Electromagnetic coil assembly, related viscous clutch and related method

Abstract

An electromagnetic coil assembly (U,U') for use with a viscous clutch may include a coil housing (44-2) made of a flux-conducting metallic material and having an annular cup shape, a winding (44-1) forming multiple turns within the coil housing, a notch (60) in the coil housing interrupting the flux-conducting metallic material, and a Hall effect sensor (56) aligned in the notch. A viscous clutch assembly (30) and a method for manufacturing the viscous clutch assembly (30) are also disclosed. In addition, a viscous clutch electrical connection and anti-rotation assembly (C) is disclosed.

Description

Technical Field

[0001] The present invention generally relates to an electrical rotation prevention assembly and system for use with an electromagnetic coil suitable for use with a viscous clutch, a viscous clutch assembly including the same, and related manufacturing and use methods thereof.

Background Art

[0002] Clutches are used to drive cooling fans in vehicle applications and in various other situations. Various dry friction clutches and fluid friction viscous clutches are available for these purposes. Viscous clutches offer advantages by enabling electrical control in a continuously variable manner.

[0003] Viscous clutches are often actuated electromagnetically. An electromagnetic coil (or solenoid) is used to actuate a mechanical valve system that regulates the volume of shear fluid (such as silicone oil) present in the working chamber, thereby controllably changing the output speed relative to the input speed of the clutch. In this way, the viscous clutch allows for continuously variable control of the clutch slip speed, so that whenever there is torque input to the clutch, the output speed can be selectively controlled within a range of approximately 0-100% of the input speed. The electromagnetic coil is electrically connected to an external controller by a wire led to a connector, and in some applications further includes a Hall effect sensor for measuring the output speed of the clutch. Some clutches are mounted on a non-rotating journal bracket, and in some applications, this provides a non-rotating mounting position for the electromagnetic coil. In clutches with a "live" (rotatable) center shaft, and / or other prior art systems for clutches mounted directly to the drive shaft of an engine or motor, anti-rotation features such as tethers are used to hold the wire and electromagnetic coil immobile (i.e., in a non-rotating state) relative to the rotating clutch. The use of non-rotating electromagnetic coils avoids the need for slip rings, brushes, or similar mechanisms to transmit power and / or signals across rotating interfaces, thereby avoiding potential problems such as wear and failure of such components during use.

[0004] Various conventional systems have been used to house electromagnetic coil wires, speed sensors and speed sensor wires, and anti-rotation bracket (ARB) functions. For example, Figure 1 shows a conventional two-part system in which the electromagnetic coil is incorporated into the clutch and the ARB is bolted to the electromagnetic coil. The Hall effect sensor is located inside the ARB and uses a fan screw on the clutch as the speed sensing target. However, the design shown in Figure 1 is expensive to manufacture and can have problems if the distance between the Hall effect sensor and the head of the fan screw is incorrect. A system like the one shown in Figure 1 was developed by VS at Horton, Inc. (Roseville, Minnesota, USA). TM It is available with the brand's direct-control fan drive.

[0005] Figure 2 illustrates another conventional system using an injection-molded / potted electromagnetic coil / connector combination with an embedded Hall effect sensor and ARB cable. The ARB cable is permanently attached to this style of coil and, once installed, is irreparable and non-replaceable by the user. This design seals the Hall effect sensor within the coil / connector, and a flux guide insert (or flux transmission insert) within the clutch housing is used as the speed sensor target, thereby eliminating the variation that occurs when using the fan screw head to detect speed. However, different lengths of ARB cables require new coil part numbers, and the user / customer generally needs to supply the corresponding connectors. Occasionally, vehicle manufacturers and other users / customers may have additional requirements prohibiting "jumpers," which mean electrical cables with one connector at each end, although the design shown in Figure 2 may require them. A system like the one shown in Figure 2 is an LCV from Horton, Inc. (Roseville, Minnesota, USA). R It is available in conjunction with the brand's fan drive.

[0006] Figure 3 shows yet another prior art system utilizing an injection-molded electromagnetic coil. The Hall effect sensor is located inside the injection-molded portion, and (similar to the system shown in Figure 2,) a flux guide insert within the clutch housing is used as the speed sensor target. A rubber hose around the electromagnetic coil cable is used as the ARB function, and a connector is added to the end of the coil cable depending on user / customer requirements. The system shown in Figure 3 requires a new part number for different electrical cable lengths, different ARB hose lengths, and different connector types. Also potentially, there is a possibility of water leakage and coil cable damage (fretting) due to the ARB hose. An example of a system like the one in Figure 3 is disclosed in Patent Document 1. A system like the one shown in Figure 3 is the LCX of Horton, Inc. (Roseville, Minnesota, USA). TM It can also be used in conjunction with the brand's fan drive.

[0007] Several challenges associated with conventional electromagnetic coil electrical connections and ARB functions include the fact that while manufacturers desire to provide a single basic clutch, users / customers, such as vehicle manufacturers, often have different requirements, including different types of electrical connectors and electrical cables of different lengths to reach corresponding components. Furthermore, during use, the electrical cables and ARB functions for the clutch may be affected by vibrations and forces resulting from the rotation of the clutch and / or airflow from the drive fan and / or contact with nearby objects (e.g., debris, drive belts). Generally, it is desirable to have electrical connectors and ARB functions that are compatible with available installation space (e.g., within the vehicle engine or motor compartment), are reliable, enable reasonably accurate speed detection, are reasonably resistant to wear or degradation, can be manufactured relatively easily and inexpensively, are relatively lightweight, facilitate end-user replacement (i.e., field serviceability), and are relatively adaptable to the diverse user / customer requirements, especially with respect to electrical cables and connectors. [Prior art documents] [Patent Documents]

[0008] [Patent Document 1] International Publication No. 2021 / 151110 [Overview of the project]

[0009] In one embodiment, an electromagnetic coil assembly for use with a viscous clutch may include a coil housing made of a flux-conducting metallic material and having an annular cup shape, windings forming multiple turns within the coil housing, a notch in the coil housing interrupting the flux-conducting metallic material, and a Hall effect sensor aligned in the notch.

[0010] In another embodiment, the viscous clutch assembly may include a rotor, a housing rotatable relative to the rotor, a working chamber located between the rotor and the housing and exposed to both, a reservoir holding a supply of shear fluid, a magnetically controllable valve assembly for regulating the flow of shear fluid between the reservoir and the working chamber, and an electromagnetic coil assembly. The valve assembly and the electromagnetic coil assembly are operably connected by a flux circuit. The electromagnetic coil assembly may include a coil housing made of a magnetic flux-conducting metallic material, windings forming multiple turns within the coil housing, and an electrical connector configured to engage with other connectors to form one or more external electrical connections. The electrical connector includes an internal conductive portion providing one or more separate electrical connection parts, at least one of which is electrically connected to the windings, such that at least one of the one or more fastener openings establishes an anti-rotation tether point for the electromagnetic coil assembly, and one or more fastener openings, each located lateral to the internal conductive portion. The electromagnetic coil assembly does not rotate. The internal conductive portion may be configured to form a seal together with other connectors when engaged with them.

[0011] A method for assembling a viscous clutch assembly may include the steps of: providing a clutch pack including a housing, rotor, reservoir, and valve assembly; securing an electromagnetic coil assembly to the clutch pack (the clutch pack and electromagnetic coil assembly may both be supported on a center shaft), wherein the electromagnetic coil assembly includes an electromagnetic coil and a coil-side connector electrically connected to the windings of the electromagnetic coil; electrically connecting the cable-side connector to the coil-side connector such that the electromagnetic coil is electrically connected to the cable-side connector, with the cable-side connector electrically connected to an electrical cable located outside the clutch pack; mechanically securing the cable-side connector and the coil-side connector together; and connecting an anti-rotation tether to the cable-side connector and the coil-side connector with mechanical fasteners. The anti-rotation tether may be directly connected to the cable-side connector with mechanical fasteners, and the cable-side connector, coil-side connector, and anti-rotation tether may be secured together with mechanical fasteners at a distance from the internal conductive portions of the cable-side connector and the coil-side connector, respectively, which electrically connect the cable-side connector to the coil-side connector.

[0012] A method for manufacturing a viscous clutch assembly includes the steps of: providing a first clutch pack including a first housing, a first rotor, a first reservoir, and a first valve assembly; providing a second clutch pack including a second housing, a second rotor, a second reservoir, and a second valve assembly (the first and second clutch packs may have the same configuration); and fixing a first electromagnetic coil assembly to the first clutch pack (both the first clutch pack and the first electromagnetic coil assembly are supported on a first center shaft). The first electromagnetic coil assembly includes a first electromagnetic coil and a first coil-side connector electrically connected to the first electromagnetic coil, and the second electromagnetic coil assembly is fixed to the second clutch pack (the second clutch pack and the second electromagnetic coil assembly may both be supported on the second center shaft), and the second electromagnetic coil assembly includes a second electromagnetic coil and a second coil-side connector electrically connected to the second electromagnetic coil (the second coil-side connector has a different configuration from the first coil-side connector). A step of (having) a first electromagnetic coil being electrically connected to a first cable-side connector, and the first cable-side connector being electrically connected to a first electrical cable located outside the first clutch pack, wherein the first electrical cable has a first length, and a second electromagnetic coil being electrically connected to a second cable-side connector, and the second cable-side connector being electrically connected to a second electrical cable located outside the second clutch pack, A step of electrically connecting the cable-side connector of a first electrical cable to a second coil-side connector, wherein the second electrical cable has a second length different from the first length of the first electrical cable, and the second cable-side connector has a different configuration from the first cable-side connector such that the first coil-side connector is incompatible with the second cable-side connector and the second coil-side connector is incompatible with the first cable-side connector; and a step of connecting the first anti-rotation tether to the first cable-side connector and the first coil-side connector with a first mechanical fastener,The first anti-rotation tether may be connected directly to the first cable-side connector with a first mechanical fastener, and the second anti-rotation tether may be connected to the second cable-side connector and the second coil-side connector with a second mechanical fastener, wherein the second anti-rotation tether is connected directly to the second cable-side connector with a second mechanical fastener.

[0013] This summary is provided as an example only, and not as an limitation. Other aspects of the present invention will be understood in light of the entire disclosure, including the entire text, claims and accompanying drawings. [Brief explanation of the drawing]

[0014] [Figure 1] This is a partial side perspective view of a prior art viscous clutch having an electromagnetic coil electrical cable and an anti-rotation tether function. [Figure 2] This is a partial side perspective view of a prior art viscous clutch having an electromagnetic coil electrical cable and an anti-rotation tether function. [Figure 3] This is a partial side perspective view of a prior art viscous clutch having an electromagnetic coil electrical cable and an anti-rotation tether function. [Figure 4A] This is a cross-sectional view of a viscous clutch and an electromagnetic coil electrical cable connection and anti-rotation assembly according to one embodiment of the present invention. [Figure 4B] This is a cross-sectional perspective view of a part of a viscous clutch and an electromagnetic coil electrical cable connection and anti-rotation assembly. [Figure 5] This is a top perspective view of a portion of the viscous clutch, the electromagnetic coil electrical cable connection, and the anti-rotation assembly. [Figure 6A] This is a left-side perspective view of the electromagnetic coil electrical cable connection and anti-rotation tether assembly connected to the viscous clutch. [Figure 6B] This is a right-side perspective view of the electromagnetic coil electrical cable connection and anti-rotation tether assembly connected to the viscous clutch. [Figure 7]Exploded perspective view of the electromagnetic coil electrical cable connection and rotation prevention tether assembly of FIGS. 6A and 6B, shown without the overmolded cover. <0000> <0000> [Figure 8] Exploded cross-sectional perspective view of the electromagnetic coil electrical cable connection and rotation prevention tether assembly and viscous clutch along line 8-8 of FIG. 7. <0000> <0000> [Figure 9] Cross-sectional view of the electromagnetic coil electrical cable connection and rotation prevention tether assembly and viscous clutch along line 9-9 of FIG. 6B, shown without the overmolded cover. <0000> <0000> [Figure 10] Partial cross-sectional view of another embodiment of the electromagnetic coil assembly, shown alone. <0000> <0000>

Best Mode for Carrying Out the Invention

[0015] <0000> The above drawings illustrate one or more embodiments of the present invention, but as described in the description, other embodiments are also contemplated. In all cases, this disclosure presents the present invention for purposes of illustration and not limitation. It should be understood that numerous other variations and embodiments can be devised by those skilled in the art that fall within the scope and spirit of the principles of the present invention. The drawings are not drawn to scale, and the use and embodiments of the present invention may include features, steps, and / or components not specifically shown in the drawings. <0000> <0000>

[0016] <0000> The disclosed embodiments of the present invention provide an electromagnetic coil assembly, an electrical anti-rotation tether connection, an associated viscous clutch assembly, and methods for manufacturing and using them. More specifically, the disclosed embodiments can include an electromagnetic coil assembly, a sensor comprising the electromagnetic coil assembly, a notch in a coil housing aligned with the sensor, a coil-side electrical connector, an electrical cable comprising a cable-side electrical connector, one or more mechanical fasteners (e.g., screws or bolts) for mechanically securing the cable-side electrical connector to the electromagnetic coil assembly, and / or an anti-rotation tether mechanically fixed to the cable-side electrical connector. In some embodiments, the electromagnetic coil and the sensor can be provided together as a single unit, which can have a common cover on or along its outer side. The viscous clutch assembly can be used as a fan drive, such as for a vehicle's cooling fan, in some embodiments. Various additional features and advantages of the present invention will be understood by those skilled in the art upon consideration of the entire disclosure, including the accompanying drawings.

[0017] This application claims priority to U.S. Provisional Patent Application No. 63 / 509,106, filed Jun. 20, 2023, which is hereby incorporated by reference in its entirety.

[0018] FIGS. 4A - 9 show a viscous clutch assembly 30 comprising an electrical anti-rotation assembly C according to one embodiment of the present invention.

[0019] In some embodiments, the viscous clutch assembly 30 may include a center shaft 32 (e.g., a “live” or rotatable center shaft) and a clutch pack P having a general configuration and method of operation similar to the embodiments disclosed in U.S. Patent No. 10,941,819 (U.S. National Entry of International Publication No. 2018 / 004833). In the embodiment shown in Figure 4A, the viscous clutch assembly 30 includes a clutch pack P having a rotor 34 rotatably fixed to the center shaft 32, a housing 36 rotatably supported on the center shaft 32 on bearings 38, a working chamber 40 positioned between the rotor 34 and the housing 36 and exposed to both, a reservoir 42 (supported by the rotor 34 and always able to rotate with the rotor 34) (in some embodiments), a return bore (not shown) for returning shear fluid from the working chamber 40 to the reservoir 42, an electromagnetic coil 44, a valve assembly 46, and a magnetic flux circuit connecting the electromagnetic coil 44 and the valve assembly 46 and passing through a flux guide insert 48 in the housing. The axis of rotation A extends along the center shaft 32 and is defined by the clutch pack P aligned with it.

[0020] As shown in the illustrated embodiment, the electromagnetic coil 44 is rotatably supported on the center shaft 32 on a pair of bearings 50 located outside the housing 36, at the rear of the viscous clutch assembly 30.

[0021] The electromagnetic coil 44 includes at least one winding 44-1 located at least partially within the coil housing 44-2, the at least one winding 44-1 forming multiple turns within the coil housing 44-2. In the drawings, the winding 44-1 is shown schematicly only for simplification. The winding 44-1 may optionally be wound on a bobbin (not shown) located at least partially within the coil housing 44-2. The coil housing 44-2 is made of a flux-conducting material (e.g., a ferromagnetic material) to conduct the magnetic flux generated when the winding 44-1 is energized. In the illustrated embodiment, the coil housing 44-2 has an annular cup shape with an axially open surface on its front.

[0022] In some embodiments, the valve assembly 46 may be configured similarly to that disclosed in International Publication No. 2023 / 183118, or alternatively, similarly to that disclosed in U.S. Patent No. 8,881,881 (U.S. transition of International Publication No. 2012 / 024497), or alternatively, it may have a different configuration preferred for a particular application.

[0023] During operation, the electromagnetic coil 44 can be selectively energized (through selective power supply to winding 44-1) to control the operation of the valve assembly 46 to adjust the volume of shear fluid (such as silicone oil) present in the working chamber 40, thereby controlling the output speed of the viscous clutch assembly 30 relative to the input speed whenever there is a torque input to the viscous clutch assembly 30. In short, in the illustrated embodiment, the magnetic flux from the electromagnetic coil 44 can move the armature 46-1 of the valve assembly 46 (e.g., rotate it axially), and then move the spring-driven valve element (e.g., reed valve) of the valve assembly 46 (e.g., rotate it simultaneously by pressing it) to cover or remove the outlet bore of the reservoir 42 (e.g., in a "fail-on" configuration). The general operation of electromagnetically controlled valves in viscous clutches is well known.

[0024] During operation of the clutch assembly 30 in a known manner, a pump mechanism (not shown) may be used to passively pump shear fluid from the working chamber 40 through the return bore to the reservoir 42.

[0025] In the illustrated embodiment, the flux guide insert 48 is made of a flux-conducting material and is embedded at the rear in the base 36B of the housing 36. The flux guide insert 48 is rotatably fixed to the housing 36 and always rotates at the same speed as the housing 36. The flux guide insert 48 may protrude or be exposed from the material of the base 36B on the opposing front and / or rear sides. In the illustrated embodiment, the rear end of the flux guide insert 48 is located close to a portion of the coil housing 44-2, with a small radial gap (first gap G1) between them. The flux guide insert 48 enables the transmission of magnetic flux through the material of the housing 36, which is normally made of a material such as aluminum that does not efficiently transmit magnetic flux.

[0026] In the illustrated embodiment, one or more additional flux guides 52 are also provided. These additional flux guides 52 may be individual flux guides, flux guide inserts, and / or flux-conducting portions of the rotor 34. In some embodiments, one or more additional flux guides 52 may be an assembly of individual elements that rotate together, which are in contact with each other and / or separated by a small gap, through which magnetic flux can be transmitted. As shown in Figure 4A, the additional flux guides 52 are located on or near the rear of the rotor 34, extending radially outward from the center shaft 32 and also axially rearward, and are located close to the front end of the flux guide insert 48 in the housing 36, with a small radial gap (second gap G2) between them. The armature 46-1 of the valve assembly 46 is positioned in close proximity to a portion of one or more additional flux guides 52 so that magnetic flux present in one or more additional flux guides 52 can act magnetically on the armature 46-1.

[0027] The flux circuit of the viscous clutch assembly 30, which transmits magnetic flux to facilitate the operation of the valve assembly 46, may have the following configuration, as shown in the illustrated embodiment: The flux circuit extends from the coil housing 44-2 of the electromagnetic coil 44 to a flux guide insert in the housing 36, across a first gap G1. Next, the flux circuit extends from the flux guide insert 48 to one or more additional flux guides 52, across a second gap G2. Subsequently, the flux circuit extends from one or more additional flux guides 52 to the armature 46-1 of the valve assembly 46. The armature 46-1, which is movable in response to the applied magnetic field, can bridge a variable distance of the generally axial gap G3, which can be reduced to zero when the electromagnetic coil 44 is energized. The flux circuit then extends from the armature 46-1 to another part of one or more additional flux guides 52, and then to the center shaft 32, which may be made of a flux-conducting material (e.g., a ferromagnetic material). Finally, the flux circuit extends from the center shaft 32, over a final air gap G4, which may be radially positioned, back to the coil housing 44 of the electromagnetic coil 44. Spacers 54 made of a magnetic (e.g., ferromagnetic) material can optionally be provided along the center shaft 32, adjacent to the bearings 38 and / or bearings 50 (e.g., in contact with the races of bearings 38 and 50 to separate them), to help establish a desired flux path for the flux circuit. As shown, the spacer 54 has a flange 54-1 extending radially outward in close proximity to the coil housing 44-2, with the final air gap G4 located between the flange 54-1 of the spacer 54 and the coil housing 44-2. In the illustrated embodiment, the flux circuit is located mainly or entirely on the rear side of the rotor 34 and is relatively compact, thereby facilitating a reduction in flux density requirements and allowing the electromagnetic coil 44 to be used in a relatively small and low-mass state.

[0028] In some embodiments, the sensor 56 (e.g., a Hall effect sensor) is supported together with the electromagnetic coil 44 as a single electromagnetic coil assembly U (e.g., the electromagnetic coil 44 and sensor 56 are overmolded (e.g., via injection molding of a polymer material)) and / or potted in a common cover 58 to form the electromagnetic coil assembly U as an integrated electromagnetic coil / sensor unit. Although not specifically shown in the drawings, additional circuitry (e.g., one or more circuit boards) may be contained within the common cover 58 and electrically connected to the sensor 56, winding 44-1 and / or other components. In Figure 4A, the common cover 58 is shown schematicly only as a boundary with a dashed line. The common cover 58 is generally made of a substantially non-conductive material. In the illustrated embodiment, the sensor 56 is a Hall effect sensor and is aligned with (i.e., axially overlapping) the rear end portion of the flux guide insert 48 (for example, the sensor 56 is at or near the front end of the electromagnetic coil assembly (or unit) U, the sensor 56 is located on or near the outer diameter of the coil housing 44-2, and the sensor 56 is operably radially inward toward the flux guide insert 48). The flux guide insert 48 has a target 48-1, which can be a circumferential interruption such as a notch, slit, hole, opening, etc., and rotates at the same speed as the flux guide insert 48 and the housing 36. During operation, the sensor 56 can detect the rotational speed of the housing 36 relative to the rotationally fixed electromagnetic coil assembly U. In this way, the flux guide insert 48 also functions as (or provides integrally with) the target 48-1, thereby eliminating the need for an additional or dedicated sensor target wheel in some embodiments, and ensuring that the operation of the flux circuit, valve assembly 46, or other clutch components is not interfered with. Furthermore, the radial arrangement of the sensor 56 and the flux guide insert 48 (and target 48-1) helps to accommodate variations in manufacturing and operational tolerances (e.g., axial misalignment) without substantially reducing detection accuracy.

[0029] The electromagnetic coil 44 (specifically, the coil housing 44-2) can transmit magnetic flux to the flux guide insert 48 in overlapping regions (regions that overlap axially, as shown in the illustrated embodiment). Normally, in this environment, the magnetic field strength from the electromagnetic coil 44 is too high, and the Hall effect sensor does not operate efficiently. Therefore, in the illustrated embodiment (see Figures 4A, 4B, 5, 8, and 9), the coil housing 44-2 is cut out around the Hall effect sensor 56 (which may be located in separate circumferential positions) to separate, or at least partially isolate, the magnetic field and flux from the electromagnetic coil 44 from the Hall effect sensor 56. In this way, there is a notch 60 that interrupts the flux-conducting metal material of the coil housing 44-2, and the coil housing 44-2 is circumferentially discontinuous adjacent to the Hall effect sensor 56. The Hall effect sensor 56 is aligned with the notch 60. In some embodiments, such as those shown in the illustration, at least a portion of the Hall effect sensor 56 is positioned within the notch 60, i.e., at least a portion of the sensor 56 extends into the notch 60 and overlaps with the material forming the wall 44-2W of the coil housing 44-2 (for example, the notch 60 radially overlaps with the thickness of the wall 44-2W through which it extends). In another embodiment, the Hall effect sensor 56 may be adjacent to the notch 60, but not in it, so as to detect through the notch 60. Proper positioning of the sensor 56 depends on the maximum nominal clearance through which Hall effect detection can be achieved for a particular sensor device and the thickness of the wall 44-2W of the coil housing 44-2 adjacent to the notch 60. The thickness of the wall 44-2W adjacent to the notch 60 must be sufficiently smaller than the maximum nominal clearance between the target 48-1 and the sensor 56 through which Hall effect detection can be achieved, in order to enable detection while maintaining a clearance between the target 48-1 and the sensor 56 that allows relative rotation without interference or contact. The notch 60 may have a substantially rectangular shape, or alternatively, in further embodiments, a different shape.In the illustrated embodiments, the wall 44-2W in which the notch 60 is located extends substantially axially and is located on the outer diameter of the coil housing 44-2. In some embodiments, the notch 60 extends to the leading edge 44-2F of the wall 44-2W of the coil housing 44-2 so that the front of the notch 60 is not constrained by the flux-conducting metallic material of the coil housing 44-2. In some embodiments, the leading edge 44-2F of the wall 44-2W of the coil housing 44-2 may extend axially forward of multiple turns of at least one winding 44-1 within the coil housing 44-2. Furthermore, in some embodiments, the front portion of the notch 60 may be located ahead of multiple turns of the winding 44-1, and the rear portion of the notch overlaps with at least a portion of multiple turns of the winding 44-1 within the coil housing 44-2 so that the target space T is located radially inward of the wall 44-2W and axially forward of multiple turns of the winding 44-1.

[0030] In another embodiment, the sensor 56 (and the notch 60) may be completely omitted.

[0031] In the illustrated embodiment (see Figures 4A and 6A-9), the electromagnetic coil 44 further includes a coil-side connector 62 which can be used to create an electrical anti-rotation connection assembly C. After the viscous clutch assembly 30 is manufactured, for example, when the viscous clutch assembly 30 is later mounted on a vehicle or other desired installation location, an electrical cable 70 with a cable-side connector 72 is attached to the electromagnetic coil 44 at the coil-side connector 62, and the electromagnetic coil assembly (which may or may not have a sensor 56 in various embodiments) is restrained in a rotationally fixed position by an anti-rotation bracket (ARB) or anti-rotation tether 74. The electrical cable 70 is located outside the clutch pack P. The electrical cable 70 may be electrically connected to an external device (not shown) that can supply power, control the operation of the electromagnetic coil 44 (e.g., establish a pulse-width modulated duty cycle of the power supplied to its winding 44-1), and / or receive sensor signals (e.g., from the sensor 56). For example, external devices are available from Horton, Inc. (Roseville, Minnesota, USA) Di+ R It may be a controller, or an engine or vehicle controller. In the attached drawings, for simplification, the cross-sectional view does not show the internal details of the electrical cable 70, such as individual wires and electrical insulators.

[0032] In the illustrated embodiment, the coil-side and cable-side connectors 62 and 72 have internal conductive portions 62-1 and 72-1, respectively, which can be connected to each other to form one or more separate electrical connections. The internal conductive portion 62-1 of the coil-side connector 62 is electrically connected to the windings 44-1 of the electromagnetic coil 44, the sensor 56 and / or other coil-side components (for simplification, the internal conductive portions 62-1 and 72-1 are shown somewhat schematically in Figures 4A and 7-9, for example, not all conductors are specifically depicted, but see also the embodiment in Figure 10 which shows additional details). The internal conductive portion 72-1 of the cable-side connector 72 is electrically connected to the wires of an electrical cable 70 (of a desired length for a particular application), which may be further electrically connected, for example, at the opposite end to a user / customer-specified connector (not shown). The internal conductive portions 62-1 and 72-1 form a seal when mated with each other, which helps to limit or prevent liquids, dust, and / or other foreign matter from passing through the coil-side connector 62 and entering the interior of the electromagnetic coil assembly U. Furthermore, the mating of the internal electrical conductor portions 62-1 and 72-1 may include mechanical mating or mating components that help to provide a structural mechanical connection that helps to provide anti-rotation locking. For example, in the illustrated embodiment, the mechanically mating mating components associated with the internal conductive portions 62-1 and 72-1 are plug and socket components 62-1A and 72-1A, such as pins, pads, sockets, etc., that mechanically lock and are located adjacent to or around the electrical component 62-1B (the electrical component of the cable-side internal conductive portion 72-1 is not specifically shown). The plug and socket components 62-1A and 72-1A may each have a non-circular shape to provide an anti-rotation function, and may further have one or more mating claws or arms and anti-return openings 62-1D and 72-1D, such as a matable stopper (see Figure 9).In some embodiments, the electrical connector at the opposite end of the electrical cable 70 may be of a different, incompatible type; that is, the cable-side electrical connector 72 may have a different configuration than the one used at the opposite end of the electrical cable 70 (not shown).

[0033] Furthermore, in the illustrated embodiments (see, for example, Figures 7 and 8), the coil-side and cable-side connectors 62 and 72 each have one or more fastener openings 62-2 and 72-2, and in the illustrated embodiments, two such fastener openings 62-2 and 72-2 are shown, one on each side of the internal conductive portions 62-1 and 72-1 of the respective body portions 62-3 and 72-3. In some embodiments, the fastener openings 62-2 of the coil-side connector 62 may be threaded, while the fastener openings 72-2 of the cable-side connector 72 may optionally not be threaded. Mechanical fasteners 76, such as screws, bolts, etc., can be inserted through the cable-side fastener openings 72-2 to mechanically secure the cable-side connector 72 and the associated electrical cable 70 to the coil-side connector 62 at a location away from or different from the mating internal conductive portions 62-1 and 72-1, and can then be mated with the coil-side connector 62 at the coil-side connector openings 62-2. For example, threaded screws or bolts used as mechanical fasteners 76 can screw-mate into threaded openings 62-2 of the coil-side connector 62, and the heads of these screws or bolts can apply a compressive retaining force to the cable-side connector 72 toward or in that direction toward the coil-side connector 62 (see, for example, Figures 6A and 6B). Thus, in the illustrated embodiment, electrical connections (and environmental seals) are made separately from the mechanical connections made by the mechanical fasteners 76 in the openings 62-2 and 72-2, and these can be purely mechanical in nature without transmitting current or signals. In a further embodiment, an immovable fastener such as a barbed connector (which may optionally be integrated into the cable-side connector 72) that mates into the openings 62-2 of the coil-side connector 62 but cannot be removed or un-mated non-destructively may be used as the mechanical fastener 76. Although the fastener openings 62-2 are described as part of the coil-side connector 62, in yet another alternative embodiment, these fastener openings 62-2 may be part of another different component of the electromagnetic coil assembly U.

[0034] Furthermore, the connection assembly includes an anti-rotation tether (or ARB tether) 74. The anti-rotation tether 74 may be a structural cable (e.g., a flexible wire rope), rod, bracket, etc., capable of transmitting a mechanical load to rotate and fix the electromagnetic coil assembly U (including the sensor 56, if present) to a rotationally fixed external mounting position such as a rotationally fixed engine compartment position, frame, engine block, etc. In the illustrated embodiment, the anti-rotation tether 74 is a structural cable with eyelets 74-1 for fastener attachment at both ends. Generally, the anti-rotation tether 74 is separate from power and / or signal conducting components (e.g., separate from the electrical cable 70) and performs a purely mechanical function. In some embodiments, the anti-rotation tether 74 may serve to provide electrical grounding. The anti-rotation tether 74 can rotate and fix or tether the cable-side connector 72, thereby allowing the coil-side connector 62 and the rest of the electromagnetic coil assembly U (including the sensor 56, if present) to rotate and fix.

[0035] In the illustrated embodiment, the anti-rotation tether 74 is secured to the electromagnetic coil 44 at the coil-side connector 62 via one or more mechanical fasteners 76 that mate in the coil-side connector opening 62-2. For example, the eyelet 74-1 at the end of the anti-rotation tether 74 in the illustrated embodiment is directly secured to the cable-side connector 72 by one of the mechanical fasteners 76 on the side of the cable-side connector 72 opposite to the coil-side connector 62. While maintaining such a direct mating connection, a washer or the like may optionally be provided between the eyelet 74-1 of the anti-rotation tether 74 and the cable-side connector 72. In a further embodiment, the eyelet 74-1 of the anti-rotation tether 74 may be secured by being sandwiched and stacked by one of the mechanical fasteners 76 between the coil-side connector 62 and the cable-side connector 72, while the anti-rotation tether 74 is still directly secured to the cable-side connector 72 by the fastener 76. In yet another embodiment, the anti-rotation tether 74 may be secured to the cable-side connector 72 by an additional dedicated tether fastener.

[0036] Figure 10 is a cross-sectional view of a portion of another embodiment of the electromagnetic coil assembly U'. The components of the electromagnetic coil assembly U' are generally the same as those described above with respect to the electromagnetic coil assembly U. However, the electromagnetic coil assembly U' further includes a bobbin 44-3 in which turns of winding 44-1 are arranged. In the illustrated embodiment, the bobbin 44-3 has a generally open surface on its outer diameter portion, for example, by having a “U” shape in cross-section that is substantially open radially outward, while the coil housing 44-2 has a cup shape that is substantially open axially forward. Furthermore, in the embodiment of Figure 10, the notch 60' is larger than the notch 60. The notch 60 was slightly larger than the sensing portion of the sensor 56, but the notch 60' in the coil housing 44-2 is larger. More specifically, the notch 60' can be configured as a slot that extends substantially or completely axially along the entire axial length of the wall 44-2W of the outer diameter portion of the coil housing 44-2 (and completely through the thickness of the wall 44-2W, interrupting the material of the coil housing 44-2 in the circumferential direction), or it can extend radially along the radially extending wall portions of the coil housing 44-2.

[0037] As can be seen from the foregoing description and the accompanying drawings, the disclosed embodiments may include mechanically fastening the electromagnetic coil assembly U or U' and the mating cable-side connector 72 together with mechanical fasteners (e.g., screws or bolts) to create a single unit, and attaching the anti-rotation (or ARB) tether 74 directly to the electrical cable (or "jumper") 70 and the associated connector 72, rather than directly to the electromagnetic coil 44.

[0038] The disclosed embodiments of the viscous clutch assembly 30 and associated electrical anti-rotation connection assembly C enable the manufacture of a “basic” or semi-general-purpose clutch pack P with a specified required coil voltage, while also enabling the later attachment of user / customer-specific electrical connectors 62 and / or 72, electrical cables 70 (of desired length), and anti-rotation tethers 74 (of desired length) to create a final part number, i.e., a final part number for a combination of application-specific tethers 74, electrical cables 70, and connector assemblies (e.g., connectors 62 and 72) in addition to the “basic” clutch of a specific voltage. This significantly reduces the number of electromagnetic coil part numbers and simplifies manufacturing, while also allowing different (first, second, etc.) electrical connectors with different configurations and that are incompatible with each other (e.g., cannot be mated with the same mating connectors) to be used with the same “basic” or semi-general-purpose clutch pack P. This facilitates modularity and manufacturing in the clutch assembly. The disclosed embodiments also help provide a relatively low-cost, reliable, accurate (for speed sensing), modular / customizable, field-serviceable, long-lasting, and wear-resistant all-in-one clutch implementation. Other features and advantages will be understood by those skilled in the art in consideration of the entirety of this disclosure, including the accompanying drawings.

[0039] Consideration of Possible Embodiments An electromagnetic coil assembly for use with a viscous clutch may include a coil housing made of a flux-conducting metallic material and having an annular cup shape, windings forming multiple turns within the coil housing, a notch in the coil housing interrupting the flux-conducting metallic material, and a Hall effect sensor aligned in the notch.

[0040] The electromagnetic coil assembly described in the preceding paragraph may optionally include, additionally and / or alternatively, one or more of the following features, configurations, and / or additional components:

[0041] The Hall effect sensor can be positioned on or near the outer diameter of the coil housing and / or can be operably oriented inward.

[0042] At least a portion of the Hall effect sensor can be placed within a notch.

[0043] The notch may extend to the leading edge of the coil housing wall such that the front of the notch is not restricted by the flux-conducting metal material of the coil housing (and one or more other sides of the notch are restricted by the flux-conducting metal material of the coil housing).

[0044] The wall can extend substantially axially and / or be located on the outer diameter of the coil housing.

[0045] The leading edge of the coil housing wall can extend axially forward through multiple turns of the winding within the coil housing.

[0046] The front portion of the notch may be positioned in front of multiple turns of the winding, and the rear portion of the notch may overlap with at least some of the multiple turns of the winding such that the target space is located radially inward of the coil housing wall in the outer diameter of the electromagnetic coil and axially in front of the multiple turns of the winding.

[0047] The notch may have a substantially rectangular shape.

[0048] The coil housing may have an annular cup shape with an axially open surface on its front.

[0049] The coil housing may include a wall located on the outer diameter of the coil housing, and the notch may be located on that wall.

[0050] There is a cover made of an essentially non-metallic material that covers multiple turns of the winding within the coil housing and further covers part of the coil housing, and the Hall effect sensor can protrude at least partially outside the cover.

[0051] An electrical connector is located adjacent to the Hall effect sensor, and the electrical connector is configured to engage with other connectors to form one or more external electrical connections, and the electrical connector is electrically connected to the winding and electrically connected to the Hall effect sensor.

[0052] A viscous clutch assembly may include a rotor, a housing rotatable relative to the rotor, a working chamber located between the rotor and the housing and exposed to both, a reservoir holding a supply of shear fluid, a magnetically controllable valve assembly for regulating the flow of shear fluid between the reservoir and the working chamber, and an electromagnetic coil assembly. The valve assembly and the electromagnetic coil assembly are operably connected by a flux circuit, and the electromagnetic coil assembly does not rotate. The electromagnetic coil assembly may include a coil housing made of a flux-conducting metallic material and having an annular cup shape, windings forming multiple turns within the coil housing, a notch in the coil housing interrupting the flux-conducting metallic material, and a Hall effect sensor aligned in the notch.

[0053] The viscous clutch of the preceding paragraph may optionally include, additionally and / or alternatively, one or more of the following features, configurations, and / or additional components:

[0054] There is a flux guide that passes through a portion of the housing, the flux guide includes a rear section having a target, the rear section is located adjacent to the Hall effect sensor and separated by a gap so that the target can rotate through the sensing area of ​​the Hall effect sensor.

[0055] A viscous clutch assembly may include a rotor, a housing rotatable relative to the rotor, a working chamber located between the rotor and the housing and exposed to both, a reservoir holding a supply of shear fluid, a magnetically controllable valve assembly for regulating the flow of shear fluid between the reservoir and the working chamber, and an electromagnetic coil assembly. The valve assembly and the electromagnetic coil assembly are operably connected by a flux circuit. The electromagnetic coil assembly may include a coil housing made of a magnetic flux-conducting metallic material, windings forming multiple turns within the coil housing, and an electrical connector configured to engage with other connectors to form one or more external electrical connections. The electrical connector includes an inner conductive portion providing one or more separate electrical connections, at least one of which may be electrically connected to the windings and configured to form a seal when engaged with other connectors, and one or more fastener openings, each located beside the inner electrical conductive portion, and the electromagnetic coil assembly does not rotate. At least one of the one or more fastener openings may be configured to establish an anti-rotation tether point for the electromagnetic coil assembly.

[0056] The viscous clutch of the preceding paragraph may optionally include, additionally and / or alternatively, one or more of the following features, configurations, and / or additional components:

[0057] An electrical connector may include mechanical connection components on or along an internal electrical connection, configured to provide a structural mechanical connection when engaged with other connectors.

[0058] The mechanical engagement component may be (A) a non-circular plug or socket component, (B) one or more retaining claws or retaining openings, and (C) a combination thereof.

[0059] The electromagnetic coil assembly may include notches in the coil housing that interrupt the magnetic flux-conducting metal material.

[0060] The Hall effect sensor can be aligned in a notch, and at least one of the one or more individual electrical connections of the inner conductive portion of the electrical connector can be electrically connected to the Hall effect sensor.

[0061] There is a flux guide that passes through a portion of the housing, the flux guide includes a rear section having a target, the rear section is located adjacent to the Hall effect sensor and separated by a gap so that the target can rotate through the sensing area of ​​the Hall effect sensor.

[0062] The rear portion of the flux guide with the target can be positioned radially inward from the wall of the coil housing and rotatable within a target space located axially forward of the multiple turns of windings within the coil housing.

[0063] The Hall effect sensor can be positioned on or near the outer diameter of the coil housing and / or can be operable to face inward toward the target space.

[0064] The notch may be configured as a notch extending to the leading edge of the coil housing wall, such that the front of the notch is not restricted by the flux-conducting metal material of the coil housing (and one or more other sides of the notch are restricted by the flux-conducting metal material of the coil housing).

[0065] At least a portion of the Hall effect sensor can extend into the notch.

[0066] A cover made of essentially non-metallic material that covers multiple turns of the windings within the coil housing, covers at least a portion of the electrical connector, and further covers a portion of the coil housing.

[0067] The Hall effect sensor can protrude at least partially from the cover.

[0068] The cover can be made from polymer material.

[0069] The cover can encapsulate at least the electromagnetic coil assembly and the electrical connector together as a single unit.

[0070] The coil housing may have an annular cup shape with an axially open surface on its front.

[0071] Rotatable center shaft

[0072] A set of bearings, wherein an electromagnetic coil assembly is supported on a center shaft by the set of bearings, and / or

[0073] The electromagnetic coil assembly can be positioned adjacent to the external rear housing of the viscous clutch assembly.

[0074] A method for assembling a viscous clutch assembly: a step of providing a clutch pack including a housing, rotor, reservoir and valve assembly; a step of securing an electromagnetic coil assembly to the clutch pack, the electromagnetic coil assembly including an electromagnetic coil and a coil-side connector electrically connected to the windings of the electromagnetic coil, and both the clutch pack and the electromagnetic coil assembly being supported on a center shaft; a step of electrically connecting the cable-side connector to the coil-side connector so that the electromagnetic coil is electrically connected to the cable-side connector and the cable-side connector is electrically connected to an electrical cable located outside the clutch pack; a step of mechanically securing the cable-side connector and the coil-side connector together; and a step of connecting an anti-rotation tether to the cable-side connector and the coil-side connector with a mechanical fastener, the anti-rotation tether being directly connected to the cable-side connector with a mechanical fastener, and the cable-side connector, the coil-side connector and the anti-rotation tether being secured together with a mechanical fastener at a distance from the internal conductive parts of the respective cable-side connector and coil-side connector so that the cable-side connector is electrically connected to the coil-side connector.

[0075] The method of the preceding paragraph may optionally include, additionally and / or alternatively, one or more of the following features, structures, and / or additional steps:

[0076] The mechanical fastener can be a threaded fastener that screws into the coil-side connector, passes through the opening of the cable-side connector and the eyelet of the anti-rotation tether, mechanically securing both the cable-side connector and the coil-side connector, and directly connecting the anti-rotation tether to the cable-side connector;

[0077] The electromagnetic coil and at least a portion of the coil-side connector are enclosed within a common cover to provide an integrated unit;

[0078] A common cover can cover the turns of the windings located within the coil housing of the electromagnetic coil;

[0079] Provide a sensor configured to sense rotational speed;

[0080] The step of enclosing at least a portion of the electromagnetic coil and coil-side connector within a common cover may further include enclosing at least a portion of the sensor within the common cover;

[0081] The sensor is placed in the notch of the coil housing of the electromagnetic coil;

[0082] The sensor can be a Hall effect sensor;

[0083] The sensor may be positioned to sense the rotation of a target supported by the clutch pack housing; and / or

[0084] Create a seal between the cable-side connector and the coil-side connector.

[0085] A method for manufacturing a viscous clutch assembly may include: providing a first clutch pack comprising a first housing, a first rotor, a first reservoir, and a first valve assembly; providing a second clutch pack comprising a second housing, a second rotor, a second reservoir, and a second valve assembly, wherein the first clutch pack and the second clutch pack have substantially or exactly the same configuration; fixing a first electromagnetic coil assembly to the first clutch pack, wherein the first electromagnetic coil assembly comprises a first electromagnetic coil and a first coil-side connector electrically connected to the first electromagnetic coil, wherein both the first clutch pack and the first electromagnetic coil assembly are supported on a first center shaft; fixing a second electromagnetic coil assembly to the second clutch pack, wherein the second electromagnetic coil assembly comprises a second electromagnetic coil and a second coil-side connector electrically connected to the second electromagnetic coil, wherein both the second clutch pack and the second electromagnetic coil assembly are supported on a second center shaft. A step of connecting a second coil-side connector to a first coil-side connector, wherein the second coil-side connector is supported by a drive shaft and has a different configuration from the first coil-side connector; a step of connecting a first cable-side connector to a first coil-side connector so that a first electromagnetic coil is electrically connected to a first cable-side connector, wherein the first cable-side connector is electrically connected to a first electrical cable located outside the first clutch pack, and the first electrical cable has a first length; a step of connecting a second cable-side connector to a second coil-side connector so that a second electromagnetic coil is electrically connected to a second cable-side connector, wherein the second cable-side connector is electrically connected to a second electrical cable located outside the second clutch pack, and the second electrical cable has a second length different from the first length of the first electrical cable, and the first coil-side connector is incompatible with the second cable-side connector, and the second cable-side connector has a different configuration from the first cable-side connector so that the second coil-side connector is incompatible with the first cable-side connector;The steps of connecting a first anti-rotation tether to a first cable-side connector and a first coil-side connector using a first mechanical fastener, wherein the first anti-rotation tether is directly connected to the first cable-side connector using the first mechanical fastener; and connecting a second anti-rotation tether to a second cable-side connector and a second coil-side connector using a second mechanical fastener, wherein the second anti-rotation tether is directly connected to the second cable-side connector using the second mechanical fastener;

[0086] The method of the preceding paragraph may optionally include, additionally and / or alternatively, one or more of the following features, structures, and / or additional steps:

[0087] This method can utilize a pool of specific common components to provide modular manufacturing of clutch assemblies with different overall configurations;

[0088] The first and second mechanical fasteners may each be threaded fasteners that screw into the first or second coil-side connector and further pass through the respective openings of the first or second cable-side connector and the respective eyelets of the first or second anti-rotation tether;

[0089] A first electromagnetic coil and at least a portion of the first coil-side connector are enclosed in a first common cover to provide a first integrated unit;

[0090] The second electromagnetic coil and at least a portion of the second coil-side connector are enclosed in a second common cover, providing a second integrated unit;

[0091] A first sensor is provided, configured to sense the rotational speed of a first housing relative to a first electromagnetic coil assembly;

[0092] The step of enclosing at least a portion of the first electromagnetic coil and the first coil-side connector within a first common cover may further include enclosing at least a portion of the second sensor within a second common cover;

[0093] The first sensor is positioned in the notch of the first coil housing of the first electromagnetic coil;

[0094] The first sensor can be a Hall effect sensor; and / or

[0095] The first sensor can be positioned to face a first target space, thereby allowing a first target, supported by the first housing of the first clutch pack, to rotate.

[0096] summary Any relative or degree terms used herein, such as “substantially,” “essentially,” “generally,” or “approximately,” should be interpreted in accordance with any applicable definitions or limitations expressly stated herein. In all cases, any relative or degree terms used herein should be interpreted to broadly encompass a range or variation that, in consideration of any relevant disclosed embodiment and the entirety of this disclosure, would be understood by a person skilled in the art to include normal manufacturing tolerance variations, accidental alignment variations, transient alignment or geometry variations, etc., induced by thermal, rotational or vibration operating conditions, transient signal fluctuations, etc. Furthermore, any relative or degree terms used herein should be interpreted to encompass a range that expressly includes, without variation, a specified quality, characteristic, parameter or value, as if no restrictive relative or degree terms were used in a given disclosure or enumeration.

[0097] It should be interpreted as referring to the inclusion of a described element, feature, or step, or a group of elements, features, or steps, and not as referring to the exclusion of other elements, features, or steps, or groups of elements, features, or steps. Unless further expressly limited, the use of the word “comprise” or its variations does not, on its own, exclude any currently existing, additional, undescribed elements, steps, or groups of elements or steps. In addition, unless further expressly limited, the words “a” and “an” as used herein refer to one or more, and do not limit the identified elements, features, steps, etc. to just one. However, the use of “a” and “an” as used herein should be interpreted according to any applicable additional limitations explicitly stated in the context of a particular use, and should not be interpreted without generally extending such context-specific limitations to all other uses.

[0098] While the present invention has been described in relation to preferred embodiments, those skilled in the art will recognize that modifications may be made in shape and detail without departing from the spirit and scope of the invention. For example, features, steps, etc., described in relation to one embodiment can generally be used in conjunction with other embodiments unless otherwise specified.

Claims

1. An electromagnetic coil assembly for use with a viscous clutch, A coil housing made of a magnetic flux-conducting metal material and having an annular cup shape, A winding that forms multiple turns within the coil housing, The notch in the coil housing interrupts the magnetic flux-conducting metal material, The aforementioned notch and the Hall effect sensor aligned with it, An electromagnetic coil assembly comprising:

2. The electromagnetic coil assembly according to claim 1, wherein the Hall effect sensor is positioned on or near the outer diameter of the coil housing and is operably facing inward.

3. The electromagnetic coil assembly according to claim 1, wherein at least a portion of the Hall effect sensor is disposed within the notch.

4. The electromagnetic coil assembly according to claim 1, wherein the notch extends to the front edge of the wall of the coil housing such that the front side of the notch is not constrained by the flux-conducting metal material of the coil housing.

5. The electromagnetic coil assembly according to claim 4, wherein the wall extends substantially axially and is located on the outer diameter of the coil housing.

6. The electromagnetic coil assembly according to claim 4, wherein the leading edge of the wall of the coil housing extends axially forward of the plurality of turns of the winding within the coil housing.

7. The electromagnetic coil assembly according to claim 1, wherein the front portion of the notch is located in front of the plurality of turns of the winding, and the rear portion of the notch overlaps with at least a portion of the plurality of turns of the winding such that the target space is located radially inward of the wall of the coil housing in the outer diameter of the electromagnetic coil and axially in front of the plurality of turns of the winding.

8. The electromagnetic coil assembly according to claim 1, wherein the notch has a substantially rectangular shape.

9. The electromagnetic coil assembly according to claim 1, wherein the coil housing has an annular cup shape with an axially open surface on its front side, the coil housing includes a wall located on the outer diameter of the coil housing, and the notch is located on the wall.

10. A cover made of essentially non-metallic material, which covers the plurality of turns of the winding within the coil housing, and further covers a portion of the coil housing, and the Hall effect sensor protrudes at least partially outside the cover, The electromagnetic coil assembly according to claim 1, further comprising the following:

11. An electrical connector located adjacent to the Hall effect sensor, configured to engage with other connectors to form one or more external electrical connections, electrically connected to the winding, and electrically connected to the Hall effect sensor. The electromagnetic coil assembly according to claim 1, further comprising the following:

12. A viscous clutch assembly, The rotor and, A housing rotatable relative to the rotor, A working chamber located between the rotor and the housing and exposed to both, A reservoir that holds the supply of shear fluid, A magnetically controllable valve assembly for regulating the flow of the shear fluid between the reservoir and the working chamber, The electromagnetic coil assembly according to claim 1, wherein the valve assembly and the electromagnetic coil assembly are operably connected by a flux circuit, and the electromagnetic coil assembly is non-rotatable, An electromagnetic coil assembly comprising:

13. A flux guide passing through a portion of the housing, including a rear portion having a target, the rear portion being positioned adjacent to the Hall effect sensor and separated by a gap so that the target can rotate through the sensing area of ​​the Hall effect sensor, The viscous clutch assembly according to claim 12, further comprising:

14. A viscous clutch assembly, The rotor and, A housing rotatable relative to the rotor, A working chamber located between the rotor and the housing and exposed to both, A reservoir that holds the supply of shear fluid, A magnetically controllable valve assembly for regulating the flow of the shear fluid between the reservoir and the working chamber, An electromagnetic coil assembly wherein the valve assembly and the electromagnetic coil assembly are operably connected by a flux circuit, Equipped with, The electromagnetic coil assembly is A coil housing made of a magnetic flux-conducting metal material, A winding that forms multiple turns within the coil housing, An electrical connector configured to be engageable with other connectors to form one or more external electrical connections, Includes, The aforementioned electrical connector is At least one of the inner conductive portions provides one or more individual electrical connections electrically connected to the winding, and is configured to form a seal together with other connectors when engaged with other connectors, One or more fastener openings, each located lateral to the inner conductive portion, wherein the electromagnetic coil assembly does not rotate, and at least one of the one or more fastener openings establishes an anti-rotation tether point for the electromagnetic coil assembly, A viscous clutch assembly, including a viscous clutch assembly.

15. The aforementioned electrical connector is Mechanical engagement components on or along the internal electrical connection, configured to provide a structural mechanical connection when engaged with other connectors. The viscous clutch assembly according to claim 14, further comprising:

16. The viscous clutch assembly according to claim 15, wherein the mechanical engagement component is selected from the group consisting of (A) a non-circular plug or socket component, (B) one or more retaining claws or retaining openings, and (C) a combination thereof.

17. The electromagnetic coil assembly is The notch in the coil housing interrupts the magnetic flux-conducting metal material, A Hall effect sensor aligned in the aforementioned notch, wherein at least one of the one or more individual electrical connections of the inner conductive portion of the electrical connector is electrically connected to the Hall effect sensor, The viscous clutch assembly according to claim 14, further comprising:

18. A flux guide passing through a portion of the housing, including a rear portion having a target, the rear portion being located adjacent to the Hall effect sensor and separated by a gap so that the target can rotate through the sensing area of ​​the Hall effect sensor, The viscous clutch assembly according to claim 17, further comprising:

19. The rear portion of the flux guide having the target is arranged to be rotatable in a target space located radially inward of the wall of the coil housing and axially forward of the plurality of turns of the winding within the coil housing, and the Hall effect sensor is located on or near the outer diameter of the coil housing and operably facing inward toward the target space, according to claim 18.

20. The electromagnetic coil assembly according to claim 17, wherein the notch is configured as a notch extending to the front edge of the wall of the coil housing so that the front side of the notch is not constrained by the magnetic flux-conducting metal material of the coil housing.

21. The electromagnetic coil assembly according to claim 17, wherein at least a portion of the Hall effect sensor extends into the notch.

22. A cover made of essentially non-metallic material that covers the plurality of turns of the winding within the coil housing, covers at least a portion of the electrical connector, and further covers a portion of the coil housing. The viscous clutch assembly according to claim 14, further comprising:

23. The electromagnetic coil assembly is The notch in the coil housing interrupts the magnetic flux-conducting metal material, A Hall effect sensor aligned in the aforementioned notch, wherein at least one of the one or more individual electrical connections of the inner conductive portion of the electrical connector is electrically connected to the Hall effect sensor, Furthermore, The electromagnetic coil assembly according to claim 22, wherein the Hall effect sensor protrudes at least partially outward from the cover, the cover is made of a polymer material, and the cover encapsulates at least the electromagnetic coil assembly and the electrical connector together as a single unit.

24. The electromagnetic coil assembly according to claim 14, wherein the coil housing has an annular cup shape with an axially open surface on the front side.

25. A rotatable center shaft, A set of bearings, wherein the electromagnetic coil assembly is supported on the center shaft by the set of bearings, The viscous clutch assembly according to claim 14, further comprising:

26. The viscous clutch assembly according to claim 14, wherein the electromagnetic coil assembly is located adjacent to the housing on the external rear side of the viscous clutch assembly.

27. A method for manufacturing a viscous clutch assembly, The steps include providing a clutch pack including a housing, rotor, reservoir, and valve assembly, A step of securing an electromagnetic coil assembly to the clutch pack, wherein the electromagnetic coil assembly includes an electromagnetic coil and a coil-side connector electrically connected to the windings of the electromagnetic coil, and both the clutch pack and the electromagnetic coil assembly are supported on a center shaft. A step of electrically connecting the cable-side connector to the coil-side connector so that the electromagnetic coil is electrically connected to the cable-side connector, wherein the cable-side connector is electrically connected to an electrical cable located outside the clutch pack, The steps include mechanically fixing both the cable-side connector and the coil-side connector, A step of connecting an anti-rotation tether to the cable-side connector and the coil-side connector with a mechanical fastener, wherein the anti-rotation tether is directly connected to the cable-side connector with the mechanical fastener, and the cable-side connector, the coil-side connector and the anti-rotation tether are fixed together with the mechanical fastener at a position away from the internal conductive parts of the cable-side connector and the coil-side connector, respectively, which electrically connects the cable-side connector to the coil-side connector. A method for providing this.

28. The method according to claim 27, wherein the mechanical fastener is a threaded fastener that is screwed into the coil-side connector and further passes through the opening of the cable-side connector and the eyelet of the anti-rotation tether to mechanically fix the cable-side connector and the coil-side connector together, and the anti-rotation tether is directly connected to the cable-side connector.

29. To provide an integrated unit, the step is to enclose at least a portion of the electromagnetic coil and the coil-side connector within a common cover, wherein the common cover covers the turns of the windings located within the coil housing of the electromagnetic coil. The method according to claim 27, further comprising:

30. A step of providing a sensor configured to detect rotational speed, wherein the step of enclosing at least a portion of the electromagnetic coil and the coil-side connector within the common cover further includes enclosing at least a portion of the sensor with the common cover. The method according to claim 29, further comprising the above.

31. A step of positioning the sensor in a notch in the coil housing of the electromagnetic coil, wherein the sensor is a Hall effect sensor and is positioned to detect the rotation of a target supported by the housing of the clutch pack. The method according to claim 30, further comprising the above.

32. Steps to create a seal between the cable-side connector and the coil-side connector. The method according to claim 27, further comprising:

33. A method for manufacturing a viscous clutch assembly, The steps include providing a first clutch pack including a first housing, a first rotor, a first reservoir, and a first valve assembly, A step of providing a second clutch pack comprising a second housing, a second rotor, a second reservoir, and a second valve assembly, wherein the first clutch pack and the second clutch pack have the same configuration, A step of securing a first electromagnetic coil assembly to the first clutch pack, wherein the first electromagnetic coil assembly includes a first electromagnetic coil and a first coil-side connector electrically connected to the first electromagnetic coil, and both the first clutch pack and the first electromagnetic coil assembly are supported on a first center shaft, A step of fixing a second electromagnetic coil assembly to the second clutch pack, wherein the second electromagnetic coil assembly includes a second electromagnetic coil and a second coil-side connector electrically connected to the second electromagnetic coil, and both the second clutch pack and the second electromagnetic coil assembly are supported on a second center shaft, and the second coil-side connector has a different configuration from the first coil-side connector, A step of electrically connecting a first bull side connector to a first coil side connector such that the first electromagnetic coil is electrically connected to the first cable side connector, wherein the first cable side connector is electrically connected to a first electrical cable located outside the first clutch pack, and the first electrical cable has a first length, A step of electrically connecting the second cable-side connector to the second coil-side connector so that a second electromagnetic coil is electrically connected to the second cable-side connector, wherein the second cable-side connector is electrically connected to a second electrical cable located outside the second clutch pack, the second electrical cable has a second length different from the first length of the first electrical cable, and the second cable-side connector has a different configuration from the first cable-side connector so that the first coil-side connector is incompatible with the second cable-side connector and the second coil-side connector is incompatible with the first cable-side connector, The first anti-rotation tether is connected to the first cable-side connector and the first coil-side connector with a first mechanical fastener, the first anti-rotation tether is directly connected to the first cable-side connector with the first mechanical fastener, A method comprising the steps of connecting a second anti-rotation tether to the second cable-side connector and the second coil-side connector with a second mechanical fastener, wherein the second anti-rotation tether is directly connected to the second cable-side connector with the second mechanical fastener.

34. The method according to claim 33, wherein the first and second mechanical fasteners are threaded fasteners that are screwed into the first or second coil-side connector, and further pass through the respective openings of the first or second cable-side connector and the eyelets of the first or second anti-rotation tether.

35. To provide a first integrated unit, the steps include enclosing at least a portion of the first electromagnetic coil and the first coil-side connector with a first common cover, To provide a second integrated unit, the steps include enclosing at least a portion of the second electromagnetic coil and the second coil-side connector with a second common cover, The method according to claim 33, further comprising the above.

36. A step of providing a first sensor configured to detect the rotational speed of the first housing relative to the first electromagnetic coil assembly, wherein the step of enclosing at least a portion of the first electromagnetic coil and the first coil-side connector within a first common cover further comprises enclosing at least a portion of the first sensor within the first common cover. The method according to claim 35, further comprising the above.

37. A step of positioning the first sensor in a notch of the first coil housing of the first electromagnetic coil, wherein the first sensor is a Hall effect sensor, and the first sensor is further positioned to face a first target space, thereby allowing a first target supported by the first housing of the first clutch pack to rotate. The method according to claim 36, further comprising the above.

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