transmission coupled to the support structure, and a motor coupled to the support structure and the transmission. The motor includes a rotor that rotates about a rotational axis, a first stator concentric with the rotational axis, and a second stator concentric with the rotational axis. The first stator applies a first torque to the rotor and the suspension via the transmission. The second stator applies a second torque to the rotor and the suspension and / or the chassis.

[0017] In another example, an actuator assembly for a vehicle includes an axial flux motor having a support structure, a main shaft that defines a rotational axis and extends through an opening in a housing, a rotor fixed to the main shaft, a first stator concentric with the rotational axis, and a second stator concentric with the rotational axis. The actuator assembly further includes a suspension rigidly connected to the support structure and compressibly coupled to the vehicle's chassis, a torsion bar rotatably coupled to the suspension and rotatably coupled to the first stator and the second stator, and a tension-compression member rotatably coupled to the second stator and rotatably coupled to the chassis.

[0018] In one example, a method of actuating at least one of a rotor or a suspension of a vehicle includes the steps of: (1) applying a first torque to the rotor, wherein the rotor is configured to rotate about a rotational axis, (2) while applying the first torque, applying a second torque to the rotor, (3) in response to applying the first torque, applying a first reaction torque to a first stator, the first stator being configured to rotate about the rotational axis, (4) in response to applying the second torque, applying a second reaction torque to a second stator, the second stator being configured to rotate about the rotational axis, wherein the second stator is coupled to the first stator via a transmission, (5) transmitting at least a portion of the first reaction torque from the first stator to the suspension via the transmission, and (6) transmitting at least a portion of the second reaction torque from the second stator to at least one of the vehicle's suspension or chassis, wherein the chassis is coupled to the suspension.

[0019] All combinations of the foregoing concepts and additional concepts discussed in greater detail below (assuming such concepts are not mutually inconsistent) are considered to be part of the inventive subject matter disclosed herein. In particular, all combinations of the claimed subject matter appearing at the end of this disclosure are considered to be part of the inventive subject matter disclosed herein. Terms explicitly employed herein and that may also appear in any disclosure incorporated by reference should be given the meaning most consistent with the particular concepts disclosed herein. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Those skilled in the art will understand that the accompanying drawings are primarily for illustrative purposes and are not intended to limit the scope of the inventive subject matter described herein. These drawings are not necessarily to scale; in some instances, aspects of the inventive subject matter disclosed herein may be shown exaggerated or enlarged in the drawings to facilitate understanding of different features. In the drawings, like reference numerals generally refer to like features (e.g., elements that are functionally similar and / or structurally similar).

[0021] Figure 1A A first actuator assembly providing vehicle propulsion and active suspension is shown.

[0022] Figure 1B A second actuator assembly providing vehicle propulsion and active suspension is shown.

[0023] Figure 1C A third actuator assembly providing vehicle propulsion and active suspension is shown.

[0024] Figure 2A An exemplary actuator assembly is shown in which the stator is directly coupled to the chassis.

[0025] Figure 2B Another exemplary actuator assembly is shown in which the stator is directly coupled to the chassis.

[0026] Figure 3A An inner view of an exemplary actuator having an axial flux motor is shown.

[0027] Figure 3B Shows Figure 3A a rear view of the actuator.

[0028] Figure 3C Shows Figure 3A an outer view of the actuator.

[0029] Figure 3D Shows Figure 3A a perspective view of the actuator.

[0030] Figure 4A Shows an inner view of an actuator assembly including an actuator coupled to a MacPherson strut suspension Figure 3A having

[0031] Figure 4B Shows Figure 4A a rear view of the actuator assembly.

[0032] Figure 4C Shows Figure 4A a perspective view of the actuator assembly.

[0033] Figure 5AA perspective view of an exemplary actuator having a Panhard rod and a differential shaft coaxial with the drive shaft is shown.

[0034] Figure 5B is shown Figure 5A A cross-sectional perspective view of the actuator.

[0035] Figure 5C is shown Figure 5A A rear view of the actuator.

[0036] Figure 5D is shown Figure 5A An inner view of the actuator.

[0037] Figure 5E is shown Figure 5A A cross-sectional schematic view of the actuator.

[0038] Figure 6A is shown including Figure 5A An exemplary actuator assembly of the actuator as a hub motor.

[0039] Figure 6B is shown including Figure 5A Another exemplary actuator assembly of the actuator mounted inside relative to the vehicle wheel.

[0040] Figure 6C is shown including Figure 5A A side view of another exemplary actuator assembly of the actuator integrated with a swing arm suspension in a wheel assembly.

[0041] Figure 7A A cross-sectional schematic view of an exemplary actuator having a bevel gear transmission.

[0042] Figure 7B A cross-sectional schematic view of an exemplary actuator having a double bevel gear transmission.

[0043] Figure 7C A cross-sectional schematic view of an exemplary actuator having a planetary gear transmission.

[0044] Figure 7D A cross-sectional schematic view of an exemplary actuator having a bevel gear transmission, wherein the bevel gear is disposed outside a support structure accommodating an inner stator and an outer stator.

[0045] Figure 7E A cross-sectional schematic view of an exemplary actuator having a planetary gear transmission, wherein the planetary gear couples the inner stator to a differential shaft on the outer stator.

[0046] Figure 8A An exemplary actuator having a multi-pulley transmission is shown.

[0047] Figure 8B Shows an exemplary actuator with a single pulley actuated transmission.

[0048] Figure 8C Shows an exemplary actuator with a double pulley actuated transmission.

[0049] Figure 8D Shows an exemplary actuator with a single pulley, double belt / cable transmission.

[0050] Figure 8E Shows a side view of an exemplary actuator with a double helical gear transmission.

[0051] Figure 8F Shows Figure 8E a top view of the actuator.

[0052] Figure 9A Shows an exemplary actuator assembly where the transmission is directly coupled to the chassis via a prismatic sliding joint.

[0053] Figure 9B Shows another exemplary actuator assembly where the transmission is directly coupled to the chassis via a rocker joint.

[0054] Figure 10A Shows a perspective view of another exemplary actuator where the rocker link and differential shaft are offset from the drive shaft and coaxial with the torsion bar.

[0055] Figure 10B Shows Figure 10A a cross-sectional perspective view of the actuator.

[0056] Figure 10C Shows Figure 10A a rear view of the actuator.

[0057] Figure 10D Shows Figure 10A an inner view of the actuator.

[0058] Figure 10E Shows Figure 10A a cross-sectional schematic view of the actuator.

[0059] Figure 11A Shows a cross-sectional schematic view of an exemplary actuator where the differential shaft is mounted to a secondary bevel gear in the transmission.

[0060] Figure 11B Shows a side view of an exemplary actuator where a double gear transmission is directly coupled to the chassis.

[0061] Figure 12A Shows a front view of an exemplary actuator assembly including an actuator with a linkage-based transmission.

[0062] Figure 12B shows the Figure 12A top view of the actuator.

[0063] Figure 12C shows the Figure 12A inner view of the actuator. DETAILED DESCRIPTION

[0064] The following is a more detailed description of various concepts related to an actuator (e.g., a component of a motor, a transmission, and a support structure) that provides one or more outputs (e.g., force, torque) for various subsystems and their implementations. Specifically, aspects related to a transmission, a motor, a coupling between the transmission, a support, a motor, and / or a reference structure, and an actuator assembly integrating the actuator are described herein. The concepts introduced above and discussed in more detail below can be implemented in various ways. Examples of specific implementations and applications are provided primarily for illustrative purposes to enable those skilled in the art to practice implementations and alternatives that are obvious to those skilled in the art.

[0065] The accompanying drawings and example implementations described below are not intended to limit the scope of the present implementation to a single embodiment. Other implementations are possible by interchanging some or all of the described or illustrated elements. In addition, in some cases where some elements of the disclosed example implementations can be implemented partially or fully using known components, only those parts of these known components that are necessary for understanding the present implementation are described in some cases, and detailed descriptions of other parts of these known components are omitted to avoid obscuring the present implementation.

[0066] In the following discussion, various examples of the actuator of the present invention are provided, where a given example or set of examples shows one or more specific features of a motor (e.g., a rotor, a stator), a support structure, and a transmission (e.g., a torsion bar, a linkage, a planetary gear, a bevel gear, a belt, a pulley, a gear train, a track drive system). Features discussed in connection with a given example of an actuator including a motor, a housing, and a transmission can be adopted in other examples of the actuator according to the present disclosure, such that various features disclosed herein can be easily combined in a given system according to the present disclosure (assuming these features are not incompatible with each other).

[0067] Generally, an actuator can actuate one or more subsystems based on one or more force / torque inputs. Depending on how the actuator is coupled to other components in the actuator assembly, the output of the actuator can be selectively applied (e.g., only one output is applied at a time), or can be applied simultaneously (e.g., one or more outputs are applied simultaneously).

[0068] In some exemplary embodiments, the actuator may include two torque sources, each torque source applying a torque input to move a first component (e.g., rotate a rotor). For each torque input, a reaction torque may be applied to a second component (e.g., a first stator) and a third component (e.g., a second stator) that support the respective torque source. The reaction torque may have the same magnitude as the torque input, but is applied in a generally opposite direction. Thus, the first, second, and third components may generally move relative to each other. For example, each of the first, second, and third components may be constrained to rotate about a common axis, and thus the respective components may rotate relative to each other. The first, second, and third components may also be constrained by other mechanical loads. Thus, the components may transfer force or torque rather than move. In this way, the actuator may provide multiple output forces / torques.

[0069] In addition, each output force / torque may be divided into additional outputs (e.g., a force may be divided into two respective force components, each force component serving as a different but coupled output). For example, the actuator may be coupled to the chassis at two different nodes. At one node, the force applied by the actuator to the chassis may cause the actuator to translate vertically (e.g., an active suspension). At the other node, the force applied between the actuator and the chassis may prevent, reduce, or resist unwanted horizontal translational movement.

[0070] The actuator disclosed herein may include an electric motor, such as an axial flux motor, a radial flux motor, or a radial-axial flux motor, having at least two torque sources of substantially equal size and output power (e.g., brushless direct current (DC) torque sources). In an axial flux motor, each torque source may be mounted to a respective stator that may rotate in response to the applied reaction torque. The two stators may share a rotor that includes permanent magnets that respond to the magnetic fields generated by coils on the respective stators. The use of a single rotor with two stators may provide additional efficiency for the overall operation of the actuator. However, the motor may include more than one rotor (e.g., it may include at least one rotor per stator).

[0071] In addition, although the exemplary embodiments described below relate to an actuator integrated in an actuator assembly that rotates a rotor and / or actuates a suspension (e.g., in a vehicle), the actuators of the present invention can also be used in other applications. For example, the actuator can provide other outputs for vehicle operation, including but not limited to ride height adjustment, steering, suspension tuning adjustment, and / or anti-dive / anti-squat. The actuator can also be used to operate other dynamic systems in a vehicle that involve two operating modes (such as seat adjustment). The actuator can be coupled to the chassis using various types of suspensions, including but not limited to MacPherson struts, torque links to the chassis through linkages similar to roll stabilizers, or any other suspension suitable for converting rotational motion into linear motion.

[0072] The benefits of having a single actuator capable of actuating two or more degrees of freedom may also apply to other technologies where space, materials, and / or allowable mass are limited. Such applications include but are not limited to outboard steering electric propulsion for watercraft, thrust vectoring in jet propulsion systems, multi-degree-of-freedom actuator systems for aircraft wings, controllable pitch propeller drives, actuation of various on-board satellite subsystems (e.g., on CubeSats), rotating platforms with additional degrees of operation (e.g., active camera stability, adjustment), stability control of optical systems, actuation of orienting and rotating components for medical tools and devices, drilling components, energy harvesting in various kinetic energy fields, and compact azimuth control of wind turbines.

[0073] For example, the actuator can be used as an in-wheel motor or installed within the sprung mass or chassis of a vehicle to adjust the ride height of the vehicle while providing traction. In this case, the actuator can be mounted at a corner of a road vehicle, where one of the output ends of the actuator is coupled to a wheel or rotatably connected to a drive shaft of the wheel. The second output end can be coupled to a height adjustment mechanism that controls the ride height of the vehicle. Each wheel can have a corresponding actuator and height adjustment mechanism. The height adjustment mechanism can include a lead screw or ball screw, which, when actuated, moves one end of a spring (e.g., a main suspension spring or roll stabilizer) that couples the sprung mass and unsprung mass of the vehicle. Another height adjustment mechanism can include one or a set of gears that are coupled to a torsion spring disposed between the sprung mass and unsprung mass. In another embodiment, a mechanism can translate the motion of an output shaft to a piston to generate pressure on a load-bearing mechanism such as an airbag or hydraulic cylinder.

[0074] An actuator having a stator directly coupled to the chassis

[0075] Figure 2AShows an example of an actuator assembly 200a, in which a slip joint transmission and a stator are directly coupled to the chassis 12. As shown, the actuator assembly 200a includes an actuator 210a having a motor 220, a transmission 240a, and a support structure 250. The motor 220 includes a rotor 221 that is mounted to a main shaft 224, and the main shaft 224 defines a rotational axis 13. The main shaft 224 may be mechanically coupled to a reference ground 11 (e.g., a wheel that is fixed to the main shaft 224 and contacts the road). The motor 220 further includes a first stator 222 and a second stator 223, and each of the first stator 222 and the second stator 223 supports a torque source (not shown) that applies an input torque to the rotor 221. The first stator 222 and the second stator 223 may be coaxially mounted with the main shaft 224 via one or more bearings. Thus, the first stator 222 and the second stator 223 may rotate relative to the main shaft 224. The main shaft 224 may also be coupled to the support structure 250 (e.g., the strut housing of a MacPherson strut). The support structure 250 may be slidably adjusted along a strut 253 that is rigidly connected to the chassis 12. In some cases, the support structure 250 and the strut 253 may form a prismatic slip joint. The actuator assembly 200a may further include springs 254a and 254b to provide a restoring force that holds the support structure 250 in a specific position along the strut 253 when the actuator 210a is under a static load.

[0076] The transmission 240a may include a slip joint housing 242 that couples the motor 220 to the support structure 250 and reacts lateral forces to the chassis 12 via the support structure 250. As shown, the transmission 240a may include links 245a and 245b, one end of each of the links 245a and 245b is coupled to the first stator 222 at a node 246 and to the second stator 223 at a node 247, and the other end is coupled to the joint housing 242 at a node 243. The links 245a and 245b may be coupled to the nodes 247, 246, and 243 via pin joints (or ball joints) to allow rotational movement about each node while restricting translational movement. The joint housing 242 may be slidable along the support structure 250. Additionally, the second stator 223 may be directly coupled to the chassis 12 via a link 248a. As shown, the link 248a may also be coupled to the node 247 on the second stator 223 and to the chassis 12 via a pin joint. The link 248a may be a rigid or compliant tension-compression member.

[0077] Torque sources coupled to the first stator 222 and the second stator 223 can generate input torques independently of each other. However, the first stator 222 and the second stator 223 can be coupled to each other via the transmission 240a. Additionally, the actuator 210a is coupled to other components of the actuator assembly 200a at three locations, namely, the rotor 221 to the reference ground 11, the support structure 250 via the strut 253 to the chassis 12, and the second stator 223 via the link 248a to the chassis 12. Thus, the actuator 210a can provide up to three force / torque outputs for two independent inputs.

[0078] Input torque and reaction torque

[0079] As described above, the actuators described herein can provide multiple outputs to mechanically actuate various subsystems (e.g., rotating wheels, actuating a suspension) of a system (e.g., a vehicle). Relative to Figure 2A the actuator assembly 200a depicted in, the actuator 210a can provide multiple force and / or torque outputs to (1) rotate the rotor 221 (e.g., rotate a wheel coupled to the rotor for propulsion) and / or (2) translate the actuator 210a relative to the chassis 12 and / or the reference ground 11 by slidably adjusting the support structure 250 along the strut 253 (e.g., actuate a suspension) and / or compensate for undesired forces and / or motions in the system based on the excess force between the first stator 222 and the second stator 223 (e.g., provide anti-dive during vehicle braking and / or anti-squat during vehicle acceleration to improve vehicle stability and / or operator comfort). In this example, the excess force generated by the reaction torque applied to the first stator 222 and the second stator 223 of the actuator 210a can be split into two force components (e.g., two orthogonal force components) applied in different directions. The magnitudes and / or directions of the two force components can be coupled. Additionally, the excess force can be applied as a non-zero force via the link 248a and / or as separate component forces at (1) the link 248a and (2) the strut 253 via the support structure 250.

[0080] In one case, a torque source coupled to the first stator 222 can generate an input torque that is applied to the rotor 221 while a torque source coupled to the second stator 223 remains inactive. The input torque can cause the rotor 221 to rotate about the axis of rotation 13 relative to the reference ground 11. When the first stator 222 generates an input torque, a corresponding reaction torque is also generated and applied to the first stator 222. The magnitudes of the reaction torque and the input torque can be substantially equal, but the directions along which the torques are applied can be substantially opposite. For example, the input torque applied to the rotor 221 can be along the clockwise direction, while the reaction torque applied to the first stator 222 can be along the counterclockwise direction.

[0081] The reaction torque applied to the first stator 222 may cause the first stator 222 to rotate about the axis of rotation 13. However, the movement of the first stator 222 may be restricted by the link 245a of the transmission 240a, which is coupled to the first stator 222 at the node 246. In other words, at least a portion of the reaction torque applied to the first stator 222 may be transmitted to the transmission 240a via the link 245a. The portion of the reaction torque transmitted to the transmission 240a may cause the joint housing 242 to slide along the support structure 250 and / or be transmitted to the second stator 223 via the link 245b.

[0082] If the second stator 223 is separated from the chassis 12, the reaction torque will cause the first stator 222 and the second stator 223 to rotate in opposite directions about the axis of rotation 13, while the joint housing 242 in the transmission 240a will slide along the support structure 250. With the removal of the link 248a between the second stator 223 and the chassis 12, any force between the chassis 12 and the actuator 210 will be applied via the suspension through the support structure 250. The stator 222 will accelerate itself inertially and pull the transmission 240a. The support structure 250 will provide the torque coupling required by the transmission 240a to accelerate the stator 223 inertially via the link 245b. The main shaft 224 will react the force from the reference ground plane 11 and the coupled force from the stator inertial load to the support structure, which will in turn be reacted by the suspension.

[0083] However, by coupling the second stator 223 to the chassis 12 via the link 248a, a net force is applied between the actuator 210a and the chassis 12, which causes the actuator 210a to translate along the strut 253 (i.e., towards or away from the reference ground 11). Referring Figure 2A to the view of the actuator assembly 200a shown in the reference, if the reaction torque is applied to the first stator 222 in a clockwise direction about the axis of rotation 13, the actuator 210a will translate towards the reference ground 11. Conversely, if the reaction torque is applied in a counterclockwise direction about the axis of rotation 13, the actuator 210a will translate away from the reference ground 11.

[0084] In another case, a torque source coupled to the second stator 223 can generate an input torque that is applied to the rotor 221 while the torque source coupled to the first stator 222 remains inactive. Similar to the previous case, the input torque can cause the rotor 221 to rotate about the axis of rotation 13 relative to the reference ground 11. A corresponding reaction torque (similar in magnitude to the input torque but applied in the opposite direction) can also be applied to the second stator 223. However, in this case, the reaction torque can be directly transmitted to the chassis 12 through the link 248a instead of being indirectly transmitted via the transmission 240a. The reaction torque can initially cause the actuation of the transmission 240a and the rotation of the first stator 222. However, under steady-state conditions, the reaction torque applied to the second stator 223 can be mainly transmitted to the chassis 12 via the link 248a. Similar to the previous case, the reaction torque can cause the actuator 210a to translate towards or away from the reference ground 11 based on the translation of the support structure 250 along the strut 253.

[0085] For the above cases, the magnitude and direction of the output force and torque generated by the actuator 210a can be controlled, in part, by adjusting the magnitude and / or direction of the torques applied by the first stator 222 and the second stator 223 on the rotor 221. However, applying torque only via the first stator 222 or the second stator 223 may cause the output force / torque to occur simultaneously, which may be undesirable. For example, it may be preferable to rotate the wheel coupled to the rotor 221 and the main shaft 224 without causing the actuator 210a to translate relative to the chassis 12. For such a case, the actuator 210a can provide certain outputs by applying torque to both the first stator 222 and the second stator 223 simultaneously.

[0086] In some cases, the actuator may superimpose the input torque and / or the reaction torque generated by the torque source to produce a summing torque and a differential torque, which selectively control which outputs are provided by the actuator. For Figure 2A the actuator 210a shown, the input torques applied by the first stator 222 and the second stator 223 in the same direction cause the rotor 221 to rotate in opposite directions. Thus, the torque experienced by the rotor 221 can be considered as the vector sum of the applied torques, ignoring friction and mechanical gain (discussed below). At the same time, the torque experienced by the transmission 240a can be considered as the vector difference of the applied torques, again ignoring friction and mechanical gain. The mechanical gain experienced by the transmission 240a can provide an additional force (e.g., for anti-dive, anti-squat functions) that can be used as an additional output from the actuator 210a.

[0087] For example, the first stator 222 and the second stator 223 may apply input torques having the same magnitude and direction. Thus, the summed torque may have twice the magnitude of the input torque, causing the rotor 221 to rotate about the axis of rotation 13. The reaction torques applied to the first stator 222 and the second stator 223 similarly have the same magnitude and are applied in a direction opposite to the input torque. Conversely, a reaction force is generated between the support structure 250 and the strut 253 mounted to the chassis 12.

[0088] In another example, the first stator 222 and the second stator 223 may apply input torques of opposite directions having the same magnitude to the rotor 221. In this case, the input torques impede the rotation of the rotor 221 (i.e., the input torques cancel each other out). The resulting reaction torques applied to the first stator 222 and the second stator 223 similarly have the same magnitude but are applied in opposite directions with respect to the axis of rotation 13. Thus, the reaction torques cause the transmission 240a to actuate and / or a net differential torque output (i.e., the differential torques have constructive interference on the respective reaction torques). This in turn causes the actuator 210a to translate along the strut 253 (actuating the suspension).

[0089] Generally, the first stator 222 and the second stator 223 may provide input torques having varying magnitudes and directions. Thus, the relative magnitude of the output force / torque provided by the actuator 210a may change based on the magnitudes and / or directions of the input torque and the corresponding reaction torque. In general, adjusting the magnitude and / or direction of one or both of the input torques to the actuator 210a may cause one or more of the following outputs: (1) rotating the rotor 221, (2) translating the actuator 210a along the strut 253, and (3) generating a reaction force between the support structure 250 and the strut 253. The relative magnitude and / or direction of one or more of the output force / torque provided by the actuator 210a may be adjusted in a substantially continuous (or discrete) manner with respect to the input torque. For example, a continuous change in the magnitude and / or direction of the input torque results in a continuous change in the output force / torque.

[0090] Mechanical Gain and Motion Ratio

[0091] Additionally, the transmission 240a may provide a mechanical gain, which may be quantified as a motion ratio depending on the relative positions of the first stator 222 and the second stator 223. The motion ratio depends on the structure of the motor 220, the transmission 240a, the support structure 250, and the connections between these components and their sub-components, including link lengths and shapes and node positions. In Figure 2AIn [the example], for instance, the linkages 245a and 245b in the actuator 210a have the same length and are symmetrically coupled to nodes 247 and 246 at a similar radial distance from the axis of rotation 13. Thus, the rotation of the first stator 222 causes the second stator 223 to rotate at a 1:1 movement ratio.

[0092] In other embodiments, the geometry of the linkages 245a and 245b and / or the positions of the nodes 247 and 246 can be altered to produce a different movement ratio between the first stator 222 and the second stator 223, thereby changing the dependence of the force / torque of each output from the actuator 210a on the input torque to the first stator 222 and / or the second stator 223. For example, the transmission 240a can be configured such that the reaction torque applied to the first stator 222 produces a greater torque between the actuator 210a and the chassis 12 than the reaction torque applied to the second stator 223 (e.g., the first stator 222 can act in a manner similar to a lower gear in a vehicle transmission that produces a greater torque). Alternatively, the reaction torque applied to the second stator 223 can produce a faster actuation rate between the actuator 210a and the chassis 12 than the reaction torque applied to the first stator 222 (e.g., the second stator 223 can act in a manner similar to a higher gear in a vehicle transmission that allows for a higher rotational speed).

[0093] In another example, the movement ranges of the first stator 222 and the second stator 223 can be modified such that the output force / torque depends in part on the angular positions of the first stator 222 and the second stator 223. For example, mechanical stops can be incorporated into the actuator 210a that limit the rotational ranges of the first stator 222 and the second stator 223. The mechanical stops can define the angular range within which the actuator 210a can produce a differential torque output at a particular node. The mechanical stops can be coupled to the support structure 250. In this way, the geometry of the actuator 210a and its internal and external connections can be selected to adjust the force / torque of the various outputs produced by the actuator 210a.

[0094] The transmission 240a can also produce an asymmetric response between the first stator 222 and the second stator 223. For example, the second stator 223 can rotate in response to a reaction torque applied to the first stator 222, but the first stator 222 can remain stationary in response to a reaction torque applied to the second stator 223. For example, this can be achieved by using a ratchet mechanism that allows the first stator 222 to rotate in only one direction (e.g., only clockwise, only counterclockwise), while the second stator 223 can rotate freely in one or more directions (e.g., clockwise and counterclockwise). The asymmetric response between the first stator 222 and the second stator 223 can provide another parameter to modify the dependence of the output force / torque on the input torque and / or reaction torque. The motion ratio between the two stators does not have to be constant or linear.

[0095] The stator is coupled to the actuator of the chassis via a rocker joint

[0096] Figure 2B Another exemplary actuator assembly 200b is shown, where the rocker joint transmission 240b and the stator are directly coupled to the chassis 12. As shown, the actuator assembly 200b shares several similarities with Figure 2A the actuator assembly 200a. As Figure 2A shown, the actuator assembly 200b includes a motor 220, a transmission 240b, and a support structure 250. The motor 220 includes a rotor 221 that is coupled to a main shaft 224 that defines a rotational axis 13. The main shaft 224 is also coupled to a reference ground 11. The motor 220 also includes a first stator 222 and a second stator 223, each of which supports a torque source and is coaxial with the main shaft 224. The main shaft 224 is supported by a support structure 250 (e.g., a strut housing) that can be slidably adjusted along a strut 253 that is rigidly mounted to the chassis 12. Springs 254a and 254b can be used to provide a restoring force to the actuator 210b.

[0097] In this case, the rocker joint transmission 240b includes a rocker joint arm 244 that rotates about a node 243. As shown, the transmission 240b includes a link 245a that is coupled to the first stator 222 at a node 246 via respective pin joints (or ball joints) and a link 245b that is coupled to the second stator 223 at a node 247. The links 245a and 245b are coupled to the rocker joint arm 244, which in turn is coupled to the support structure 250 at the node 243. The rocker joint arm 244 can be coupled to the links 245a and 245b and the support structure 250 via respective pin joints (or ball joints).

[0098] The second stator 223 is also directly connected to the chassis 12 by a connecting rod 248b that is connected to the second stator 223 at a node 249. Here, the node 249 is not juxtaposed with the node 247. Instead, it is radially offset, for example, by using a cam as shown in Figure 2B . The length of the connecting rod 248b and the (radial) position of the node 249 can be selected to provide a desired motion ratio between the rotation of the second stator 223 and the translation of the support structure 250.

[0099] The actuator assembly 200b can be operated in a manner similar to the actuator assembly 200a, where the transmission 240a can be considered an instantaneous linearization of the transmission 240b. The torque sources on the first stator 222 and the second stator 223 can each generate an input torque applied to the rotor 221, causing the rotor 221 to rotate about the axis of rotation 13 relative to the reference ground 11. Each torque source can generate a corresponding reaction torque applied to the first stator 222 and the second stator 223. For the second stator 223, the applied reaction torque can be directly transmitted to the chassis 12 via the connecting rod 248b, which in turn can cause the actuator 210b to translate along the strut 253 away from or towards the reference ground 11.

[0100] For the first stator 222, the applied reaction torque can be transmitted to the rocker joint arm 244 via the connecting rod 245a. This in turn can cause the rocker joint arm 244 to rotate about the node 243 relative to the support structure 250. However, the constraint applied by the connecting rod 248b that connects the second stator 223 to the chassis 12 can alternatively cause at least a portion of the reaction torque transmitted from the first stator 222 to the transmission 240b to be transmitted to the second stator 223 via the connecting rod 245b. This reaction torque can then create a net force or net torque between the actuator 210b and the chassis 12, causing the actuator 210b to translate along the strut 253 via the support structure 250. Reaction forces / torques can also be applied between the support structure 250 and the chassis 12, which can be used as another output (e.g., anti-dive, anti-squat).

[0101] The geometry of the rocker joint arm 244 can be modified to adjust the dependence of each output force / torque on the respective input torque and / or reaction torque generated by the torque sources on the first stator 222 and the second stator 223. For example, the length of the rocker joint arm 244 can affect the angular rotation range of the first stator 222 and / or the second stator 223. The orientation of the rocker joint arm 244 (which may depend on the respective positions of the nodes 247 and 246 and the lengths of the connecting rods 245a and 245b) can also affect the direction of the reaction force applied to the support structure 250 via the transmission 240b. For example, the rocker joint arm 244 can be an elongated member where the force is mainly transmitted along the length of the arm (lateral forces are more likely to cause the rocker joint arm 244 to rotate).

[0102] Axial Flux Motor with Panhard Link and Coaxial Drive Shaft and Differential Shaft

[0103] Figures 3A to 3D Shows kinematically equivalent to Figure 2B Several views of an exemplary actuator 310 of actuator 210b. As shown, actuator 310 may include an axial flux motor 320. Motor 320 includes a rotor 321 mounted on a main shaft 324. Motor 320 also includes a first stator 322 and a second stator 323, which are coaxially constrained by the main shaft 324 and are disposed on opposite sides of the rotor 321. As shown, the first stator 322 and the second stator 323 may each be coupled to their respective housings, which together form a substantially enclosed cavity to accommodate the rotor 321 while still allowing rotational movement between the first stator 322 and the second stator 323.

[0104] The first stator 322 and the second stator 323 each include a torque source, which includes one or more magnets disposed on the rotor 321 or the corresponding stator and one or more coils disposed on the rotor 321 or the corresponding stator opposite the one or more magnets. A current applied to the one or more coils via associated electronics (not shown) generates a magnetic field, which in turn interacts with the permanent magnetic field of the one or more magnets, causing the rotor 321 (and / or the stator) to rotate. For this axial flux motor 310, the magnets and coils are respectively mounted on the surfaces of the rotor 321 and the stator. Motor 320 can also be a radial flux motor (where one or more magnets and coils are mounted on the periphery (e.g., the outer edge of the rotor 321, the inner edge of the stator surrounding the rotor 321)) or a combined radial-axial flux motor.

[0105] Actuator 310 may include a support structure 350 that provides mechanical support to motor 320 and transmission 340. As previously described, support structure 250 can remain stationary relative to the reference frame of actuator 310. In other words, support structure 350 does not move relative to motor 320 and transmission 340, but moves relative to the reference ground or chassis. As shown, support structure 350 can allow the main shaft 324 to rotate while constraining other degrees of freedom. Support structure 250 can also define an opening 311 to couple support structure 350 to a strut housing (see Figures 4A to 4C ). As shown, opening 311 can be shaped to allow insertion of the strut housing. Support structure 350 can be securely coupled to the strut housing using one or more fasteners.

[0106] The transmission 340 may include a first arcuate link 345a coupled to the first stator 322 at node 346 and a second arcuate link 354b coupled to the second stator 323 at node 347. The links 345a and 345b are coupled to a torsion bar 344 that rotates about a rotational axis passing through node 343 relative to the support structure 350. The torsion bar 344 may be disposed within an opening in the support structure 350 that permits rotation of the torsion bar 344 while constraining other degrees of freedom of the torsion bar. In this example, the support structure 350 constrains the motion of the centroid of the torsion bar to a particular arc relative to the support structure 350.

[0107] Like Figure 2B the actuator 210b in, the actuator 310 in FIG. 3 is configured to generate summing torque and differential torque outputs applied to the rotor 321. The forces / torques of these outputs can be used to actuate various subsystems. For example, the summing torque can cause a drive shaft to rotate, which in turn causes a wheel to rotate. And the differential torque can actuate an active suspension system.

[0108] Figures 4A to 4C Illustrated is an actuator assembly 400 incorporating Figures 3A to 3D the actuator 310. As shown, the actuator 310 is integrated into a suspension system, where the actuator 310 uses the summing torque to rotate a wheel 410 coupled to the spindle 324. The differential torque is used to actuate a suspension coupled to the chassis 12.

[0109] Figures 4A to 4C Illustrated is a support structure 350 of the actuator 310 coupled to a strut housing 412 via an opening 311. The strut housing 412 may be slidably adjusted along a strut 453 coupled to the chassis 12. A spring 454 is disposed along the strut 453 and coupled to the chassis 12 and the support structure 350 to provide a restoring force when actuating the suspension. The actuator assembly 400 further includes a link 448 (shown as a tension-compression member or push rod) that couples the second stator 323 to the chassis 12 at node 349. As shown, the link 448 may be coupled to the second stator 323 and the chassis 12 via respective ball joints. The actuator assembly 400 may further include a lower control arm 482 and a tie rod 480, one end of each of the lower control arm 482 and the tie rod 480 being coupled to the chassis 12 and the other end being coupled to the support structure 350. The lower control arm 482 and the tie rod 480 may also constrain the kinematic motion of the support structure 350. Thus, the strut housing 412, the strut 453, the lower control arm 482, and the tie rod 480 together form a MacPherson strut suspension.

[0110] The reaction torque applied to the first stator 322 and the second stator 323 may generate a redundant force, which may be transmitted along the link 448 to the chassis 12 to translate the actuator 310 along the strut 453 via the strut housing 412 and / or prevent compression or extension of the actuator 310 when the vehicle brakes or accelerates, respectively. As described above, a reaction force / torque may be generated between the strut housing 412 and the strut 453, which may provide another output (e.g., reacting to a force component).

[0111] Axial flux motor having a rocker link and offset drive and differential shafts

[0112] Figures 5A to 5E Another exemplary actuator 510 is shown, where the transmission 540 has a rocker link that constrains the movement of the first stator 522 and the second stator 523 in the axial flux motor 520. Similar to actuator 310, the transmission 540 includes a torsion bar 544, which is a mechanically rigid member constrained by a support structure 550 to rotate about an axis parallel to the axis of rotation of the main shaft 524. The torsion bar 544 is coupled to the first stator 522 via a link 545a at a node 546 and to the second stator 523 via a link 545b at a node 547. Links 545a and 545b are free to rotate at their respective joints. The support structure 550 may be mounted to a suspension or load reaction reference frame (e.g., a vehicle chassis). For this case, the second stator 523 may be coupled to an external subsystem at a node 549 via a differential shaft 562 on the second stator 523. The differential shaft 562 may rotate about the same axis of rotation as the rotor 521 and the main shaft 524. Compared to actuator 310, actuator 510 operates in a similar manner, except that a differential torque is output via the differential shaft 562 instead of a force via a link or pushrod member (e.g., link 448).

[0113] Figure 6A An exemplary actuator assembly 600a is shown that incorporates Figures 5A to 5EThe actuator 510 serves as a wheel hub motor. As shown, the summation torque applied to the rotor 521 can cause the wheel 410 mounted to the main shaft 524 to rotate. The differential torque provided by the differential shaft 562 can be applied to the torque shaft 610. In this way, the actuator 510 does not directly generate a force / torque output to actuate the chassis 12 from the unsprung mass, but instead transfers the differential torque as a pure torque to the chassis 12 via the inner torque shaft 610. The torque transmitted to the torque shaft 610 can be used to actuate other subsystems (e.g., actuate the suspension via another mechanism). The actuator assembly 600a also includes a lower A-arm 682, an upper A-arm 684, and a tie rod 680 that form part of the suspension. The A-arms 682 and 684 and the tie rod 680 are coupled to the chassis 12 and the support structure 550 (the portions of the support structure 550 to which the arms 682 and 684 and the tie rod 680 are coupled are not shown).

[0114] Figure 6B Another exemplary actuator assembly 600b is shown, where the actuator 510 is mounted inside the sprung mass of the vehicle or the chassis 12. As shown, the actuator assembly 600b includes a drive shaft 624 that couples the main shaft 524 of the motor 520 to the wheel 410. Thus, the summation torque applied to the rotor 521 can be used to rotate the wheel 410 via the drive shaft 624. The differential shaft 562 is coupled to a linkage 620 that transfers the differential torque to an actuating member 622, which can be coupled to other subsystems (e.g., actuate a suspension mechanism).

[0115] Figure 6C Another exemplary actuator assembly 600c is shown, where Figures 3A to 3D the actuator 310 is incorporated into a swingarm suspension. Swingarm suspensions are commonly used in various types of vehicles, including but not limited to motorcycles, bicycles, and scooters. As shown, the actuator 310 can be mounted to a support frame 630 that can have forks on both sides for supporting the wheel 410. The support frame 630 can in turn be mounted to the chassis 12 via arms 632 (e.g., front arm, rear arm) that are rotatably coupled to the support frame 630 and the chassis 12. The arms 632 can constrain the center of mass of the wheel to travel along a curved path (e.g., an arc). The support frame 630 can also be coupled to the chassis 12 via a shock absorber 634 to provide suspension. The shock absorber 634 can be coupled to the support frame 630 via a pin joint. The actuator 310 can be coupled to the chassis 12 via a rod 636 that is rotatably coupled to the chassis 12 and the actuator 310.

[0116] Thus, the rod 636 can be actuated (e.g., differential torque) by the actuator 310 such that the rod 636 causes the strut 634 to contract or extend. The transmission 340 can couple the first stator 322 to the second stator 323 via the linkages 345a and 345b and the torsion bar 344, thereby allowing reaction torque to be transferred from the first stator 322 to the second stator 323 (or vice versa). Thus, the rod 636 can be connected to the first stator 322 or the second stator 323.

[0117] Axial Flux Motor with Bevel Gear Transmission

[0118] Figure 7A Another exemplary actuator 710a having a bevel gear transmission 740a is shown. As shown, the actuator 710a can include an axial flux motor 720, where the rotor 721 is mounted to the main shaft 724. The motor 720 can include a first stator 722a and a second stator 723a that are disposed on opposite sides of the rotor 721 and are coaxially constrained to rotate about the main shaft 724 via one or more bearings (each bearing is represented by an "X" as a circle). The motor 720 can be supported and surrounded by a support structure 750. The transmission 740a can couple the first stator 722a to the second stator 723a via the bevel gear 748a. The bevel gear 748a can rotate relative to the support structure 750 at the node 743 via one or more bearings. Generally, only one bevel gear 748a can be used; however, Figure 7A A transmission 740a including two bevel gears 748a to provide additional mechanical support is shown.

[0119] The bevel gear 748a can include one or more gear teeth that mesh with corresponding gear teeth on the first stator 722a at the node 746 and on the second stator 723a at the node 747. Thus, rotation of the first stator 722a in response to reaction torque causes the bevel gear 748a to rotate, which in turn causes the second stator 723a to rotate in the opposite direction. In this way, the bevel gear transmission 740a provides reverse rotation between the first stator 722a and the second stator 723a. Thus, the actuator 710a operates kinematically in the same manner as Figure 2B the actuator 210b shown. Summing torque can be applied to rotate the rotor 721, and differential torque can be output at the differential shaft 762 fixed to the second stator 723a. Reaction force / torque can be applied to the support structure 750 via the bevel gear 748a.

[0120] Figure 7BAnother exemplary actuator 710b is shown, which has a transmission 740b with a double bevel gear mechanism. The transmission 740b includes a double bevel gear 748b that meshes with a first stator 722b and a second stator 723b via separate bevel gears mounted to the same main shaft 724. Based on the relative sizes of the bevel gears in the double bevel gear 748b and / or the relative tooth diameters from the main shaft axis 13, the double bevel gear 748b can allow for different speed ratios between the first stator 722b and the second stator 723b. For example, the gear coupled to the first stator 722b can be larger than the gear coupled to the second stator 723b, which results in an increase in the torque transmitted between the first stator 722b and the double bevel gear 748b and / or an increase in the rotational speed between the second stator 723b and the double bevel gear 748b.

[0121] Figure 7C Another exemplary actuator 710c is shown, which has a transmission 740c with a planetary gear mechanism. In this case, the transmission 740c can include a planetary gear 748c that rotates about an axis of rotation parallel to the main shaft 724. As shown, a support structure 750 can constrain other translational and rotational degrees of freedom of the planetary gear 748c. Actuator 710c can operate in a manner similar to Figure 7A actuator 710a.

[0122] Figure 7D Another exemplary actuator 710d is shown, where the transmission 740d includes a bevel gear mechanism that is housed in a support structure 750 from a motor 720, and the motor 720 is disposed in the support structure 750. In this case, a first stator 722d is mounted to a differential shaft 764 that transmits differential torque. The rotor 721 and a second stator 723d are coaxial with the differential shaft 764. The rotor 721 also includes a drive shaft (main shaft) 724 coupled to a rotor frame 726 that partially surrounds the first stator 722d. Actuator 710d operates in a manner similar to Figure 7A actuator 710a, where the transmission 740d includes bevel gears 748d that mesh with the first stator 722d and the second stator 723d. However, in this case, the second stator 723d transmits a reaction torque to the first stator 722d via the transmission 740d.

[0123] Figure 7EAnother exemplary actuator 710e is shown, where the transmission 740e includes a planetary gear mechanism, and the first stator 722e outputs differential torque via the differential shaft 764. Actuator 710e is similar to actuator 710d, except that the bevel gear 748d is replaced by a planetary gear 748e to couple the first stator 722e and the second stator 723e. As shown, the planetary gear 748e can rotate about an axis parallel to the axis of rotation of the differential shaft 764 and can otherwise be constrained by the support structure 750 along other translational and rotational degrees of freedom.

[0124] Axial Flux Motor with Belt Transmission

[0125] Figure 8A An exemplary transmission 840a that uses a belt mechanism to transfer reaction torque is shown. As shown, the first stator 822 can be coupled to a pulley 832 mounted to a shaft. The second stator 823 can be coupled to a pulley 831 that is mounted via one or more bearings to a shaft that rotates concentrically about the first stator 822. The pulleys 831 and 832 can be coupled to a main pulley 830 via belts 836 and 838, respectively. The main pulley 830 can be coupled to and constrained by a support structure 850. Thus, rotation of the second stator 823 causes the main pulley 830 to rotate via the belt 836, which in turn causes the first stator 822 to rotate in the opposite direction via the belt 838. In this way, the transmission 840a can provide a function similar to that of Figures 2A to 7E the transmission. The transmission 840a can also include an idler pulley 834 to guide and / or provide tension to the belt 838.

[0126] The idler pulley 834 can be translationally constrained by the support structure 850. Additionally, a chain and / or cable can replace the belts 836 and 838. The belts 836 and 838 can rely on frictional contact with the respective pulleys to transfer torque. Thus, the size of the belts 836 and 838 and / or the structure of the transmission 840a can be adjusted to increase the contact area between the belts 836 and 838 and the respective pulleys to reduce slippage. In some cases, the belts 836 and 838 can have teeth that engage corresponding teeth on the pulleys to further reduce slippage. However, in some cases, it may be preferred for the belts 836 and 838 to slip in a controlled manner.

[0127] Figure 8BAn exemplary actuator 810b with a single pulley transmission 840b is shown. As shown, the actuator 810b may include a first stator 822 and a second stator 823 that rotate about the same axis of rotation. The transmission 810b may include a belt 843, one end of which is coupled to the first stator 822 at node 846 and the other end of which is coupled to the second stator 823 at node 847. The belt 843 may be guided by a pulley 842 disposed between the first stator 822 and the second stator 823. Thus, when the first stator 822 rotates, the belt 843 is pulled along the first stator 822. This in turn creates tension along the belt 843, which causes the pulley 842 and the second stator 823 to rotate in response. In particular, the second stator 823 rotates in a direction opposite to that of the first stator 822. For this design, the length of the belt 843 can be adjusted to adjust the angular displacement range of the first stator 822 and the second stator 823.

[0128] Figure 8C An exemplary actuator 810c with a dual pulley transmission 840c is shown. As shown, the transmission 840c may include pulleys 844a and 844b that are each configured to guide a belt 845. Different from Figure 8B the belt 843 in actuator 810b, the belt 845 in actuator 810c is not fixed to the first stator 822 or the second stator 823. Instead, the belt 845 is wound around the first stator 822, the second stator 823, and the pulleys 844a and 844b in a tensioned state. However, the actuator 810c operates in a manner similar to that of the actuator 810b by providing a reverse rotational movement between the first stator 822 and the second stator 823. For this design, the length of the belt 845 can be constrained by the dimensions and layout of the first stator 822, the second stator 823, and the pulleys 844a and 844b.

[0129] Figure 8D An exemplary actuator 840d with a single pulley, dual belt transmission 840d is shown. As shown, the transmission 840d may include a cylindrical pulley 846 that rotates about an axis of rotation parallel to the axis of rotation of the first stator 822 and the second stator 823. For this design, the transmission 840d includes a belt 849a that couples the first stator 822 to the pulley 846 and a belt 849b that couples the second stator 823 to the pulley 846. The belt 849a can be twisted to form an additional loop wound around the pulley 846 to enable the transmission 840d to provide a reverse rotational movement between the first stator 822 and the second stator 823. In some cases, one or both of the belts 849a and 849b can be fixed to their respective stators to constrain the range of rotation.

[0130] Figure 8E andFigure 8F Shows several views of an exemplary actuator 810e having a double helical gear transmission 840e. As shown, the transmission 840e may include helical gears 860 and 862 that rotate relative to a support structure 850. The helical gears 860 and 862 may mesh, thereby causing reverse rotational movement between the gears 860 and 862. A first stator 822 may be coupled to the helical gear 860 via a belt 866 that is guided by a pulley mounted to the helical gear 860. Similarly, a second stator 823 may be coupled to the helical gear 862 via a belt 868 that is guided by a pulley mounted to the helical gear 862. Thus, when the first stator 822 rotates, the belt 866 is pulled, creating tension that causes the helical gear 860 to rotate. This in turn causes the helical gear 862 and the second stator 823 to rotate in the opposite direction via the belt 868. The belt 866 and the belt 868 may each be kept taut via an idler pulley 864. The idler pulley 864 may be constrained by the support structure 850 to rotate about an axis parallel to the axes of the helical gears 860 and 862.

[0131] Exemplary actuator having a transmission coupled to the chassis

[0132] Figure 9A Shows an actuator assembly 900a having a slip joint transmission 940a, where the transmission 940a is directly coupled to the chassis 12. As shown, the actuator assembly 900a includes an actuator 910a having a motor 920, a transmission 940a, and a support structure 950. As previously described, the motor 920 includes a rotor 921 that is mounted to a main shaft 924 that defines a rotational axis 13. The main shaft 924 may be mechanically coupled to a reference ground 11 (e.g., via a wheel on the road). The motor 920 also includes a first stator 922 and a second stator 923, each of which supports a torque source (not shown) to apply torque to the rotor 921. The first stator 922 and the second stator 923 may be coaxially constrained to the main shaft 924 via one or more bearings. The main shaft 924 may also be coupled to the support structure 950. The support structure 950 may be slidably adjusted along a strut 953 that is rigidly connected to the chassis 12. As previously described, the actuator assembly 900a may include springs 954a and 954b to provide a restoring force to the actuator 910a.

[0133] The transmission 940a can also be coupled to the first stator 922 and the second stator 923 in a manner similar to the previous embodiments. The transmission 940a can include a link 945a that couples the first stator 922 at node 946 to the joint housing 942 at node 943; and a link 945b that couples the second stator 923 at node 2204 to the joint housing 942. The links 945a and 945b can be coupled to the stator and the joint housing 942 via pin joints (or ball joints). In this embodiment, the transmission 940a is directly coupled to the chassis 12 at node 949 via a link 948, which changes the way the reaction torque is transmitted in the actuator 910a. For example, when a reaction torque is applied to the first stator 922, at least a portion of the reaction torque is transmitted to the joint housing 942 via the link 945a. This in turn causes the joint housing 942 to slide along the support structure 950. However, since the joint housing 942 is directly coupled to the chassis 12, the reaction torque is mainly transmitted from the transmission 940a to the chassis 12 (rather than to the second stator 923). The reaction torque applied to the second stator 923 provides a similar behavior. Since the second stator 923 does not receive the reaction torque from the first stator 922, the first stator 922 and the second stator 923 can be loaded in a symmetric manner when similar reaction torques are applied from various torque sources.

[0134] However, the actuator 910a can be operated in a manner similar to the previous embodiments. The input torque can be represented as the vector sum of the torques applied to the rotor 921. The transmission 940a causes a reverse rotation between the first stator 922 and the second stator 923, so the reaction torque can be represented as a differential torque output. The differential torque can generate a force between the transmission 940a and the chassis 12 along the link 948, and the force causes the actuator 910a to translate along the strut 953. In addition, the differential torque can generate a reaction force / torque between the support structure 950 and the strut 953 of the actuator 910a, which can be used as an additional output (e.g., for anti-dive, anti-squat).

[0135] Figure 9B Another exemplary actuator assembly 900b is shown, where the transmission 940b includes a rocker joint and is directly coupled to the chassis 12. Similar to the actuator 210b, the transmission 940b can include a rocker joint arm 944 that is coupled to the links 945a and 945b and the node 943 on the support structure 950. Additionally, the rocker joint arm 944 can also be directly coupled to the chassis 12 at node 949 via a link 948. However, the transmission 940b can be operated in a manner similar to the actuator 210b, and the actuator assembly 900b can transmit torque in a manner similar to the actuator 910a.

[0136] Figures 10A to 10E Shows several views of an exemplary actuator 1010 having a transmission 1040, the transmission 1040 having a Panhard rod that also provides a differential torque output. Actuator 1010 is kinematically similar to actuator 910b and thus operates in a similar manner. (Unless otherwise noted, reference numerals with the same ending digits are kinematically equivalent, e.g., Figure 9B the rotor 921 in Figure 10E is kinematically equivalent to the rotor 1021 in .) As shown, transmission 1010c includes links 1045a and 1045b coupled to a torsion bar 1044. In this case, the differential axle 1062 is directly coupled to the torsion bar. Thus, the reaction torque applied to the first stator 1022 and the second stator 1023 can be transmitted through the torsion bar as an output.

[0137] Figure 11A Shows another exemplary actuator 1110a, where the transmission 1140a has a bevel gear mechanism that directly outputs differential torque. Actuator 1110 is also kinematically similar to Figure 9B actuator 910b and thus operates in a similar manner. (Again, unless otherwise noted, reference numerals with the same ending digits are kinematically equivalent.) Transmission 1140b includes a bevel gear 1148a that meshes with a first stator 1122 and a second stator 1123 to create a reverse rotational movement between the first stator 1122 and the second stator 1123. However, in this case, bevel gear 1148a includes an auxiliary gear that meshes with a secondary bevel gear 1148b that supports the differential axle 2350. In this way, the rotation of the first stator 1122 and / or the second stator 1123 causes bevel gear 1148a to rotate, which in turn causes secondary bevel gear 1148b to rotate, thereby outputting differential torque at node 1149.

[0138] Figure 11BAnother exemplary actuator 1110b is shown, where a dual gear transmission 1140b is coupled to a chassis 12. As shown, the transmission 1140b may include a first gear 1160 meshing with a first stator 1122 and a second gear 1162 meshing with a second stator 1123. The first gear 1160 and the second gear 1162 may also mesh together to produce a reverse rotational movement between the first stator 1122 and the second stator 1123. The first gear 1160 and the second gear 1162 may be supported by a support structure 1150. Additionally, the second gear 1162 may be coupled to the chassis 12 via a linkage 1148c. Thus, the reaction torque transmitted to the first gear 1160 and / or the second gear 1162 may then be transmitted to the chassis 12 via the linkage 1148c to produce a driving force that translates the actuator 1110b relative to the chassis 12. Actuator 1110b is also kinematically similar to Figure 9B actuator 910b in

[0139] Figures 12A to 12C Several views of an exemplary actuator assembly 1200 that outputs translational motion and / or force rather than differential torque are shown. In this case, actuator 1210 is kinematically equivalent to Figure 9A actuator 910a in

[0140] In Figures 8A to 8F the transmission depicted can be readily incorporated into an actuator where the transmission is directly coupled to the chassis 12. This can be accomplished in part by adding a differential shaft to one of the components in the transmission. For example, the differential shaft can be provided on one of the pulleys in a pulley-based transmission as shown in Figures 8A to 8F which can then be directly coupled to the chassis 12.

[0141] Conclusion

[0142] All parameters, dimensions, materials, and configurations described herein are exemplary only, and actual parameters, dimensions, materials, and / or configurations will depend on the specific application or applications for which the teachings of the present invention are used. It should be understood that the foregoing embodiments are presented primarily by way of example, and that within the scope of the appended claims and their equivalents, embodiments of the present invention may be practiced in a manner other than as specifically described and claimed. Inventive embodiments of the present disclosure relate to each individual feature, system, article, material, kit, and / or method described herein.

[0143] In addition, any combination of two or more such features, systems, articles, materials, kits and / or methods is included within the scope of the invention disclosed herein, as long as these features, systems, articles, materials, kits and / or methods are not mutually inconsistent. Other substitutions, modifications, changes and deletions may also be made to the design, working conditions and arrangement of the corresponding elements of the exemplary embodiments without departing from the scope of the present disclosure. The use of numerical ranges does not exclude equivalents beyond the range that perform the same function in the same manner to produce the same results.

[0144] Moreover, various inventive concepts may be embodied as one or more methods, of which at least one example has been provided. In some cases, the actions performed as part of a method may be sequenced in different ways. Thus, in some inventive embodiments, the individual actions of a given method may be performed in an order different from the order specifically shown, which may include performing some actions simultaneously (even if such actions are shown as sequential actions in illustrative embodiments).

[0145] All publications, patent applications, patents, and other references mentioned herein are incorporated by reference in their entirety.

[0146] All definitions, as defined and used herein, should be understood to have the same meaning as dictionary definitions, definitions in documents incorporated by reference, and / or ordinary meanings of the defined terms.

[0147] Unless expressly indicated to the contrary, the indefinite articles "a" and "an" as used herein in the specification and claims should be understood to mean "at least one".

[0148] As used herein in the specification and claims, the phrase "and / or" shall be understood to mean "one or both" of the elements so combined, i.e., the elements exist conjointly in some cases and severally in other cases. Multiple elements listed in "and / or" should be construed in the same manner, i.e., "one or more" of the elements so combined. There may optionally be other elements in addition to those specifically identified by the "and / or" clause, whether or not those specifically identified elements are relevant. Thus, as a non-limiting example, a reference to "A and / or B" when used in conjunction with open-ended language such as "comprising" can, in one embodiment, refer to only A (optionally including elements other than B); in another embodiment, can refer to only B (optionally including elements other than A); in yet another embodiment, can refer to both A and B (optionally including other elements); and so on.

[0149] As used herein in the specification and claims, "or" shall be understood to have the same meaning as "and / or" as defined above. For example, when separating items in a list, "or" or "and / or" shall be interpreted as inclusive, i.e., including at least one, but also including more than one of the multiple elements or the listed elements, as well as optionally including other unlisted items. Only expressly stated contrary terms, such as "only one... " or "exactly one... ", or when used in a claim, "consisting of" will refer to including only one of the multiple elements or the listed elements. Generally, the term "or" as used herein when preceded by an exclusive term such as "either", "one of", "only one of" or "exactly one of" shall be interpreted as indicating an exclusive alternative only (i.e., "one or the other but not both"). When used in a claim, "consisting essentially of" shall have the ordinary meaning as used in the field of patent law.

[0150] As used herein in the specification and claims, when referring to a list of one or more elements, the phrase "at least one" shall be understood to mean at least one element selected from any one or more of the listed elements, but not necessarily including at least one of each and every particular element listed in the listed elements, and not excluding any combinations of elements in the listed elements. This definition also allows for the optional presence of additional elements, whether related or unrelated to those specifically identified in the list of elements referred to by the phrase "at least one". Thus, as a non-limiting example, "at least one of A and B" (or equivalently, "at least one of A or B", or equivalently "at least one of A and / or B") can, in one embodiment, mean at least one, optionally including more than one A, without B (and optionally including elements other than B); in another embodiment, it can mean at least one, optionally including more than one B, without A (and optionally including elements other than A); in yet another embodiment, it can mean at least one, optionally including more than one A, and at least one, optionally including more than one B (and optionally including other elements); and so on.

[0151] In the claims, as well as in the specification above, all transitional phrases such as "comprising", "including", "carrying", "having", "containing", "involving", "holding", "consisting of", and the like are to be understood to be open-ended, i.e., meaning including but not limited to. As set forth in section 2111.03 of the United States Patent and Trademark Office's Manual of Patent Examining Procedure, only the transitional phrases "consisting of" and "consisting essentially of" should be closed or semi-closed transitional phrases, respectively.

Claims

1. An actuator assembly for coupling a wheel of a vehicle to the chassis of the vehicle, the actuator assembly comprising: A support structure configured to be coupled to the chassis via a suspension; A motor including: A main shaft rotatably coupled to the support structure and configured to be mounted to the wheel; A rotor mounted to the main shaft; A first stator rotatably coupled to the main shaft; and A second stator rotatably coupled to the main shaft; A transmission directly coupled to the first stator, the second stator, and the support structure to constrain rotational movement of the first stator and the second stator; and A link directly coupled to the transmission and configured to be directly coupled to the chassis, wherein the support structure, the motor, and the transmission are configured to be translatable relative to the chassis together.

2. The actuator assembly according to claim 1, wherein the transmission comprises: A first link directly coupled to the first stator; A second link directly coupled to the second stator; And A joint housing slidably coupled to the support structure and directly coupled to the first link, the second link, and the link.

3. The actuator assembly according to claim 1, wherein the transmission comprises: A first link directly coupled to the first stator; A second link directly coupled to the second stator; And A rocker arm rotatably coupled to the support structure and directly coupled to the first link, the second link, and the link.

4. The actuator assembly according to claim 1, wherein the transmission comprises: A torsion bar coupled to the support structure and the link, the torsion bar configured to twist about a first axis.

5. The actuator assembly according to claim 4, wherein the main shaft defines a second axis parallel to the first axis.

6. The actuator assembly according to claim 1, wherein the transmission couples the first stator and the second stator together such that rotation of the first stator causes the second stator to rotate with a 1:1 motion ratio.

7. The actuator assembly according to claim 1, wherein: The main shaft defines a rotational axis; The transmission comprises: A first link directly coupled to the first stator at a first point offset from the rotational axis by a first radial distance, the first link having a first length; and A second link directly coupled to the second stator at a second point offset from the rotational axis by a second radial distance, the second link having a second length; and At least one of the following is satisfied: The first length and the second length are different; or The first radial distance and the second radial distance are different.

8. The actuator assembly according to claim 1, wherein: When the first stator applies a first torque to the rotor, the first torque causes a first reaction torque to be applied to the first stator; When the second stator applies a second torque to the rotor, the second torque causes a second reaction torque to be applied to the second stator; And When the first reaction torque and the second reaction torque generate an excess force, the excess force is divided into a first force component and a second force component such that the first force component is configured to be transmitted to the chassis via the link and the second force component is configured to be transmitted to the chassis via the support structure and the suspension.

9. A vehicle, the vehicle comprising: a chassis; wheels; a suspension for facilitating movement of the wheels relative to the chassis; and the actuator assembly according to claim 1, wherein: the support structure is directly coupled to the suspension; the spindle is mounted to the wheel; and the link is directly coupled to the chassis.

10. The vehicle according to claim 9, wherein the suspension comprises: a strut having a first end fixedly and slidably coupled to the support structure and a second end fixedly coupled to the chassis; and a lower control arm coupled to the support structure and the chassis.

11. The vehicle according to claim 9, wherein the suspension comprises a MacPherson strut suspension.

12. The vehicle according to claim 9, wherein the suspension comprises: a tie rod coupled to the support structure and the chassis.

13. An actuator assembly for coupling a wheel of a vehicle to the chassis of the vehicle, the actuator assembly comprising: a support structure configured to be coupled to the chassis via a suspension; a motor comprising: a spindle rotatably coupled to the support structure and configured to be mounted to the wheel; a rotor mounted to the spindle; a first stator rotatably coupled to the spindle; and a second stator rotatably coupled to the spindle; a transmission directly coupled to the first stator, the second stator, and the support structure to constrain rotational movement of the first stator and the second stator, the transmission comprising: a first link directly coupled to the first stator; a second link directly coupled to the second stator; a torsion bar coupled to the first link, the second link, and the support structure; and a rocker arm rotatably coupled to the support structure, the first link, and the second link; and a link directly coupled to the rocker arm and configured to be directly coupled to the chassis, wherein the support structure, the motor, and the transmission are configured to be translatable relative to the chassis together.

14. The actuator assembly according to claim 13, wherein: the spindle defines a first axis; and the torsion bar is configured to twist about a second axis parallel to the first axis.

15. The actuator assembly according to claim 13, wherein: the spindle defines a rotational axis; the first link is directly coupled to the first stator at a first point offset from the rotational axis by a first radial distance, the first link having a first length; and the second link is directly coupled to the second stator at a second point offset from the rotational axis by a second radial distance, the second link having a second length; and at least one of the following is satisfied: the first length and the second length are different; or The first radial distance and the second radial distance are different.

16. A vehicle, the vehicle comprising: A chassis; Wheels; A suspension for facilitating movement of the wheels relative to the chassis; And The actuator assembly according to claim 13, wherein: The support structure is directly coupled to the suspension; The main shaft is mounted to the wheel; and The link is directly coupled to the chassis.

17. The vehicle according to claim 16, wherein the suspension comprises: A strut having a first end fixedly and slidably coupled to the support structure and a second end fixedly coupled to the chassis; And A lower control arm coupled to the support structure and the chassis.

18. The vehicle according to claim 16, wherein the suspension comprises: A tie rod coupled to the support structure and the chassis.

19. An actuator assembly for coupling a wheel of a vehicle to the chassis of the vehicle, the actuator assembly comprising: A support structure configured to be coupled to the chassis via a suspension; A motor, the motor comprising: A main shaft rotatably coupled to the support structure and configured to be mounted to the wheel, the main shaft defining a rotational axis; A rotor mounted to the main shaft; A first stator rotatably coupled to the main shaft; and A second stator rotatably coupled to the main shaft; A transmission directly coupled to the first stator, the second stator, and the support structure to constrain rotational movement of the first stator and the second stator, the transmission comprising: A first link directly coupled to the first stator at a first point offset from the rotational axis by a first radial distance, the first link having a first length; A second link directly coupled to the second stator at a second point offset from the rotational axis by a second radial distance, the second link having a second length; and A torsion bar coupled to the first link, the second link, and the support structure; and A link directly coupled to the transmission and configured to be directly coupled to the chassis, wherein: The support structure, the motor, and the transmission are configured to be translatable relative to the chassis together; and At least one of the following is satisfied: The first length and the second length are different; or The first radial distance and the second radial distance are different.

20. A vehicle, the vehicle comprising: A chassis; Wheels; A suspension for facilitating movement of the wheels relative to the chassis; And The actuator assembly according to claim 19, wherein: The support structure is directly coupled to the suspension; The main shaft is mounted to the wheel; and The link is directly coupled to the chassis.

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