Abstract:
An isolator decoupler comprising a pulley, the pulley journalled to a shaft, a torsion spring having an end engaged with the pulley, the torsion spring loadable in an unwinding direction, a one-way clutch carrier, a one-way clutch disposed between the shaft and the one-way clutch carrier, a wrap spring engagable with an inner surface of the one-way clutch carrier, the wrap spring coupled to the torsion spring, and the wrap spring loadable in the unwinding direction such that the wrap spring through friction is able to lockably engage the inner surface in a driving direction.

Description:
FIELD OF THE INVENTION 
     The invention relates to an isolator decoupler having a wrap spring engagable with an inner surface of the one-way clutch carrier, the wrap spring coupled to the torsion spring, and the wrap spring loadable in the unwinding direction such that the wrap spring through friction is able to lockably engage the inner surface in a driving direction. 
     BACKGROUND OF THE INVENTION 
     Diesel engines used for passenger car applications is increasing due to the benefit of better fuel economy. Further, gasoline engines are increasing compression ratios to improve the fuel efficiency. As a result, diesel and gasoline engine accessory drive systems have to overcome the vibrations of greater magnitude from crankshafts due to above mentioned changes in engines. 
     Due to increased crankshaft vibration plus high acceleration/deceleration rates and high alternator inertia the engine accessory drive system is often experiencing belt chirp noise due to belt slip. This will also reduce the belt operating life. 
     Crankshaft isolators/decouplers and alternator decouplers/isolators have been widely used for engines with high angular vibration to filter out vibration in engine operation speed range. However, although a crankshaft isolator can function very well in engine running speed range; it still presents problems during engine start-up or shut-down due to the natural frequency of the isolator itself. 
     Representative of the art is U.S. Pat. No. 8,047,920 which discloses a decoupler having an output member, a one-way clutch, a spring and a spring limiter. The spring is disposed between an output portion of the one-way clutch and the output member to bias the output portion in a predetermined rotational direction relative to the output member. The spring limiter can be configured to lock an output of the one-way clutch to the output member to transmit rotary power between the one-way clutch and the output member without stressing the spring beyond a predetermined point and/or to limit rotational movement of the output portion and an associated end of the spring relative to the output member in the predetermined rotational direction. A method for operating a decoupler is also provided. 
     What is needed is an isolator decoupler having a wrap spring engagable with an inner surface of the one-way clutch carrier, the wrap spring coupled to the torsion spring, and the wrap spring loadable in the unwinding direction such that the wrap spring through friction is able to lockably engage the inner surface in a driving direction. The present invention meets this need. 
     SUMMARY OF THE INVENTION 
     The primary aspect of the invention is an isolator decoupler having a wrap spring engagable with an inner surface of the one-way clutch carrier, the wrap spring coupled to the torsion spring, and the wrap spring loadable in the unwinding direction such that the wrap spring through friction is able to lockably engage the inner surface in a driving direction. 
     Other aspects of the invention will be pointed out or made obvious by the following description of the invention and the accompanying drawings. 
     The invention comprises an isolator decoupler comprising a pulley, the pulley journalled to a shaft, a torsion spring having an end engaged with the pulley, the torsion spring loadable in an unwinding direction, a one-way clutch carrier, a one-way clutch disposed between the shaft and the one-way clutch carrier, a wrap spring engagable with an inner surface of the one-way clutch carrier, the wrap spring coupled to the torsion spring, and the wrap spring loadable in the unwinding direction such that the wrap spring through friction is able to lockably engage the inner surface in a driving direction. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The accompanying drawings, which are incorporated in and form a part of the specification, illustrate preferred embodiments of the present invention, and together with a description, serve to explain the principles of the invention. 
         FIG. 1  is a cross section of the inventive device. 
         FIG. 2  is an exploded view of the device in  FIG. 1 . 
         FIG. 3  is a cross section detail of  FIG. 1 . 
         FIG. 4  is a cross section of an alternate embodiment of the inventive device. 
         FIG. 5  is an exploded view of the device in  FIG. 4 . 
         FIG. 6  is a cross section perspective detail of  FIG. 4 . 
         FIG. 7  is a perspective section detail of  FIG. 4 . 
         FIG. 8  is a perspective section detail of  FIG. 4 . 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     This invention relates to alternator tuning devices, particularly to alternator isolating pulleys with torsional springs for isolation and/or one-way clutches for decoupling. To minimize the physical size of the spring and one-way clutch it is beneificial to have an overload feature that prevents torque in excess of a predetemined amount to be transmitted to the spring and/or one-way clutch. Excessive torque applied to either the spring or one-way clutch could cause either componet to fail. What is needed is a slip feature that permits decoupling of two locked elements when a specific torque is exceeded. 
     It is known that the rated peak torque of an alternator is less than the peak torque observed when starting the engine. For example, a typical automotive alternator will have a rated peak torque of 12 Nm, an inertia of 0.0030 kg m 2 , and an acceleration rate at the alternator of 8,400 rad/s 2  during engine starting. Using Equation 1 at engine start-up the device must be able to handle 25.2 Nm of torque, but will never see such a high torque during all other operating conditions.
 
T=Iα  Equation 1
 
     T=torque 
     I=alternator inertia 
     α=acceleration rate 
     To prevent needing to use a spring and one-way clutch that can handle the starting torque the proposed device uses a wrap spring that is decoupled after the peak rated torque. 
       FIG. 1  is a cross section of the inventive device. Pulley  5  engages with a drive belt to drive the device. The belt (not shown) may comprise any profile known in the art, including multi-rib, toothed or flat. The profile  51  shown for the pulley in  FIG. 1  is for a multi-ribbed belt. 
     Pulley  5  is jounalled to shaft  1  by a needle bearing  4 . Needle bearing  4  allows relative rotational motion between shaft  1  and pulley  5  while also transfering the radial load to shaft  1 . The radial load is a function of the preload or tension on the drive belt. Shaft  1  is also used to connect the device to a driven accessory such as an alternator. 
     Power flows from the belt to pulley  5 , and then to one end  61  of torsion spring  6 . Torsion spring  6  is an elastic member that attenuates vibration and provides the torsional vibration isolating function of the device. The other end  62  of torsion spring  6  is connected to spring carrier  9 . Spring carrier  9  is coupled to wrap spring  7 . Wrap spring  7  is engaged with the spring carrier  9  at a wrap spring end  71 . Spring carrier  9  receives end  71  in a receiving portion  91 . Wrap spring  7  has a square or rectangular cross section in order to optimize the surface available to contact the inner surface  81  of clutch carrier  8 . Wrap spring  7  is contained within a width (W) of the one-way clutch carrier. 
     In order to transmit power, wrap spring  7  is loaded in the unwinding direction which casues it to radially expand during operation. This casues the wrap spring to frictionally engage an inner surface  81  of the clutch carrier  8 . The fricitonal engagement locks the wrap spring and the clutch carrier together to efficiently transmit power. 
     Thrust washers  2  engage both sides of projection  17 . Projection  17  extends radially from shaft  1 . Thrust washers  2  locate pulley  5  axailly along shaft  1 . 
       FIG. 2  is an exploded view of the device in  FIG. 1 . Wrap Spring  7  can be decoupled or slipped relative to clutch carrier  8  to prevent overstressing torsion spring  6 , thereby avoiding overloading one-way clutch  14 . In operation, wrap spring  7  begins to decouple from the inner surface  81  of the clutch carrier  8  after pulley  5  has been anugluarly displaced from the load (or drive) position to a predetermined angle. This predetermined angle is selected so that the torque in torsion spring  6  never exceeds a point where torsion spring  6  or one-way clutch  14  can be damaged. The predetermeind angle for the device in this embodiment is 58 degrees, however, this number is not limiting and can be adjusted depending upon the particular application. 
     In the inventive device wrap spring  7  does not contact the pulley nor the shaft. Wrap spring  7  is contained within a widht (W) of the one-way clutch carrier  8 . 
       FIG. 3  is a cross section detail of  FIG. 1 . To cause wrap spring  7  to decouple or slip, stop  501  on pulley  5  contacts tang  701  on wrap spring  7 , thereby causing wrap spring  7  to wind up and thereby contract radailly inward away from clutch carrier  8  inner surface  81 . The radially inward movement of wrap spring  7  away from clutch carrier  8  reduces the amount of torque that can be transmitted through the frictional engagement of wrap spring  7  to clutch carrier  8  before relative slip occurs between the wrap spring and the clutch carrier. 
     Clutch carrier  8  transfers the torque from wrap spring  7  to one-way clutch  14 . One-way clutch  14  enables shaft  1  to be decoupled from the decoupler when the speed of shaft  1  is greater than the speed of the pulley  5  so that shaft  1  overruns pulley  5 . 
     Bushing  12  is disposed inside clutch carrier  8  and allows relative motion between spring carrier  9  and clutch carrier  8 . Thrust washer  13  permits relative motion between clutch carrier  8  and front cover  10 , which is rigidly fixed to pulley  5 . Cap  11  protects the device from the enviroment by preventing debris from entering. There are two thrust washers ( 2 ) to axially postion pulley  5  relative to shaft  1  while permiting relative rotational motion between the two components. Rear cover  3  is fixed to pulley  5  and enables both thrust washers to be contained between pulley  5  and shaft  1 . 
       FIG. 4  is a cross section of an alternate embodiment of the inventive device. In this alternate embodiment, pulley  5  is journalled to shaft  1  by a ball bearing  15  in addition to the needle bearing  4 . 
       FIG. 5  is an exploded view of the device in  FIG. 4 .  FIG. 6  is a cross section perspective detail of  FIG. 4 . 
     In this embodiment, torsion spring end  62  is engaged with pulley  5  and end  61  is engaged with spring carrier  9 . End  61  engages the spring carrier at portion  91 . Wrap spring  7  is engaged between spring carrier  9  and clutch carrier  8 . Retaining ring.  16  enables spring carrier  9  to transmit torque to wrap spring  7 . Torque from spring carrier  9  is transmitted to retaining ring  16  through three keys  162  on retaining ring  16 . The torque from retaining ring  16  is then transferred to the protruding portion  161  of retaining ring  16  engages an end  71  of wrap spring  7 , whereby wrap spring  7  is loaded in operation (see  FIG. 7 ). 
     A bushing  12  allows spring carrier  9  to slidingly engage clutch carrier  8 . Bushing  12  allows clutch carrier  8  to slidingly engage shaft  1 . 
     In operation, a torque applied to pulley  5  applies a load to torsion spring  6  in the unwinding direction. This torque is transmitted to spring carrier  9  accordingly, which in turn applies a load to wrap spring  7  in the unwinding direction thorugh a contact at end  71 . The amount that torsion spring  6  “unwinds” is a function of the applied torque. Differences in an applied torque to torsion spring  6  will cause the pulley  5  to rotate slightly ahead of a given position of shaft  1 . 
     Loading wrap spring  7  in the unwinding direction causes warp spring  7  to radially expand. The radial expansion causes wrap spring  7  to frictionally engaged with inner surface  81  of clutch carrier  8 . The fricitonal engagement “locks” wrap spring  7  to clutch carrier inner surafce  81  which allows transmission of torque to the clutch carrier  8  up to a predetermeind torque limit. One-way clutch  14  also engages, thereby turning shaft  1 . 
     To cause wrap spring  7  to decouple or slip, pulley  5  rotationally advances under the influence of an increasing torque, thereby causing stop  501  projecting inward from pulley  5  to contact tang  701  on wrap spring  7  upon input of a predetermined excess torque. During normal operation stop  501  does not contact end  701 . Further movement of pulley  5  causes wrap spring  7  to partially wind up, thereby contracting radially inward away from clutch carrier inner surface  81 . The radially inward movement of wrap spring  7  away from clutch carrier inner surface  81  reduces the amount of normal force and therby the fricitonal torque that can be transmitted through wrap spring  7  to clutch carrier  8  before relative slip occurs between the wrap spring  7  and the clutch carrier  8 . This feature prevents damage to the device during an overtorque operating condition. 
       FIG. 7  is a perspective section detail of  FIG. 4 . 
       FIG. 8  is a perspective section detail of  FIG. 4 . 
     Although a form of the invention has been described herein, it will be obvious to those skilled in the art that variations may be made in the construction and relation of parts without departing from the spirit and scope of the invention described herein.