Installation tool for rotary coupling devices, rotary coupling devices and installation tool kits, and methods for installing rotary coupling devices

Abstract

A tool for installing a rotary coupling device on a shaft, a rotary coupling device and installation tool kit, and a method for installing a rotary coupling device are provided. The coupling device includes a hub centered about the axis of the shaft and spaced from the shaft. A bore in the hub is aligned with the bore in the shaft and receives a fastener extending through the hub bore into the shaft bore. The tool includes a body having a shape complementary to the shape of the hub and defining an aperture defining at least one plane, and an arm extending from and away from the body in a direction perpendicular to the axis. At least a portion of the arm is spaced axially from the hub, allowing the tool to access the deeply recessed hub and prevent rotation of the device and shaft when the fastener is turned.

Description

[Technical Field]

[0001] The present invention relates to the installation of a rotary coupling device, such as a clutch or brake, on a shaft. In particular, the present invention relates to an installation tool for the rotary coupling device, a rotary coupling device and installation tool kit, and a method of installing a rotary coupling device whereby the rotary coupling device and shaft are secured against rotational movement when fasteners used to secure the rotary coupling device to the shaft are rotated, thereby maintaining rotational alignment of the rotary coupling device and shaft and allowing the fasteners to be tightened to a desired torque. [Background technology]

[0002] A rotary coupling device, such as a clutch or brake, is used to control the transfer of torque between two objects. The device includes a component, such as a rotor, coupled to one object and a component, such as an armature, coupled to another object. The rotor and armature are selectively engaged to transfer torque between the objects.

[0003] In certain applications, one object may include a shaft to which the rotary coupling device is attached, while the other object may include a pulley supported on the rotary coupling device. Some conventional rotary coupling devices include a pair of spaced-apart hubs, one of which is disposed around the shaft and supports one of the rotor and armature, and the other of which is spaced from the shaft and supports the other of the rotor and armature. The hub spaced from the shaft can be aligned with the shaft using a key located in aligned keyways on the shaft and hub. Fasteners extending through bores in the hub and into corresponding bores in the shaft can then be used to secure the rotary coupling device to the shaft.

[0004] During installation of a rotary coupling device on a shaft, rotation of a fastener used to secure the rotary coupling device to the shaft can cause a corresponding rotation of the shaft. This behavior can result in an inability to tighten the fastener to the desired torque. To prevent shaft rotation, a hub spaced from the shaft is shaped to allow the hub to be gripped by a tool so that the hub and shaft can be held against rotation as the fastener is rotated. However, in some conventional rotary coupling devices, the hub is recessed relatively far into a pulley or another component of the device supported by the hub. In such devices, conventional wrenches and other tools may not be able to reach the hub to grip it and / or interfere with other tools used to rotate the fastener. Installers, therefore, often use time-consuming and / or unsafe methods to engage the hub and prevent it and the shaft from rotating.

[0005] The inventors herein have recognized a need for an installation tool for a rotary coupling device, a rotary coupling device and installation tool kit, and a method for installing a rotary coupling device that minimizes and / or eliminates one or more of the above-identified disadvantages. Summary of the Invention [Means for solving the problem]

[0006] The present invention relates to the installation of a rotary coupling device, such as a clutch or brake, on a shaft. In particular, the present invention relates to an installation tool for the rotary coupling device, a rotary coupling device and installation tool kit, and a method of installing a rotary coupling device whereby the rotary coupling device is secured against rotational movement when fasteners used to secure the rotary coupling device to the shaft are rotated, maintaining rotational alignment of the rotary coupling device and the shaft and allowing the fasteners to be tightened to a desired torque.

[0007] According to one embodiment, a tool for installing a rotary coupling device on a shaft includes a body defining an aperture configured to be positioned about an axis extending through the shaft, a hub of the rotary coupling device, and a fastener extending through the hub and into the shaft. The aperture has a shape complementary to the shape of the hub of the rotary coupling device and defines at least one plane. The tool further includes an arm extending from the body. The arm includes an axially extending portion extending from the body in a direction parallel to the axis and a radially extending portion extending from and away from the axially extending portion in a direction perpendicular to the axis.

[0008] According to another embodiment, a tool for installing a rotary coupling device on a shaft includes a body defining an aperture configured to be positioned about an axis extending through the shaft, a hub of the rotary coupling device, and a fastener extending through the hub and into the shaft. The aperture has a shape complementary to the shape of the hub of the rotary coupling device and defines at least one flat surface. The body has a first axial end configured to receive the hub and a second axial end spaced from the hub. The tool further includes an arm extending from the second axial end of the body in a direction perpendicular to and away from the axis.

[0009] A rotary coupling device and installation tool kit according to one embodiment includes a rotary coupling device configured to attach to a shaft. The rotary coupling device has a hub configured to be disposed about and spaced from the axis of rotation of the shaft. The hub has a bore centered about the axis of rotation, aligned with a corresponding bore in the shaft, and configured to receive a fastener that extends through the bore in the hub and into the bore in the shaft along the axis of rotation. The rotary coupling device and installation tool kit further includes a tool for installing the rotary coupling device on the shaft. The tool includes a body positioned about the axis of rotation and defining an aperture configured to receive the hub of the rotary coupling device. The aperture has a shape complementary to the shape of the hub and defines at least one plane. The tool further includes an arm extending from the body. At least a portion of the arm is configured to be axially spaced from the hub and extends perpendicular to and away from the axis of rotation. The tool is configured to be secured against movement about the axis of rotation when a fastener is rotated into the hub and shaft of the rotary coupling device.

[0010] A method of installing a rotary coupling device according to one embodiment includes attaching a rotary coupling device to a shaft such that a hub of the rotary coupling device is disposed about an axis of rotation of the shaft and spaced apart from the shaft. The hub has a bore centered about the axis of rotation and configured to align with a corresponding bore in the shaft. The method further includes moving a tool along the axis of rotation and into engagement with the hub. The tool includes a body having a shape complementary to the shape of the hub of the rotary coupling device and defining an aperture that defines at least one plane. The tool further includes an arm extending from the body in a direction perpendicular to and away from the axis of rotation. At least a portion of the arm is axially spaced apart from the hub of the rotary coupling device. The method further includes inserting a fastener through the bore in the hub and into the bore of the shaft, and rotating the fastener about the axis of rotation while preventing rotation of the tool about the axis of rotation, thereby preventing rotation of the hub and shaft of the rotary coupling device.

[0011] An installation tool for a rotary coupling device, a rotary coupling device and installation tool kit, and a method for installing a rotary coupling device according to the teachings of the present invention represent improvements over conventional tools, kits, and methods. In particular, the tools, kits, and methods of the present invention allow an installer to prevent rotation of the rotary coupling device hub, and therefore the shaft to which the rotary coupling device is attached, during rotation of a fastener used to secure the rotary coupling device to the shaft, even in devices where the hub is deeply recessed within a pulley or another component of the device. As a result, alignment of the shaft and rotary coupling device can be maintained, and fasteners can be tightened to a desired torque without using the time-consuming and / or unsafe method of engaging the hub and rotating the shaft.

[0012] The foregoing and other aspects, features, details, utilities, and advantages of the present invention will become apparent from reading the following description and claims, and from studying the accompanying drawings.

[0013]

[0014]

[0015]

[0016]

[0017] [Brief explanation of the drawings]

[0018] [Figure 1] 1 is a plan view of a rotary coupling device forming part of one embodiment of a rotary coupling device and installation tool kit in accordance with the disclosed teachings. FIG. [Figure 2] FIG. 2 is a cross-sectional view of the rotary coupling device of FIG. 1. [Figure 3] FIG. 3 is a perspective view of one embodiment of an installation tool for the rotary coupling device of FIGS. [Figure 4] 1-2 and the installation tool of FIG. 3; [Figure 5]FIG. 3 is a perspective view of another embodiment of an installation tool for the rotary coupling device of FIGS. [Figure 6] 1 is a flow chart illustrating one embodiment of a method for installing a rotary coupling device. DETAILED DESCRIPTION OF THE INVENTION

[0019] Referring now to the figures, wherein like reference numerals are used to identify identical components in the various views, FIGS. 1-2 illustrate a rotary coupling device 10 according to one embodiment of the present invention, which forms part of a rotary coupling device and installation tool kit. The device 10 functions as a clutch to selectively transfer torque from an input shaft 12 to an output member 14. The device 10 also functions as a brake to the output member 14 when torque is not being transferred to the output member 14. The device 10 may be provided for use in a riding lawn mower or similar device. However, those skilled in the art will appreciate that the device 10 may be used in a wide variety of applications requiring a clutch or brake. The device 10 may include a spacer or hub 16, a rotor 18, an electromagnet including a field shell 20 and a conductive assembly 22, a brake plate 24, an armature 26, and one or more permanent magnets 28.

[0020] The input shaft 12 provides a torque source for driving the output member 14. The shaft 12 may be made from conventional metals and metal alloys and may be solid or tubular. The shaft 12 is centered about an axis of rotation 30 and is driven by an engine, electric motor, or other conventional power source. The shaft 12 extends through the hub 16 and defines a bore 32 in one axial end configured to receive a fastener (not shown), such as a bolt, used to secure the device 10 to the shaft 12. The bore 32 may include a plurality of threads configured to engage corresponding threads on the fastener. In the illustrated embodiment, the input shaft 12 is inserted into the device 10 on the opposite side of the device 10 from the output member 14. However, it should be understood that the orientation of the input shaft 12 and hub 16 may be reversed such that the input shaft 12 is inserted into the device 10 on the same side as the output member 14.

[0021] The output member 14 transmits torque to a driven device, such as a lawnmower blade, and may include a conventional pulley around which a torque transmission belt is wound and which is coupled to the driven device.

[0022] The hub 16 is provided to support the output member 14 in assembled relationship with the other components of the device 10 and may be made from conventional materials, including powdered metal. The hub 16 may be disposed about and centered on an axis 30. The hub 16 is generally annular in shape and defines a bore 34. The bore 34 may be disposed about and centered on the axis 30, aligned with a bore 32 in the shaft 12, and configured to extend through the bore 34 and into the bore 32 to receive a fastener (not shown) used to secure the clutch 10 to the input shaft 12. One axial end of the hub 16 proximate the input shaft 12 has a generally circular outer surface but defines a keyway configured to receive a key 36 of the rotor 18 that extends into aligned keyways in the input shaft 12 and hub 16. The opposite axial end of the hub 16 distal from the input shaft 12 defines a flange 38. 1, flange 38 has a shape that defines one or more flat surfaces 40 that can be gripped or otherwise engaged by an installation tool, which will be described in more detail below. In the illustrated embodiment, flange 38 defines two diametrically opposed flat surfaces 40 that are separated from one another by a pair of arcuate or curved edges.

[0023] 2, rotor 18 is provided for selective engagement with armature 26 to transmit torque between input shaft 12 and output member 14. Rotor 18 is disposed about axis 30 and is coupled to input shaft 12 for rotation therewith. Rotor 18 may be fabricated from conventional metals and metal alloys and includes a hub 42 and a rotor disc 44.

[0024] Hub 42 is tubular and includes a radially inwardly extending key 36 configured to be received in a keyway in input shaft 12 and hub 16. Proximate each axial end, hub 42 supports bearings 46, 48. At its radially outermost diameter, hub 42 defines an axially extending inner rotor pole 50. Hub 42 further defines an axially extending recess 52 radially inward of pole 50 for purposes described below.

[0025] The disk 44 extends radially outward from the hub 42. The disk 44 is coupled to the hub 42, such as through a press-fit relationship including a plurality of complementary lugs and indentations. As is known in the art, the disk 44 may include multiple radially spaced rows of angularly spaced, banana-shaped slots 54. When the conduction assembly 22 is energized, the slots 54 transfer magnetic flux back and forth between the disk 44 and the armature 26 across an air gap that enables high-torque engagement between the rotor 18 and the armature 26. In the illustrated embodiment, the disk 44 includes three rows of slots 54. However, it should be understood that the number of rows of slots 54, the number of slots 54 within any one row, and the size and shape of the slots 54 may vary. At its outer diameter, the disk 44 defines an axially extending outer rotor pole 56. The pole 56 is radially aligned with and spaced radially outward from the pole 50.

[0026] A field shell 20 is provided to house the conduction assembly 22. The shell 20 also forms part of the magnetic circuit that causes selective engagement of the rotor 18 and the armature 26. The field shell 20 may be made from conventional metals and metal alloys, including steel. The shell 20 is cylindrical and disposed about the shaft 30. Referring to FIG. 1, the shell 20 is secured against rotation, for example, via fasteners 58 extending through slots in the shell 20. Referring again to FIG. 2, the shell 20 is generally U-shaped in cross section and includes radially inner and radially outer annular members 60, 62.

[0027] The inner member 60 is supported by the outer ring of the bearing 46. The member 60 is generally L-shaped in cross section and defines an axially extending inner pole 64. The pole 64 extends into the recess 52 in the hub 42 of the rotor 18 and is disposed radially inward of the inner rotor pole 50.

[0028] The outer member 62 is coupled to and supported by the inner member 60. The outer member 62 defines an end wall 66, an axially extending outer pole 68, and a flange 70. The end wall 66 extends radially outward from the member 60 and defines one or more recesses 72 for purposes described below. The pole 68 is integral with and extends axially from the end wall 66. The pole 68 is disposed radially outward from the poles 56 of the rotor 18. An aperture 74 is formed through the pole 68, and also through the pole 68, through which the leads for the conduction assembly 22 extend outward. The flange 70 is integral with and extends radially outward from the end of the pole 68 opposite the end wall 66. Referring to FIG. 1, the flange 70 extends along at least a portion of the circumference of the pole 68 .

[0029] The conduction assembly 22 is provided to create a magnetic circuit between the rotor 18, spacer 76 (or hub 16 if the input shaft 12 is reversed), field shell 20, and armature 26 to cause movement of the armature 26 into engagement with the rotor 18 and transmission of torque from the input shaft 12 to the output member 14. The conduction assembly 22 is generally annular and is disposed within the field shell 20 about the axis 30. In particular, the assembly 22 is disposed between the inner pole 64 and the outer pole 68 of the shell 20. The assembly 22 includes an electrical conductor 78 and a shell 80.

[0030] The conductors 78 may comprise conventional copper coils, although other known conductors may alternatively be used. The conductors 78 may be electrically connected to a power source (not shown), such as a battery. When the conductors 78 are energized, a magnetic circuit is formed between the rotor 18, the spacer 76 (or the hub 16 if the input shaft 12 is reversed), the field shell 20, and the armature 26. Magnetic flux flows across the air gap from the poles 68 of the shell 20 to the poles 56 of the rotor 18. The magnetic flux then travels back and forth between the disks 44 and the armature 26 across the air gap between them. The magnetic flux then flows along various paths, indicated by arrows in FIG. 2, from the disks 44 to the hub 42 of the rotor 18 and back to the members 60, 62 of the field shell 20.

[0031] A shell 80 is provided to house the conductors 78 and is also used to mount the conductors 78 within the field shell 20. The shell 80 may be molded from conventional plastic. The shell 80 may include integral terminal connections 82, through which the conductors 78 may be electrically connected to a power source. The connections 82 may extend through apertures 74 in the field shell 20. The shell 80 may also define one or more lugs 84 sized to be received in the recesses 72 in the end wall 66 to prevent rotation of the conduction assembly 22. The shell 80 may further include a radially outwardly extending flange 86 disposed adjacent the outer pole 68 of the field shell 20, which may be secured to the field shell 20 at multiple locations.

[0032] The brake plate 24 provides a braking surface for engagement of the armature 26 with the brake output member 14. The brake plate 24 may be made from conventional materials having relatively low magnetic reluctance, including conventional metals and metal alloys, such as steel. The brake plate 24 extends around at least a portion of the circumference of the device 10 and is coupled to the field shell 20. In particular, the brake plate 24 is coupled to the flange 70 of the field shell 20 using one or more fasteners 88. The fasteners 88 may be made from a non-magnetic material or a material having relatively high magnetic reluctance to reduce or eliminate magnetic flux transfer between the brake plate 24 and the field shell 20, thereby facilitating clutch engagement when the conduction assembly 22 is energized. The brake plate 24 may be axially spaced from the flange 70 of the field shell 20 using one or more spacers 90. The spacers 90 may include bores 92 through which the fasteners 88 extend. The spacers 90 may similarly be made from a non-magnetic material or a material having a relatively high magnetic reluctance to reduce or eliminate magnetic flux transfer between the brake plate 24 and the field shell 20. Referring to FIG. 1, the brake plate 24 may include one or more radially extending, arcuately spaced tabs 94 separated by radially extending, arcuately spaced slots 96 formed in the brake plate 24 for purposes described below.

[0033] The armature 26 is provided to transmit braking torque to the output member 14 and selectively transmit driving torque from the rotor 18 to the output member 14. The armature 26 may be fabricated from a variety of conventional metals and metal alloys, including steel. The armature 26 is annular in configuration and disposed about the shaft 30. The armature 26 is axially spaced from the rotor 18 by an air gap. Like the rotor disk 44, the armature 26 includes multiple radially spaced rows of angularly spaced slots 98 to facilitate the transfer of magnetic flux back and forth between the rotor 18 and the armature 26 when the conduction assembly 22 is energized. In the illustrated embodiment, the armature 26 includes two rows of slots 98. The radially inner row of slots 98 in the armature 26 is located between the radially inner row and the radially central row of slots 54 in the rotor disk 44. The radially outer row of slots 98 in the armature 26 is disposed between the radially central row and the radially outer row of slots 54 in the disk 44. It is understood that the number of rows of slots 98 in the armature 26, the number of slots 98 in any one row, and the size and shape of the slots 98 may vary. The armature 26 is coupled to the output member 14. In particular, the armature 26 may be coupled to the output member 14 by a plurality of leaf springs 100. The springs 100 transmit driving and braking torque from the armature 26 to the output member 14 and allow axial movement of the armature 26 relative to the member 14 and toward and away from the rotor disk 42. The springs 100 may be made of stainless steel and are connected at one end to the armature 26 and at the opposite end to the output member 14 using conventional fasteners 102, such as rivets, screws, bolts, or pins.

[0034] The magnets 28 are provided to create a magnetic circuit between the brake plate 24 and the armature 26 to draw the armature 26 into engagement with the brake plate 24 and provide braking torque to the output member 14. The magnets 28 may include neodymium iron boron (Nd—Fe—B) magnets or other known permanent magnets. With reference to FIG. 2 , the magnets 28 may be embedded in a closed bore 104 in the brake plate 24 and positioned so that one face of the magnet 28 is flush with one side (and engagement face) of the brake plate 24. With reference to FIG. 1 , the magnets 28 may be arcuately spaced apart from one another around the circumferential extension of the brake plate 24. A single magnet 28 may be disposed in each tab 94, with the slots 96 functioning to magnetically isolate each magnet 28 from the other magnets 28. Alternatively, two or more magnets 28 may be disposed in a single tab 94 (and / or with the slots 96 removed), provided the magnets 28 are appropriately spaced from one another. Magnets 28 may also be positioned on every other tab 94 to increase the wear surface. It is further understood that the number and location of magnets 28 within brake plate 24 may vary depending on the characteristics of device 10 and associated design requirements. As shown, magnets 28 are positioned such that adjacent magnets have facing poles of the same polarity, thereby forming a parallel magnetic circuit. Alternatively, magnets 28 may be positioned such that adjacent magnets have facing poles of opposite polarity, thereby forming a less efficient series magnetic circuit. Referring again to FIG. 2, magnets 28 are axially aligned with a portion of armature 26 and are oriented so that magnetic flux travels axially through said magnets 28.

[0035] While a particular form of rotary coupling device is shown in Figures 1-2, it is understood that the rotary coupling devices and installation tool kits described herein may vary, and the installation tools described below may be used with a variety of different rotary coupling devices. For example, device 10 may function as both a clutch and a brake, but the device may be configured to function only as a clutch or only as a brake. Device 10 is actuated using electromagnetic power, but device 10 may alternatively be actuated through fluid (pneumatic or hydraulic) power. The kits described herein may include, and the installation tools described herein may be used with, any rotary coupling device that includes a hub, such as hub 16, configured to be attached to a shaft, such as input shaft 12, disposed about and spaced from a rotational axis 30 of shaft 12, and includes a bore 34 centered about the rotational axis 30, aligned with a corresponding bore 32 in shaft 12, and configured to receive a fastener extending along the rotational axis 30, through bore 34 in hub 16, and into bore 32 in shaft 12.

[0036] 3, there is shown one embodiment of a tool 106 for installing a rotary coupling device, such as device 10, on a shaft, such as input shaft 12. Tool 106 includes a body 108 and an arm 110.

[0037] The body 108 is configured to receive the engagement hub 16, specifically to engage the flange 38 of the hub 16. The body 108 may be annular in shape and define an aperture 112 extending therethrough. Referring to FIG. 4, during use, the aperture 112 is configured to be positioned about an axis 30 extending through the input shaft 12, the hub 16, and a fastener (not shown) extending through the bore 34 of the hub 16 and into the bore 32 of the input shaft 12. The aperture 112 has a shape complementary to the shape of the flange 38 of the hub 16 and the aperture 112. Referring again to FIG. 3, the aperture 112 defines at least one flat surface 114. The flat surface 114 is configured to engage a corresponding flat surface 40 of the flange 38 of the hub 16. The flat surfaces 40 and 114 cooperate to prevent relative rotation between the hub 16 and the tool 106. In the illustrated embodiment, the radially outer surface 116 of the body 108 is circular in shape, and the aperture 112 defines a pair of diametrically opposed flat surfaces 114 separated by a curved or arcuate segment 118. However, it should be understood that the shape of the body 108 can vary, so long as the aperture 112 (which may be open or closed) has a shape complementary to the shape of the hub 16 and defines at least one flat surface 114 configured to engage a corresponding flat surface 40 of the hub 16 to prevent relative rotation between the hub 16 and the tool 106.

[0038] Arms 110 extend from body 108 and are provided to allow a user to block or prevent movement of tool 106, and consequently hub 16 and input shaft 12 of device 10, when a fastener passing through bore 34 in hub 16 and entering bore 32 in input shaft 12 is rotated to secure device 10 to input shaft 12. In the illustrated embodiment, arms 110 include an axially extending portion 120 and a radially extending portion 122.

[0039] Portion 120 extends from body 108 in a direction parallel or substantially parallel to axis 30. Referring again to FIG. 4, the configuration of portion 120 of arm 110 allows body 108 of tool 106 to engage hub 16 of device 10 even when hub 16 is deeply recessed within output member 14. Referring again to FIG. 3, portion 120 is generally rectangular in shape, with each side of portion 120 being flat. However, it should be understood that the shape of portion 120 can vary. A first axial end 124 of portion 120 is coupled to body 108, and a second axial end 126 of portion 120 is coupled to portion 122 of arm 110. The width w of portion 120 is constant except for end 124 of portion 120, where the width of portion 120 increases as portion 120 contacts body 108. Similarly, the depth d of portion 120 is constant except at end 124 of portion 120 where the depth of portion 120 decreases when portion 120 contacts body 108 .

[0040] Portion 122 extends radially from portion 120 of arm 110 in a direction perpendicular or substantially perpendicular to and away from axis 30. Portion 122 is also generally rectangular in shape, with each side of portion 122 being flat. One end 128 of portion 122 is joined to end 126 of portion 120 of arm 110. End 128 of portion 122 and end 126 of portion 120 together define a curved transition section 130 having an arc of 90 degrees or approximately 90 degrees. The opposite end 132 of portion 122 defines a semicircular edge and defines an aperture 134 that can be used to secure arm 110 to a fixed structure to prevent movement of tool 106 when tool 106 is not in use and / or to attach tool 106 with a peg or other structure. In the illustrated embodiment, the aperture 134 is square in shape, although it is understood that the shape of the aperture 134 may vary.

[0041] 5, there is shown another embodiment of a tool 136 for installing a rotary coupling device, such as device 10, on a shaft, such as input shaft 12. Tool 136 includes a body 138 and an arm 140.

[0042] The body 138 is configured to receive the engagement hub 16 and, in particular, engage the flange 38 of the hub 16. The body 138 may be annular in shape and defines an aperture 142 extending therethrough. During use, the aperture 142 is configured to be positioned about an axis 30 extending through the input shaft 12, the hub 16, and a fastener (not shown) that extends through the bore 34 of the hub 16 and into the bore 32 of the input shaft 12. The aperture 142 has a shape complementary to the flange 38 of the hub 16, and the aperture 142 defines at least one flat surface 144. The flat surface 144 is configured to engage the flange 38 of a corresponding flat surface 40 of the hub 16. The flat surfaces 40 and 144 cooperate to prevent relative rotation between the hub 16 and the tool 136. In the illustrated embodiment, the aperture 142 defines a pair of diametrically opposed flat sides 144 separated by a curved or arcuate segment 146. Furthermore, the shape of the radially outer surface of the body 138 varies along its axial length. A portion 148 of the body 138 defining a first axial end 150 of the body 138 is configured to engage the hub 16 during use of the tool 136 and has a radially outer surface with a shape corresponding to the shape of the aperture 142. In particular, the portion 148 defines a pair of diametrically opposed flat sides 152 separated by diametrically opposed curved or arcuate sides 154. Another portion 156 of the body 138 defining a second axial end 158 of the body 138 is spaced from the hub 16 during use of the tool 136, is circular in shape, and projects further outward in a full radial direction from the axis 30 relative to the portion 148 of the body 138. Again, it should be understood that the shape of the body 138 can vary, so long as the aperture 142 (which may be open or closed) has a shape complementary to the shape of the hub 16 and defines at least one flat surface 144 configured to engage a corresponding flat surface 40 of the hub 16 to prevent relative rotation between the hub 16 and the tool 136.

[0043] Arm 140 extends from body 138 and is provided to allow a user to block or prevent movement of tool 136, and consequently, hub 16 and input shaft 12 of device 10, when a fastener passing through bore 34 in hub 16 and entering bore 32 in input shaft 12 is rotated to secure device 10 to input shaft 12. Arm 140 extends from end 158 of body 138 in a direction perpendicular or substantially perpendicular to and away from axis 30. Arm 140 is generally rectangular in shape, with each side of arm 140 being flat. One end 160 of arm 140 is coupled to end 158 of body 138. The opposite end 162 of the arm 140 defines a semicircular edge and may define an aperture similar to the aperture 134 in the tool 106 that may be used to secure the arm 140 to a fixed structure to prevent movement of the tool 136 and / or to attach the tool 136 to a peg or other structure when the tool 136 is not in use.

[0044] A method of installing the rotary coupling device 10 will now be described with reference to FIG. 6 . The method may begin with step 164, in which the device 10 is attached to the input shaft 12. If an existing rotary coupling device is being replaced, step 164 may be preceded by steps related to removing the existing rotary coupling device and preparing (e.g., cleaning) the input shaft 12. Step 164 may include several sub-steps 166, 168. In sub-step 166, one of the device 10 and the shaft 12 is rotated about axis 30 relative to the other of the device 10 and the shaft 12 to align the key 36 of the rotor hub 42 with the keyway of the shaft 12. In sub-step 168, one of the device 10 and the shaft 12 is moved along axis 30 relative to the other of the device 10 and the shaft 12 to move the key 36 into the keyway of the shaft 12. Upon completion of sub-step 168, the hub 16 is positioned about the axis of rotation 30 of the shaft 12 and spaced from the shaft 12, with the bore 34 in the hub 16 centered about the axis 30 and aligned with the bore 32 in the shaft 12. The method may continue with step 170 of moving the tool 106 or 136 along the axis 30 and into engagement with the hub 16. In particular, the body 108 of the tool 106 or the body 138 of the tool 136 is moved along the axis 30 until the flange 38 of the hub 16 enters the aperture 112 or 142 of the corresponding tool 106, 136. As a result, the flats 114 or 144 of the corresponding tool 106, 136 engage the flag 40 of the flange 38 of the hub 16. Once the tool 106 or 136 is engaged with the hub 16, the method may continue with step 172 of inserting a fastener through the bore 34 of the hub 16 and into the bore 32 of the shaft 12. The method may then continue with step 174 of rotating the fastener about the axis 30 while simultaneously preventing rotation of the tool 106, 136 about the axis 30 until the fastener is tightened to the desired torque. By preventing rotation of the tool 106 or 136, the interface of the flats 114 or 144 of the tool 106 or 136, respectively, and the flats 40 of the flange 38 of the hub 16 prevents the hub 16 of the device 12 from rotating about the axis 30.Additionally, the interface of the aligned keyway keys 36 in the shaft 12 and hub 16 prevents rotation of the shaft 12 about the axis 30. In this manner, turning and tightening the fastener does not result in rotation of the shaft 12, thereby preventing misalignment of the device 10 and shaft 12 and tightening the fastener to the desired torque.

[0045] An installation tool 106 or 136 for a rotary coupling device 10, a kit of the rotary coupling device 10 and installation tool 106 or 136, and a method of installing a rotary coupling device 10 in accordance with the teachings of the present invention represent improvements over conventional tools, kits, and methods. In particular, the tool 106 or 136, kit of 10, 106, or 136, and method of the present invention allow an installer to prevent rotation of the rotary coupling device hub 16, and therefore the shaft 12 to which the rotary coupling device 10 is attached, during rotation of fasteners used to secure the rotary coupling device 10 to the shaft 12, even in devices where the hub 16 is deeply recessed within the pulley 14 or another component of the device 10. As a result, alignment of the shaft 12 and rotary coupling device 10 can be maintained, and fasteners can be tightened to a desired torque without using time-consuming and / or unsafe methods of engaging the hub and rotating the input shaft 12.

[0046] While the present invention has been illustrated and described with reference to one or more specific embodiments thereof, it will be understood by those skilled in the art that various changes and modifications can be made therein without departing from the spirit and scope of the invention.

Claims

1. A rotary coupling device and installation tool kit comprising: a rotary coupling device configured to attach to a shaft, the rotary coupling device having a hub configured to be disposed about an axis of rotation of the shaft and spaced from the shaft, the hub having a bore centered about the axis of rotation, aligned with a corresponding bore in the shaft, and configured to receive a fastener extending through the bore in the hub and into the bore in the shaft along the axis of rotation; a tool for installing the rotary coupling device on the shaft; wherein the tool comprises: a body positioned about the rotation axis and defining an aperture configured to receive the hub of the rotary coupling device, the aperture having a shape complementary to a shape of the hub and defining at least one plane; an arm extending from the body, at least a portion of the arm configured to be axially spaced from the hub and extending perpendicular to and away from the axis of rotation; wherein the tool is configured to be secured against movement about the axis of rotation when the fastener is rotated into the hub and shaft of the rotary coupling device.

2. The arm an axially extending portion extending from the body in a direction parallel to the axis of rotation; a radially extending portion extending from the axially extending portion in a direction perpendicular to and away from the axis of rotation; 10. The rotary coupling device and installation tool kit of claim 1, comprising:

3. 3. The rotary coupling device and installation tool kit of claim 2, wherein the radially extending portion of the arm includes a first end connected to the axially extending portion of the arm, a second end opposite the first end, and an aperture proximate the second end.

4. 2. The rotary coupling device and installation tool kit of claim 1, wherein the body has a first axial end configured to receive the hub and a second axial end spaced from the hub, and the arm extends from the second axial end of the body.

5. The rotary coupling device and installation tool kit of claim 1 , wherein the body is annular in shape.

6. The rotary coupling device and installation tool kit of claim 1 , wherein the aperture defines first and second diametrically opposed planes.

7. 1. A method of installing a rotary coupling device, comprising: attaching the rotary coupling device to the shaft such that a hub of the rotary coupling device is disposed about an axis of rotation of the shaft and is spaced from the shaft, the hub having a bore centered on the axis of rotation and configured to align with a corresponding bore in the shaft; moving a tool along the axis of rotation and into engagement with the hub, the tool including a body having a shape complementary to a shape of the hub of the rotary coupling device and defining an aperture that defines at least one plane, and an arm extending from the body in a direction perpendicular to and away from the axis of rotation, at least a portion of the arm being axially spaced from the hub of the rotary coupling device; inserting a fastener through the bore in the hub and into the bore in the shaft; rotating the fastener about the axis of rotation while preventing rotation of the tool about the axis of rotation, thereby preventing rotation of the hub and shaft of the rotary coupling device; A method comprising:

8. The arm of the tool an axially extending portion extending from the body in a direction parallel to the axis of rotation; a radially extending portion extending from the axially extending portion in a direction perpendicular to and away from the axis of rotation; The method of claim 7, comprising:

9. 9. The method of claim 8, wherein the radially extending portion of the arm includes a first end connected to the axially extending portion of the arm, a second end opposite the first end, and an aperture proximate the second end.

10. 8. The method of claim 7, wherein the body has a first axial end configured to receive the hub and a second axial end spaced from the hub, and the arms extend from the second axial end of the body.

11. The method of claim 7 , wherein the body is annular in shape.

12. The method of claim 7 , wherein the aperture defines first and second diametrically opposed planes.

13. Attaching the rotary coupling device to the shaft includes: Rotating one of the rotary coupling device and the shaft relative to the other rotary coupling device about the rotation axis to align a key of the rotary coupling device disposed in a keyway of the hub with a keyway of the shaft; moving one of the rotary coupling device and the shaft relative to the other of the rotary coupling device and the shaft along the rotation axis to move the key into the keyway of the shaft; The method of claim 7, comprising:

14. 1. A tool for installing a rotary coupling device on a shaft, comprising: a body defining an aperture configured to be positioned about an axis extending through the shaft; a hub of the rotary coupling device; and a fastener extending through the hub and into the shaft, the aperture having a shape complementary to a shape of the hub of the rotary coupling device and defining at least one plane; an arm extending from the body; and the arm comprises: an axially extending portion extending from the body in a direction parallel to the axis; a radially extending portion extending from the axially extending portion in a direction perpendicular to and away from the axis; Including tools.

15. The tool of claim 14 , wherein the body is annular in shape.

16. The tool of claim 14 , wherein the aperture defines first and second diametrically opposed planes.

17. 15. The tool of claim 14, wherein the radially extending portion of the arm includes a first end connected to the axially extending portion of the arm, a second end opposite the first end, and an aperture proximate the second end.

18. 1. A tool for installing a rotary coupling device on a shaft, comprising: a body defining an aperture configured to be positioned about an axis extending through the shaft; a hub of the rotary coupling device; and a fastener extending through the hub and into the shaft, the aperture having a shape complementary to a shape of the hub of the rotary coupling device and defining at least one flat surface, the body having a first axial end configured to receive the hub and a second axial end spaced from the hub; an arm extending from the second axial end of the body in a direction perpendicular to and away from the axis; Tools including.

19. The tool of claim 18 , wherein the body is annular in shape.

20. The tool of claim 18 , wherein the aperture defines first and second diametrically opposed planes.

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