Electromechanical actuator cartridge

Abstract

Electromechanical actuator cartridge comprising: an actuating arrangement comprising: a sleeve containing: a switching device groove extending at least partially circumferentially around the sleeve and configured to axially accommodate an extension of a switching device; and several gaps extending from an axial side of the sleeve to the switching device groove; and an actuator motor rotaryally coupled to the actuating arrangement.

Description

TECHNICAL FIELDThe present description relates generally to an electromechanical actuator cartridge for a switching device. More specifically, the present disclosure relates to the electromechanical actuator cartridge having switching device grooves intersecting a switching device groove for efficient assembly with the switching device groove.BACKGROUND AND SUMMARYCertain vehicles are equipped with transmissions that provide the powertrain with speed-to-torque conversion. Multi-speed transmissions offer the possibility of actively adapting the transmission ratio. To allow a change in the transmission ratio, some transmissions are equipped with shift forks that allow the engagement and disengagement of the gears.JP 2013 / 234703 A to Uemoto discloses an electric actuator for a transmission clutch. The Uemoto electric actuator includes an electric motor that axially displaces a shift lever that moves a shift fork that engages a clutch sleeve.The inventors have recognized several potential disadvantages of Uemotos actuator and other prior transmission actuators. For example, the system of Uemoto may require complex installation steps. For example, the assembly steps of the system may directly relate to a main housing in the transmission system to install the actuator. The inventors have recognized that it is necessary to mount an actuator assembly separately from the main transmission system and then install the actuator assembly into the main transmission system using a drop-in mounting process.The above-described problems can be solved by an electromechanical actuator cartridge. The electromechanical actuator cartridge includes an actuation assembly having a sleeve. The sleeve includes a shifter groove extending circumferentially around the sleeve and configured to axially receive a shifter groove, and a plurality of gaps extending from an axial side of the sleeve to the shifter groove. The actuator cartridge also includes an actuator motor rotationally coupled to the actuator assembly. This electromechanical actuator cartridge makes it possible to mount the cartridge before it is installed in a transmission and to check its function (e.g. by end-of-line tests), so that the actuator cartridge can be installed efficiently at a later point in time and the production process of the transmission is simplified.In another example, the electromechanical actuator cartridge may further include an installation brake configured to prevent rotation of the screw shaft and is removably coupled to a cartridge housing. This installation brake makes it possible to keep the sleeve in a desired axial position during the installation of the cartridge and then to remove it from the cartridge if desired. In this way, the efficiency of the transmission production can be further increased.In one example, the sleeve may be connected to or integrated with a nut that is threaded onto a rotationally coupled screw shaft of the actuator motor. In this way, the motor can be used for efficient axial displacement of the sleeve.It should be understood that the summary above is provided to introduce in simplified form a selection of concepts that are further discussed in the detailed description. It is not intended to identify key or essential features of the claimed subject matter, the scope of which is clearly defined by the claims that follow the detailed description. Moreover, the claimed subject matter is not limited to implementations that address the shortcomings recited above or in other parts of this disclosure.BRIEF DESCRIPTION OF THE FIGURESFIG. 1 shows an example of a vehicle system having a transmission that includes an actuator and a shift fork. FIGS. 2 and 3 show an example of an electromechanical actuator cartridge for a transmission. FIG. 4 shows a cross-sectional view of the actuator cartridge of FIG. 2. Fig. 5 shows a screw shaft in the actuator cartridge of Fig. 2. FIG. 6 shows a shaft of an actuator motor configured to cooperate with the screw shaft of FIG. 5. FIG. 7 is a cross-sectional view of a screw shaft and a drain channel in the actuator cartridge of FIG. 2. FIG. 8 shows an installation brake that cooperates with a screw shaft from FIG. 7. FIG. 9 shows the actuator cartridge of FIG. 2 before being installed in a transmission housing. FIG. 10 shows a gear housing and a shift fork arranged to engage with a sleeve of the actuator cartridge of FIG. 2. FIG. 11 shows the actuator cartridge of FIG. 2 after installation in a transmission housing. FIG. 12 is a flow chart showing a method of installing an actuator cartridge in a gear case FIGS. 13A and 13B show a shift fork and shift fork pads.DETAILED DESCRIPTIONThe following description relates to systems for a vehicle as shown in FIG. 1. The vehicle includes a system with an electromechanical actuator cartridge as shown in FIGS. 2-4. The electromechanical actuator cartridge may include an actuator motor that may trigger rotation of a screw shaft of an actuator assembly. The actuator motor can engage the screw shaft via a slot and a shaft extension, as shown in FIGS. 5 and 6, respectively. Additionally, a drain line shown in FIG. 7 may be positioned near the interface between the actuator motor and the actuation assembly to reduce the risk of flooding the actuator motor with lubricant from the actuation assembly. Rotation of the screw shaft may result in a nut and sleeve of the actuator assembly sliding axially along the screw shaft when there is no installation brake. The installation brake shown in FIG. 8 may be included in the electromechanical actuator cartridge during installation of the electromechanical actuator cartridge into a gear housing, as shown in FIG. 9. As shown in FIG. 10, the installation of the electromechanical actuator cartridge into the transmission housing includes aligning the gaps of the sleeve of the actuation assembly with the shift fork pads of a shift fork. The installation brake may be removed from the electromechanical actuator cartridge and fasteners may be attached to the electromechanical actuator cartridge once it is installed in the gear housing as shown in FIG. 11. A method for installing an electromechanical actuator cartridge into the gear housing is illustrated in FIG. 12.Figs. 1-11 and 13A-13B include a coordinate system for orienting the views. In one example, the y-axis may be a vertical axis (e.g., parallel to a gravitational axis), the x-axis may be a longitudinal axis (e.g., a horizontal axis), and / or the z-axis may be a lateral axis. However, in other examples, the axes may have other orientations.FIG. 1 shows a schematic illustration of a vehicle 100 having a powertrain 102, which may include an engine 104 and a system 106. In the illustrated example, the system is a transmission. In other examples, however, it can also be a multi-start axis or a transaxle. In some examples, the prime mover 104 may be an electric motor (a traction motor). In such an example, the electric motor may be electrically connected to an energy storage device 108 (e.g., one or more traction batteries, capacitors, fuel cells, combinations thereof, and the like). Moreover, in the example of the electric motor, the motor may be configured to operate as a generator under certain conditions, for example, to provide electrical power to charge the energy storage device 108. In other examples, the prime mover 104 may be an internal combustion engine. For example, the vehicle 100 may be a hybrid vehicle, a pure electric vehicle, or an internal combustion engine vehicle.In the illustrated example, the system 106 provides mechanical power to a differential 110 of an axle assembly 112. However, it should be appreciated that the system 106 may additionally or alternatively provide mechanical power to the other axle assembly 114 of the vehicle 100. In still other examples, the transmission may be incorporated into one of the axles to form an electric axle assembly. In the example of the electric axle, in some cases, an engine may provide mechanical power to the other axle. However, a variety of powertrain architectures may be used in various embodiments.The system 106 (e.g., a transmission) may be configured to receive torque from the prime mover 104 via a shaft (e.g., a driveshaft) and / or other suitable mechanical component. The system 106 comprises an electromechanical cartridge drive 116. The electromechanical cassette actuator 116 is a cassette-type actuator for adjusting a transmission shift device 118. The shift device 118 may be a shift fork in some cases. The shifting device 118 switches on and off a clutch 120 that engages and disengages a gear 122. In this way, the operating gear ratio of the transmission may be adjusted. The electromechanical cassette drive 116, the shift device 118, the clutch 120 and the transmission 122 are schematically illustrated in FIG. 1. However, these components have greater structural complexity, as discussed in more detail in FIGS. 2-11 and 13A-13B.Although a clutch and associated actuation arrangement are schematically illustrated in FIG. 1, the system 106 and the other transmissions described herein may include multiple clutches with associated actuation arrangements that may have a similar or different architecture to the clutch and actuation arrangement, the architecture of which is discussed herein with reference to FIGS. 2-11 and 13A-13B. Therefore, the system 106 may be a multi-speed transmission having multiple selectable individual gear ratios.The system 106 may provide torque to the differential 110. Output torque may be mitigated based on selective adjustments to gear engagement at system 106 to meet desired vehicle operation. The torque of the system 106 may drive the rotation of the differential 110, which in turn may drive the rotation of the axle shafts 124 rotationally coupled to the vehicle wheels 126. In the example shown, the system 106 is spaced from the differential 110 and the axle assembly 112. However, it should be appreciated that in alternative examples, the transmission may be incorporated into the axle assembly 112. In such an example, the axle assembly 112 may be configured as an electric axle into which the transmission (e.g., a manual transmission) and a traction motor are installed. Electric axles can be efficiently installed in a plurality of vehicle platforms.A controller 152 may form part of a control system 150. The controller 152 may include a microcomputer having components such as a processor 154 (e.g., a microprocessor unit), input / output ports, an electronic storage medium 156 for executable programs and calibration values (e.g., read-only memory chip, read-only memory, diagnostic memory, data bus, and the like). The storage medium may be programmed with computer readable data representing instructions executable by the processor for performing the methods and control techniques described herein, as well as other variants that are expected but not expressly listed. Thus, the control techniques, methods, and the like described herein may be stored as instructions in non-transitory memory.As shown, the control system 150 receives information from sensors 158 and sends control signals to actuators 160. The sensors 158 may include, for example, sensors such as a battery charge sensor, a clutch position sensor, etc.The controller 152 may receive input data from the sensors, process the input data via a processor, and in response to the processed input data, trigger one or more actuators based on instructions or code programmed therein corresponding to one or more routines. In some examples, the controller 152 may include commands that send a command signal to the actuator 116 of the shifting device 118 to engage or disengage the clutch 120 to change the transmission operating gear ratio.FIGS. 2 and 3 show an electromechanical actuator cartridge 200. The electromechanical actuator cartridge 200 may be incorporated into a gear box, such as the system 106 shown in FIG. 1 or another suitable gear box. Thus, the electromechanical actuator cartridge 200 is configured to actuate a shift device 201 (e.g., a shift fork) when installed, which in turn actuates a clutch 203 (e.g., a dog clutch or a synchronizer). These devices are schematically shown in Figures 2-3. In practice, however, these devices have greater structural complexity. The mechanical interaction between the switching device and the actuator cartridge 200 is explained in more detail in FIG. 9.The electromechanical actuator cartridge 200 includes an actuator motor 202 and an actuator assembly 204. The actuator motor 202 is rotationally coupled to the actuation assembly 204. In addition, the actuating assembly 204 converts the rotational movement into an axial displacement of the switching device 201.In some examples, the actuator motor 202 may be a brushless direct current (DC) motor. However, the actuator motor 202 may take a variety of forms. The actuator motor 202 may be, for example, an alternating current (AC) motor. In the example shown, the actuator motor 202 has an electrical interface 205. The electrical interface 205 allows the motor to receive control commands and electrical energy for its operation. It will also be appreciated that the actuator motor 202 includes a rotor and a stator that cooperate electromagnetically.The actuation assembly 204 includes a sleeve 206. The sleeve 206 includes a pair of shifter grooves 208 that extend at least partially circumferentially around the sleeve 206. The two shifter grooves 208 are disposed along an outer surface 210 of the sleeve 206. In the illustrated example, the shifter grooves 208 each extend partially circumferentially around the exterior of the sleeve 206. However, in other embodiments, a shifter groove may extend circumferentially around the entire sleeve 206 or most of the sleeve (e.g., 0o-270o, in one example of application).The two shift device grooves 208 are profiled to axially engage an extension of the shift device 201, such as a cushion of a shift fork. The axial limitation of the selector extensions allows the sleeve to axially displace the selector in opposite axial directions to engage and disengage the clutch 203.The sleeve 206 further includes gaps 212 (e.g., a pair of gaps), each of the gaps extending from an axial side 213 of the sleeve to one of the shifter grooves 208. The gaps 212 may extend in a direction parallel to the x-axis. Thus, the gaps 212 may provide a path for extending the shifter groove to be inserted into the shifter grooves during installation of the actuator cartridge. In this way, the actuator cartridge can be efficiently connected to the switching device. For example, shift fork pads may be positioned in the gaps 212 and then slid axially into the grooves 208. Subsequently, the actuator cartridge 200 or the switching device 201 may be rotated (about the x-axis) to bring the switching device extensions out of alignment with the grooves 208. In this way, the switching pads may be positioned in one of the switching device grooves 208 such that the sleeve may axially displace the switching device in opposite axial directions.The grooves 208 may in some cases be defined by opposing walls 270 and 272 and an end wall 274. Additionally, the gaps 212 may be bounded by opposing walls 276 and 278. Moreover, the wall 278 may extend into the groove and form part of the boundary of the groove. In this way, the sleeve may be profiled to efficiently engage a shift fork pad or other suitable component of the shift device. However, in other examples, other groove and / or gap contours may be used.The sleeve 206 may be coupled or connected to a nut 214. When the sleeve and the nut are separate components, the sleeve 206 may be circumferentially disposed about a body 400 of the nut 214 (see FIG. 4 ). In such an example, the sleeve may be press fit to the nut, engaged with the nut, fastened to the nut via fasteners (e.g., bolts, pins, and the like), and / or welded to the nut. Thus, an inner circumferential surface of the sleeve 206 may be in surface contact with or otherwise contact the body of the nut 214.The nut 214 may include a head 216. The head 216 may include one or more apertures 218, which may be configured to receive one or more fasteners 220. The fasteners 220 may extend through the head 216 of the nut 214 and into the sleeve 206. In this way, the fasteners 220 may connect the sleeve 206 to the nut 214. However, other suitable fastening techniques are also possible, as already mentioned.The nut 214 is screwed to a screw shaft 222 in the embodiment shown in FIGS. 2-3. Thus, the nut 214 has an internal thread 401, and the screw shaft 222 has an external thread 403, as shown in FIG. 4. Threads 401 on screw shaft 222 may be located on a portion of the shaft between a bearing 402 and a bearing 406, which will be discussed in more detail herein. Portions of the screw shaft 222 that are outside of the thread may have a smooth surface in some cases.Continuing with FIGS. 2-3, in the illustrated example, the actuation assembly 204 also includes a sleeve guide 224. However, other configurations of the actuation arrangement are also possible. In the example shown, the sleeve guide 224 is connected to the sleeve 206 and prevents rotation of the sleeve and nut 214 during rotation of the screw shaft 222 by the actuator motor 202. For example, a protrusion 405 (e.g., a rail) and / or a planar surface of the sleeve 206 may cooperate with the sleeve guide 224 as shown in FIG. 4 such that the sleeve guide prevents rotational movement of the sleeve 206. Therefore, the nut 214 and the sleeve 206 axially translate along the screw shaft 222 as the actuator motor 202 rotates the screw shaft. As shown in FIGS. 2-3, the sleeve guide 224 may be coupled to a bridge 226 of a cartridge housing 234 of the actuation assembly 204. In the example shown, the bridge 226 extends between a bearing interface portion 228 and a body 230 of the cartridge housing 234.The bridge 226 allows easier access to the gaps 212 in the sleeve 206. Specifically, the bridge 226 may span an arc (measured with respect to the axis of rotation 251 of the screw shaft 222). The arc may range from 0o-30o, 0o-20o, or 0o-15o, depending upon the application. The bridge allows for an open space around the cartridge housing 234, such that the actuator cartridge 200 can be quickly and easily attached to the shift device 201 (e.g., the shift fork), which facilitates assembly and disassembly of the transmission. The opening is located between the bearing interface portion 228 and the housing of the cartridge housing 230.The actuator cartridge 200 may also include a screw shaft mount 232 that may have a flange 236 extending radially outward. The screw shaft support 232 will be discussed in more detail herein with reference to FIG. 4.In the illustrated example, the cartridge housing 234 includes attachment interfaces 248 that extend radially away from the cartridge housing (e.g., away from the x-axis). However, other cartridge housing configurations are also possible.Each of the attachment interfaces 248 includes one of a plurality of fastener openings 250. The fastener openings 250 are configured to receive fasteners such as bolts, screws, or other suitable fasteners to connect the electromechanical actuator cartridge 200 to a gear housing 260 schematically depicted in FIG. 2. The attachment interfaces may be parallel to the rotation axis 251 of the screw shaft 222.An installation brake 240 may be included (e.g., temporarily included) in the electromechanical actuator cartridge 200. Thus, the installation brake can be used when installing the actuator cartridge and replaced by a plug when using the cartridge. The installation brake 240 prevents the rotation of the screw shaft 222 during installation of the electromechanical actuator cartridge 200. The installation brake 240 includes a head 242 located outside the cartridge housing 234 and a brake pin located in a brake pin opening. The installation brake 240 will be discussed in more detail in connection with FIG. 8. The sectional plane A-A' shows the cross-sectional view shown in Figs. 5 and 8. The sectional plane B-B' shows the cross-sectional view shown in Figs. 4 and 7.FIG. 4 shows a cross-sectional view of the electromechanical actuator cartridge 200 including the actuator assembly 204 and the actuator motor 202. The actuator motor 202 and the actuation assembly 204 are arranged such that the actuator motor and the screw shaft 222 are arranged coaxially with each other.In the illustrated example, the bearing interface portion 228 includes the bearing 402 coupled to a distal end 404 of the screw shaft 222. An inner ring of the bearing 402 may be connected to the distal end 404 of the screw shaft 222, and an outer ring of the bearing 402 may be connected to the bearing interface portion 228. In the example shown, the screw shaft mount 232 includes the bearing 406 connected to the screw shaft 222 proximate an end of the screw shaft that is opposite the distal end 404. An inner ring of the bearing 406 may be connected to the screw shaft 222, and an outer ring of the bearing 406 may be connected to the screw shaft holder 232.In the example illustrated in FIG. 4, the bearing interface portion 228 includes an opening 407 that allows to reduce (e.g., avoid) the risk of oil or air entrapment. In other words, the openings 407 reduce the risk that oil and air will become trapped in the joint and cause installation problems due to the pressure that arises. The opening 407 (e.g., a cylindrical opening) may be installed in a bore 1013 as shown in FIG. 10. However, in other examples, the opening at the interface of the bearing may be omitted.As shown in FIG. 4, the screw shaft mount 232 may include a drain channel 408 having an opening 409. As shown in FIG. 4, the drain line 408, and more specifically, the opening 409, is located below the screw shaft 222 with respect to the y-axis. Moreover, the discharge passage opening 409 may be axially disposed between the bearing 406 and the actuator motor 202 with respect to the x-axis. The drain line 408 will be described in more detail in connection with FIG. 7.The screw shaft 222 is rotationally coupled to the actuator motor 202 via a slotted interface. For example, the screw shaft 222 may include a slot 410 that engages a rotor shaft 412 of the actuator motor 202. In the example shown, rotor shaft 412 is coaxial with screw shaft 222 to increase the efficiency of the cartridge. However, in another example, the rotor shaft and the screw shaft may be parallel or perpendicular to each other. In such an example, sprockets, additional shafts, chains, and the like may be used to establish the rotational connection between the motor and the screw shaft, but this may reduce the space efficiency of the cartridge. The interface between the screw shaft 222 and the actuator motor 202 will be described in more detail in FIGS. 5 and 6.A bearing 414 may be coupled to the rotor shaft 412. It is understood that another bearing may be mounted on the opposite side of the rotor shaft with respect to the X axis. Additionally, a seal 416 may be disposed between an outer surface 418 of a housing 420 of the actuator motor 202 and an inner surface 422 of the screw shaft mount 232. In this way, the probability of undesired escape of lubricant from the actuator cartridge is reduced. However, in other examples, the seal in the cartridge may be omitted. Additionally, a seal 424 may be disposed between the cartridge housing 234 and the screw shaft mount 232. In this way, the risk of undesired lubricant escape is reduced. The screw shaft mount 232 includes a body 426 disposed within the cartridge housing 234 in the example shown. In addition, the flange 236 of the screw shaft mount 232 extends radially outward from the body 426. The flange 236 makes it possible to fasten the actuator motor 202 and the cartridge housing 234 to the screw shaft holder 232 in a space-saving manner. However, in other embodiments, other profiles may be used for the screw shaft support.Rotation of the screw shaft 222 causes axial displacement of the sleeve 206 in the opposite directions 450 and 452 due to the interaction between the sleeve and the sleeve guide 224. In this way, the rotational movement of the motor causes axial displacement of the sleeve, the shift device, the clutch and so on.It should be appreciated that the actuator cartridge 200 may be assembled as a unit prior to installation into the transmission. More specifically, the actuator motor 202, screw shaft mount 232, cartridge housing 234, screw shaft 222, sleeve 206, nut 214, sleeve guide 224, and / or bearings 402 and 406 may be assembled to form a unit that can be efficiently handled for later installation into the transmission. Thus, the actuator cartridge 200 can be efficiently assembled prior to installation into the transmission, e.g., at a separate location or at a manufacturing facility. At a later time, the cartridge can then be efficiently assembled into the transmission as a monolithic unit, which increases the efficiency of assembly. Moreover, the installation of the actuator cartridge into the gear may require the use of fewer tools than gear boxes in which the components of the cartridge are individually installed into the gear box. Moreover, the use of the actuator cartridge in this manner allows the cartridge to be installed in a limited space transmission architecture if desired. The repair and replacement of the actuator cartridge can also be carried out more efficiently if the cartridge is preassembled as a unit. This increases the attractiveness to customers.Again, FIG. 4 shows the bridge 226 of the cartridge housing 234 extending between the housing bearing interface portion 228 and the housing body 230 (with respect to the x-axis). The sleeve guide 224 is disposed below the bridge 226 with respect to the y-axis, although other positions of the sleeve guide are also possible.The electromechanical actuator cartridge 200 may also include an O-ring 238 disposed in a groove 241 in a flange 243 of the cartridge housing 234. The groove 241 receives the O-ring 238 which serves as a face seal. The mechanical seal may be desirable because no axial force is required to mount the actuator, as in a piston / radial seal, and once axially installed, the actuator can still easily rotate to the mounted position until the fasteners are mounted and tightened.FIG. 5 shows the screw shaft 222 of the electromechanical actuator cartridge 200 in the screw shaft holder 232. The screw shaft 222 includes the slot 410 for connection to the shaft of an actuator motor, such as the actuator motor 202 of FIG. 2, the slot 410 is located at an end 502 of the screw shaft 222 and extends parallel to the x-axis into the screw shaft. Additionally, in some examples, the slot 410 may extend straight across a surface of the end 502, parallel to the y-axis.The screw shaft 222 may include a flat surface portion 504 that is proximate the end 502 of the screw shaft. The screw shaft 222 may include a plurality of planar surfaces 504, in some examples. In other examples, the screw shaft 222 may include one or more apertures or recesses profiled to engage the installation brake to substantially prevent relative movement between the installation brake and the screw shaft. In this way, the efficiency of installation of the actuator cartridge 200 may be increased by reducing the possibility of misalignment between the shift fork pads and the gaps in the sleeve of the actuator cartridge. In the illustrated example, the installation brake 240 includes a brake pin 506 having a distal end 508. In the example shown, the brake bolt 506 extends through the cartridge housing 234 and the screw shaft mount 232 such that the brake bolt distal end 508 can lead from the screw shaft mount to the screw shaft 222. In addition, the distal end 508 may contact one of the planar surfaces 504 of the screw shaft 222 such that the brake bolt 506 and the screw shaft are in planar contact. Thus, the brake bolt 506 can prevent the rotation of the screw shaft 222. In other examples, the distal end of the brake pin may engage an opening or recess in the shaft to prevent rotation thereof.The screw shaft holder 232 may include a recessed portion 510. The end 502 of the screw shaft 222 may be positioned in at least a portion of the opening 512 relative to the x-axis. Through the opening 512 in the recessed area 510, the slot 410 of the screw shaft 222 can be connected to the shaft of an actuator motor. In addition, the recessed portion 510 may be configured to engage with a portion of the actuator motor 202.FIG. 6 shows shaft 412 and a portion 602 of actuator motor 202. The portion 602 may circumferentially surround the shaft 412, and a recessed region 604 may be disposed between the portion 602 and the shaft. In the example shown, portion 602 may be profiled to mate with a recessed area of an actuator assembly, such as recessed area 510 of FIG. 5, however, other motor and cartridge housing profiles are also possible.In the example shown, the shaft 412 extends outwardly from the actuator motor 202. Additionally, the shaft 412 may extend further outward than the portion 602 of the actuator motor 202 relative to the x-axis. The shaft 412 includes an extension 606 that can engage the slot 410 of FIG. 5. Thus, the extension 606 may have a rectangular cross-section with respect to the y-z plane. When connected to the slot 410, the extension 606 of the shaft 412 may transmit torque from the actuator motor 202 to the actuator assembly 204. In this way, the slot 410 and the extension 606 allow the actuator motor 202 to rotate the screw shaft 222 and adjust an axial position of the nut 214 and the sleeve 206 of FIG. 2. However, in other embodiments, other interfaces between the motor shaft and the screw shaft may be used. The shafts may be secured via, for example, flanges, an interference fit, welds, combinations thereof, and the like.FIG. 7 shows a cross-sectional view of the screw shaft 222 and the screw shaft holder 232. In the example shown, the actuator cartridge 200 also includes the drain line 408. The drain line 408 includes an opening 409 and a portion 706. The opening 409 of the drain passage 408 is located in a recess 708 of the screw shaft holder 232 and below the screw shaft 222 with respect to the y-axis. In addition, the opening 409 may be disposed near the actuator motor 202 with respect to the x-axis. The recess 708 forms a space around the screw shaft 222 that is adjacent the end 710 of the screw shaft.In the example shown, portion 706 is disposed at an angle to the y-axis. Specifically, the angle is downward and the portion 706 extends below the bearing 406 such that the oil is directed away from the actuator motor. Portion 706 is fluidly connected to opening 409 such that lubricant from bearing 406 may enter opening 409 and flow through portion 706. The downward angle (relative to the y-axis) of portion 706 allows lubricant to drain by gravity through drain line 408 and away from actuator motor 202. The lubricant (e.g., oil) may be supplied to the bearing 406, e.g., on the outer surface 712 of the bearing. A portion of the lubricant then flows through the bearing 406 to its inner side 714 and into a cavity 716 around the screw shaft 222. Subsequently, the lubricant flows into the opening 409 of the drain line 408 and exits the drain line at the line opening 718 to direct the lubricant away from the actuator motor 202.In this manner, drain line 408 directs lubricant (e.g., lubricant from bearing 406) away from actuator motor 202 and reduces the likelihood of actuator motor flooding with the lubricant.FIG. 8 shows the installation brake 240 in cooperation with the screw shaft 222. The installation brake 240 includes the brake pin 506. The brake bolt 506 extends through the cartridge housing 234 and the screw shaft mount 232 via a brake bolt aperture 802. The distal end 508 of the brake bolt 506 may contact one of the planar surfaces 504 of the screw shaft 222 such that the brake bolt and screw shaft are in planar contact. Thus, the brake bolt 506 prevents the rotation of the screw shaft 222 in the installed state in the actuator cartridge 200. Once the electromechanical actuator cartridge 200 is installed in a gear box, the installation brake 240 may be removed from the actuator cartridge and a plug assembled to the brake bolt aperture 802. In this way, the installation brake 240 may maintain a position of the screw shaft 222 and the sleeve 206 of FIG. 2 during installation of the electromechanical actuator cartridge 200 into a transmission, and the plug may prevent dirt and / or lubricant from passing through the brake bolt aperture 802 during operation of the transmission. The electromechanical actuator cartridge 200 can be more easily installed as an individual part with the installation brake 240, in particular in a transmission with a small installation space.FIG. 9 shows the electromechanical actuator cartridge 200 before being installed in a transmission housing. For better illustration of the electromechanical actuator cartridge 200 and a switching device 902, the transmission housing is omitted. In the example shown, the shifting device 902 is a shifting fork. For example, the shift fork may be designed to translate. In another example, the shift fork may be constructed to rotate about an axis.In the example shown, the shift fork 902 includes shift fork pads 904. The shift fork pads 904 may be disposed in the gaps 212 of the sleeve 206. The shift fork pads 904 may be connected to the recesses 212 such that the shift fork 902 is coupled to the sleeve 206. During installation of the actuator cartridge 200, the cartridge may be axially slid towards the shift fork 902 (e.g., relative to the x-axis) to position the shift fork pads 904 within the gaps 212. As mentioned above, the cartridge may be rotated after axial translation to secure the shift fork pads 904 within the shifter grooves 208. The pads 904 are shown extending through the walls 905 of the shift fork 902 to ensure secure attachment of the pads. However, in other examples, the shift fork pads may also engage recesses in the shift fork that do not extend completely through the walls.Figure 9 again shows the bridge 226, bearing interface portion 228, and body 230 of the cartridge housing 234. The bridge 226 has an outer surface 906 and side surfaces 908. The bearing interface portion 228 includes a recess 910 (e.g., a curved recess) that enables quick insertion of the cradle pads 904 into the gaps 212 in the sleeve 206. However, in other examples, the recess may be omitted and the diameter of the bearing interface portion may be reduced, for example.FIG. 10 shows the shift fork pads 904 of the shift fork 902 aligned with the sleeve 206 of the electromechanical actuator cartridge 200 of FIG. 2. For example, the shift fork pads 904 may be aligned with the gaps 212 as shown in FIG. 9. The shift fork 902 may be housed in a transmission housing 1002. For example, the shift fork 902 may be disposed between a mounting part 1004 of the transmission case 1002 and a housing part 1006 of the transmission case with respect to the x-axis. The attachment portion 1004 may include fastener openings 1008, each sized to receive at least a portion of a fastener (e.g., a bolt, a screw, and the like). Fasteners may pass through the fastener openings 250 of FIG. 2 and into the fastener openings 1008 to connect the electromechanical actuator cartridge 200 of FIG. 2 to the gear housing 1002. A mounting surface 1009 of the mounting part 1004 may be in planar contact with a surface of the cartridge housing 234 when the electromechanical actuator cartridge 200 of FIG. 2 is installed.As shown in FIG. 10, the mounting portion 1004 includes an opening 1010 sized to receive the actuation assembly 204 of the electromechanical actuator cartridge 200 of FIG. 2. For example, when the electromechanical actuator cartridge is installed in the gear housing 1002, the actuating arrangement can be axially displaced through the opening 1010, as shown in FIG. 10. In some examples, the actuator motor may not be passed through the opening 1010 such that the actuator motor and the actuation assembly are disposed on opposite sides of the mounting portion 1004 with respect to the X axis. The installation of the electromechanical actuator cartridge into the gear housing 1002 by axial displacement through the opening 1010 allows a fast installation process and thus increases the efficiency of the installation. Moreover, the electromechanical actuator cartridge 200 can be easily removed from the transmission housing 1002 for repair and replacement by sliding it axially out of the opening without requiring other parts of the transmission to be removed from the vehicle if desired. In this way, gear repair is facilitated.The shift fork pads 904 are disposed 180 degrees apart from a central axis 1012, which may be coaxial with the axis of rotation of the screw shaft when the actuator cartridge is installed in the transmission. However, the pads may have other suitable locations in alternative arrangements.FIG. 13A shows a detailed view of the shift fork 902 with shift fork pads 904. The brackets 1300 may be used to retain the pad in the bores 1302 of the shift fork. The clips 1300 retain the bearing in the fork bore and prevent the fork plates 904 from unintentionally moving in the axial direction during assembly. The clips 1300 may be press clips that are pressed on from the side, or a snap ring. The shift fork 902 may additionally include a raised step 1304 that prevents the pad from rotating. Without the raised step, the bolster may be accidentally touched by the nut during installation of the actuator and, in some cases, rotated out of proper alignment. In this way, the raised step 1304 holds the pad firmly during assembly. FIG. 13B shows a detail view of the shift fork pad 904. The shift fork pad 904 includes a shaft portion 1350 and a pad portion 1352.FIG. 11 shows the electromechanical actuator cartridge 200 after installation in a transmission housing. To better illustrate the electromechanical actuator cartridge 200 and the shift fork 902, the transmission housing is omitted. In addition, fasteners 1102 may connect the electromechanical actuator cartridge 200 to the gear housing. For example, the fasteners 1102 may pass through fastener openings 250 in the cartridge housing 234 and into the gear housing (e.g., into the fastener openings 1008 of FIG. 10 ) to securely secure the electromechanical actuator cartridge 200 to the gear housing. In some examples, the fasteners 1102 may be bolts or screws.In the illustrated example, the shift fork pads 904 are disposed in the shifter grooves 208 of the sleeve 206. Thus, the shift fork 902 may cooperate with the sleeve 206 such that axial movement of the sleeve causes axial movement of the shift fork. For example, during operation of the actuator motor 202, the sleeve 206 and the shift fork 902 may move together parallel to the x-axis. The shift fork pads 904 may be positioned in the shifter grooves 208 by rotation of the electromechanical actuator cartridge 200 about the X axis. Thus, the gaps 212 may be displaced from axial alignment with the shift fork pads 904 and the shift fork pads may be positioned in the shifter grooves 208.Once the electromechanical actuator cartridge 200 is assembled to the shift fork 902, the installation brake 240 of FIG. 10 may be replaced with a plug 1104 shown in FIG. 11. The plug 1104 may be positioned within the brake pin opening 802, and may reduce the likelihood of dirt and / or lubricant entering or exiting the brake pin opening. The plug 1104 is not connected to the screw shaft 222 so that the screw shaft may rotate and the nut 214 and sleeve 206 may move axially along the screw shaft. In the example shown, the O-ring 238 is shown in the electromechanical actuator cartridge 200.FIG. 12 shows a method 1200 for installing an actuator cartridge in a transmission. The method 1200 may be used to install the electromechanical actuator cartridge 200 described above, in one example. However, in other examples, method 1200 may also be used to incorporate other suitable actuator cartridges into a transmission. At least a portion of the method steps can be carried out by the manufacturing personnel. Additionally or alternatively, at least a portion of the method steps may be performed by machines, which may be at least partially automated and include a controller that may store the steps as instructions and execute the instructions as control commands via a processor.At 1202, method 1200 includes inserting an installation brake into an actuator cartridge to cooperate with a screw shaft of an actuator assembly. The actuator cartridge may include an opening configured to receive at least a portion of an installation brake. Further, the opening may extend through a screw shaft mount of the actuator assembly such that the opening extends inward toward the screw shaft from an outer surface of the actuator cartridge. At least a portion of the installation brake may be positioned within the opening. In addition, one end of the installation brake may be connected to a planar surface of the screw shaft. In this way, the installation brake can prevent rotation of the screw shaft because the end of the installation brake comes into contact with the flat surface of the screw shaft. By preventing the rotation of the screw shaft, the position of a sleeve and a nut of the actuator cartridge can be fixed on the screw shaft, and the installation of the actuator cartridge into a gear housing can be facilitated by reducing the number of the freely movable parts of the actuator cartridge.At 1204, method 1200 includes aligning shift fork pads of a shift fork with gaps in the sleeve of the actuation assembly. The gaps of the sleeve may be configured to receive the shift fork pads of a shift fork. For example, the gaps on the sleeve may be positioned such that the shift fork pads may be inserted into the gaps by axial movement of the actuator cartridge and / or the sleeve. The shift fork pads and the gaps of the sleeve may be axially aligned by adjusting a position of the actuator cartridge relative to the shift fork. For example, the shift fork may already be incorporated into a transmission, and the actuator cartridge may be aligned with the shift fork while all or a portion of the actuator cartridge is outside a housing of the transmission.At 1206, method 1200 includes axially displacing the actuator cartridge. Once the gaps of the sleeve are aligned with the shift fork pads, the entire actuator cartridge (e.g., the actuator assembly and actuator motor) may be axially displaced toward the shift fork. The actuator cartridge can be slid until the shift fork pads are positioned in the gaps of the sleeve. In addition, the actuator cartridge can be displaced until it lies wholly or partly in the transmission housing.At 1208, the method 1200 includes rotating the actuator cartridge to move the gaps of the sleeve of the actuation assembly out of radial alignment with the shift fork pads. The actuator cartridge can be rotated about its longitudinal axis relative to the shift fork. Thus, the gaps of the sleeve may be rotated out of alignment with the shift fork pads and the shift fork pads may be positioned with the shifter grooves. The shifter grooves may be configured to prevent axial movement of the sleeve relative to the shift fork pads. For example, any axial movement of the sleeve along the screw shaft of the actuator cartridge may result in axial movement of the shift fork pads in the same direction. In this way, the sleeve may be used to adjust a position of the shift fork pads and thus the actuator cartridge may be used to adjust a clutch of the transmission via the shift fork. By connecting the shift fork pads to the sleeve of the actuator cartridge via an axial displacement and a rotation of the actuator cartridge, the assembly effort of the actuator cartridge is reduced. In addition, the actuator cartridge can remain axially aligned with the shift fork during installation, as a result of which the installation space in the transmission housing required for installing the actuator cartridge is reduced.At 1210, method 1200 includes securing the actuator cartridge to the transmission housing via fasteners. Fastening devices can be used for connecting the actuator cartridge to the gear housing. Thus, a position of the actuator cartridge relative to the transmission housing may be fixed, and the actuator motor may be used to adjust a position of the shift fork via rotation of the screw shaft when the installation brake is removed.At 1212, method 1200 includes replacing the installation brake with a plug. Once the actuator cartridge is installed, it may no longer be desirable to integrate the installation brake into the actuator cartridge. Thus, the installation brake may be removed so that the screw shaft may rotate when actuated by the actuator motor. In addition, an axial position of the nut and the sleeve is adjusted by the rotation of the screw shaft, thereby adjusting a position of the shift fork. The shift fork, in turn, may change a transmission gear ratio via a clutch, e.g., a dog clutch.The invention is further described in the following paragraphs. In one aspect, an electromechanical actuator cartridge is provided that includes an actuator assembly and an actuator motor rotationally coupled to the actuator assembly. The actuation assembly includes a sleeve having a shifter groove extending at least partially circumferentially around the sleeve and configured to axially engage an extension of a shifter groove, and a plurality of gaps extending from an axial side of the sleeve to the shifter groove.In another aspect, a method of installing an electromechanical actuator cartridge is provided, comprising aligning a pair of grooves contained in a sleeve of the electromechanical actuator cartridge with shift fork pads contained in a shift fork of a transmission, axially displacing the electromechanical actuator cartridge to move the shift fork pads through the pair of grooves and into a fork pad groove contained in the sleeve, and rotating the electromechanical actuator cartridge to move the pair of grooves out of radial alignment with the shift fork pads.In another aspect, an electromechanical ball screw actuator cartridge is provided that includes a ball screw assembly having a sleeve coupled to or integrated with a nut threadedly engaged with a screw shaft and a rotationally coupled actuator motor. The sleeve includes a shift fork pad groove extending circumferentially around the sleeve and configured to axially receive shift fork pads, and a pair of gaps extending from an axial side of the sleeve to the shift fork pad groove.In all aspects or combinations of the aspects, the sleeve may be coupled to or integrated with a nut threaded onto a rotationally coupled screw shaft of the actuator motor.In any of the aspects or combinations of the aspects, the electromechanical actuator cartridge may further include an installation brake configured to prevent rotation of the screw shaft and to be removably attached to a cartridge housing.In any of the aspects or combinations of the aspects, the installation brake may include a brake bolt extending through the cartridge housing and a screw shaft bracket, and a distal end contacting a planar surface on the screw shaft.In any of the aspects or combinations of the aspects, the electromechanical actuator cartridge may further include a sleeve guide coupled to a cartridge housing and preventing rotation of the sleeve and the nut during actuation of the electromechanical actuator cartridge.In any of the aspects or combinations of the aspects, the sleeve guide may be connected to a bridge extending between a bearing interface portion of the cartridge housing enclosing a bearing connected to a distal end of the screw shaft and a body of the cartridge housing enclosing a screw shaft mount.In any of the aspects or combinations of the aspects, the actuator motor and the screw shaft may be arranged coaxially with each other.In any of the aspects or combinations of the aspects, the electromechanical actuator cartridge may further include a screw shaft mount at least partially enclosed within a cartridge housing, the screw shaft mount including a drain line configured to receive oil from a bearing coupled to the screw shaft and drain the oil in a direction away from the actuator motor.In any of the aspects or combinations of the aspects, the screw shaft may be rotationally coupled to the actuator motor via a slotted interface.In any of the aspects or combinations of the aspects, the shift device may be a shift fork that includes shift fork pads that mate with the multiple gaps.In any of the aspects or combinations of the aspects, the electromechanical actuator cartridge may further comprise a cartridge housing having a plurality of fastener openings configured to receive a plurality of fasteners configured to be attached to a gear housing.In any of the aspects or combinations of the aspects, the actuator motor may be a brushless DC motor.In any of the aspects or combinations of the aspects, the installation method may further include, prior to aligning the pair of grooves, installing an installation brake in the electromechanical actuator cartridge, the installation brake configured to prevent rotation of a screw shaft in the electromechanical actuator cartridge.In any of the aspects or combinations of the aspects, the ball screw electro-mechanical actuator cartridge may further include an installation brake comprising a brake bolt extending through a brake bolt opening in a cartridge housing, the brake bolt comprising a distal end contacting a planar surface of the screw shaft.In any of the aspects or combinations of the aspects, the ball screw electro-mechanical actuator cartridge may further include a drain line having an inlet opening into an opening around a screw shaft bearing and an outlet guiding the oil away from the actuator motor.In any of the aspects or combinations of the aspects, the ball screw electro-mechanical actuator cartridge may further include a cartridge housing having a brake bolt opening and a plug connected to the brake bolt opening.In any of the aspects or combinations of the aspects, the electromechanical actuator ball screw cartridge may further include a sleeve guide coupled to a cartridge housing and preventing rotation of the sleeve and the nut during actuation of the electromechanical actuator ball screw cartridge, the sleeve guide coupled to a bridge extending between a bearing interface portion of the cartridge housing including a bearing coupled to a distal end of the screw shaft and a body of the cartridge housing including a screw shaft mount.In all aspects or combinations of aspects, the bridge may not circumferentially enclose the gap pair.In another illustration, a ball screw shift fork actuator is provided that includes an actuator unit that includes a motor rotationally coupled to a threaded shaft that is threadably engaged with a nut assembly that includes axial slots that open into a circumferential recess and are profiled to receive shift fork pads.FIGS. 2-11 and 13A-13B are drawn approximately to scale, except for the schematically depicted components. However, in other embodiments, the components may have different relative dimensions.Figures 1-11 and 13A-13B show example configurations with relative positioning of the various components. When these elements are in direct contact with or directly coupled to each other, they may be referred to as being in direct contact or directly coupled, respectively, at least in one example. Similarly, elements depicted adjacent or contiguous to each other may be referred to as adjacent or contiguous to each other, at least in one example. For example, components which are in planar contact with one another can be referred to as being in planar contact. As another example, in at least one case, elements that are separated from each other and between which only a space is located and that do not have other components may be referred to as such. In yet another example, elements depicted above / below each other, on opposite sides or left / right of each other may be referred to as such relative to each other. Further, in at least one example, as shown in the figures, a top element or point of an element may be referred to as a "top" of the component and a bottom element or point of the element may be referred to as a "bottom" of the component. As used herein, the terms top / bottom, top / bottom, top / bottom may refer to a vertical axis of the figures and be used to describe the positioning of elements of the figures relative to each other. Thus, in one example, items displayed above other items are vertically disposed above the other items. As another example, the shapes of the elements depicted in the figures may be referred to as such (e.g., circular, straight, planar, curved, rounded, beveled, angled, or the like). Further, the illustrated elements that intersect one another may be referred to as intersecting elements or intersecting elements in at least one example. Further, for example, an element shown inside another element or outside another element may be referred to as such.The following claims particularly emphasize certain combinations and sub-combinations that are considered novel and non-obvious. These claims may refer to "a" element or "a first" element or the equivalent thereof. Such claims are to be understood to include inclusion of one or more such elements, with two or more such elements not being required or excluded. Other combinations and sub-combinations of the disclosed features, functions, elements, and / or characteristics may be claimed by altering the present claims or by filing novel claims in this or a related application. Such claims, whether broader, narrower, equal or different in scope than the original claims, are also considered to be included within the subject matter of the present disclosure.References included in the specificationThis list of documents cited by the applicant has been produced in an automated manner and is only included for the better information of the reader. The list is not part of the German patent application or utility model application. The DPMA does not take any adhesion for any faults or omissions.Patent Literature citedJP 2013 / 234703 A

[0003]

Claims

An electromechanical actuator cartridge comprising: an actuator assembly comprising: a sleeve including: a shifter groove extending at least partially circumferentially around the sleeve and configured to axially receive an extension of a shifter; and a plurality of gaps extending from an axial side of the sleeve to the shifter groove; and an actuator motor rotationally coupled to the actuator assembly.The electromechanical actuator cartridge of claim 1, wherein the sleeve is coupled to or integrated with a nut threaded onto a screw shaft rotationally coupled to the actuator motor.The electromechanical actuator cartridge of claim 2, further comprising an installation brake configured to: prevent rotation of the screw shaft; and removably attach to a cartridge housing.The electromechanical actuator cartridge of claim 3, wherein: the installation brake comprises a brake bolt extending through the cartridge housing and a screw shaft mount; and the brake bolt has a distal end contacting a planar surface on the screw shaft.The electromechanical actuator cartridge of any of claims 2 to 4, further comprising a sleeve guide coupled to a cartridge housing and preventing rotation of the sleeve and the nut during actuation of the actuator cartridge.The electromechanical actuator cartridge of claim 5, wherein the sleeve guide is coupled to a bridge extending between: a bearing interface portion of the cartridge housing enclosing a bearing coupled to a distal end of the screw shaft; and a body of the cartridge housing enclosing a screw shaft mount.The electromechanical actuator cartridge of any one of claims 2 to 6, wherein the actuator motor and the screw shaft are arranged coaxially with each other.The electromechanical actuator cartridge of any of claims 2 to 7, further comprising: a screw shaft mount at least partially enclosed within a cartridge housing; wherein the screw shaft mount includes a drain line configured to: receive oil from a bearing coupled to the screw shaft; and drain the oil in a direction away from the actuator motor.The electromechanical actuator cartridge of any of claims 2 to 8, wherein the screw shaft is rotationally coupled to the actuator motor via a slotted interface.The electromechanical actuator cartridge of any preceding claim, wherein the switching device is a shift fork that includes shift fork pads that engage the plurality of gaps.The electromechanical actuator cartridge of any preceding claim, further comprising a cartridge housing including a plurality of fastener openings configured to receive a plurality of fasteners configured to be secured to a gear housing.The electromechanical actuator cartridge of any preceding claim, wherein the actuator motor is a brushless direct current (DC) motor.The electromechanical actuator cartridge of any of claims 2 to 12, further comprising: a sleeve guide coupled to a cartridge housing and preventing rotation of the sleeve and nut during actuation of the electromechanical actuator cartridge with ball screw; wherein the sleeve guide is coupled to a bridge extending between: a bearing interface portion of the cartridge housing enclosing a bearing coupled to a distal end of the screw shaft; and a body of the cartridge housing enclosing a screw shaft mount; wherein the bridge does not enclose the gap pair over the entire circumference.The electromechanical actuator cartridge of claim 13, further comprising a drain line having: an inlet opening into an opening around a screw shaft bearing; and an outlet directing the oil away from the actuator motor.The electromechanical actuator cartridge of any preceding claim, further comprising: an installation brake having a brake bolt extending through a brake bolt opening in a cartridge housing, the brake bolt having a distal end contacting a planar surface on the screw shaft; a brake bolt opening in the cartridge housing; and / or a plug fitting into the brake bolt opening.

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