Abstract:
A harmonic drive linear actuator includes a first annular member defining a longitudinal axis and lying on a plane, which is perpendicular to the longitudinal axis. The first member is relatively flexible along a direction parallel to the plane. A second member is substantially coaxially aligned with the first member to define opposed substantially cylindrical surfaces and are fixed for non-relative rotation about the longitudinal axis. An actuator is provided for flexing the first annular member into at least two spaced-apart points of contact between the opposed surfaces and for sequentially flexing the first member to rotate the at least two points of contact circumferentially about the axis. The first and second surfaces define cooperating thread-forms thereon, which selectively engage to effect controlled, bidirectional relative axial displacement between the members in response to sequential flexure of the first member. The linear actuator can be conjoined with an actuator piston of a vehicle brake caliper assembly.

Description:
RELATED PATENT APPLICATIONS 
     This application claims priority to U.S. provisional patent applications Ser. No. 60/676,181 filed 29 Apr. 2005, entitled “Harmonic Linear Actuator” and Ser. No. 60/691,144 filed 16 Jun. 2005, entitled “Harmonic Linear Actuator and Flexing Splined Interlock for Harmonic Motor or Linear Actuator.” 
    
    
     TECHNICAL FIELD 
     The present invention relates to electro-mechanical actuators, and particularly to linear actuators. More particularly still, the present invention relates to the application of harmonic drives as linear actuators and the adaptation thereof for automotive applications. 
     BACKGROUND OF THE INVENTION 
     Harmonic drives have been used as motors and actuators in many electro-mechanical applications. One type of harmonic motor has a rotatable rotor and a surrounding non-rotatable stator. The rotor makes a single point of contact with the inner circumference of the stator. The single point of contact rotates around (i.e. rolls around) the inner circumference of the stator. The rotor rotates a few degrees about its longitudinal axis for each complete rotation of the single point of contact about the inner circumference of the stator. In one modification, the outer circumference of the rotor and the inner circumference of the stator have gear teeth. Such motors find use in high torque, low speed motor applications. 
     In one known variation, the rotatable rotor is above a non-rotatable stator, the rotatable rotor flexes or wobbles downward to make a single point of contact with the stator, the single point of contact rotates around an “inner circumference” of the stator, and the rotor rotates a few degrees about its longitudinal axis for each complete rotation of the single point of contact. 
     In another type of harmonic motor, a shaft is surrounded by a shaft driving member which is brought into a single point of contact with the shaft by electro-restrictive devices, wherein the rotor rotates a few degrees for each complete rotation of the single point of contact around the inner circumference of the shaft driving member. 
     Harmonic drive gear trains are known. In one known design, a motor rotates a “wave generator” which is an egg-shaped member, which flexes diametrically opposite portions of the surrounding flex-spline gear, which is inside an inner gear. As the diametrically opposite teeth of the flex-spline gear contact the teeth of the outer gear, the rotatable one of the gears rotates with respect to the non-rotatable one of the gears. 
     U.S. Pat. No. 6,664,711 to T. Baudendistel describes a harmonic motor which includes a first annular member, a second member, and a device for flexing the first annular member. One of the members is rotatable about the motor&#39;s longitudinal axis, and the other member is non-rotatable. The flexing device flexes the first annual member into at least two spaced-apart points of contact with the second member, and sequentially flexes the first annular member to rotate the at least two spaced-apart points of contact about the longitudinal axis which rotates the rotatable one of the members about the longitudinal axis. 
     By using at least two points of contact between the members, the rotatable one (i.e., the rotor) is being driven by at least two points of contact by the non-rotatable one (i.e. the stator or rotor driving member). Driving the motor with at least two points of contact provides a more robust and more smoothly operating motor than is otherwise provided by the prior art. 
     In certain applications, linear actuators are preferred to motors. For example, a brake system for a motor vehicle, and in particular an automotive vehicle, functionally reduces the speed of the vehicle or maintains the vehicle in a rest position. Various types of brake systems are commonly used in automotive vehicles, including hydraulic, anti-lock or “ABS”, and electric or “brake by wire”. For example, in a hydraulic brake system, the hydraulic fluid transfers energy from a brake pedal to a brake pad for slowing down or stopping rotation of the wheel of the vehicle. Electronic systems control the hydraulic fluid in the hydraulic brake system. In the electric brake system, the hydraulic fluid is eliminated. Instead, the application and release of the brake pad is controlled by an electric caliper. 
     Generally, the electric caliper includes a motor and a gear system. Typically, either a few large gears or many small gears for the gear system are needed to achieve the necessary load transfer. Also, the geometry of the motor influences its efficiency, since the preferred shape is long and thin. However, there is a limited amount of space available in the wheel for packaging the type of gears and motor necessary to obtain the same load transfer as in the hydraulic brake system. Therefore, space limitations constrain the use of an electric caliper in an automotive vehicle. 
     U.S. Pat. No. 6,626,270 to D. Drenner et al. describes a brake caliper which includes an electric motor having a shaft and an associated gear system including first and second planetary gears rotatable engaged with the motor shaft. At least one of the planetary gears is engaged with the shaft and a piston, and is operatively engaged with a first carrier. The other planetary gear is operatively engaged with the first stage carrier and a second carrier. A ball screw is engaged with the second stage carrier for rotation therewith, and a ball screw nut is operatively engaged with the ball screw. 
     Although having many advantages to mechanical brake systems, more recent prior art systems based upon hydraulic pressure behind a piston or, alternatively, an electric motor employed to turn a ballscrew to move a piston to create clamping force in a brake caliper also have drawbacks. Hydraulic brake systems employ a closed hydraulic system filled with hydraulic fluid to control the piston. This approach, although currently common in the industry, can present adverse environmental, assembly, control and safety aspects. Likewise, the electro-mechanical system approach employs multiple parts, which have certain inefficiencies, namely a motor, planetary gear set and ballscrew. These components, in addition to being expensive and difficult to assemble and maintain, also can have the disadvantage of high inertia and back-drivability resistance. 
     It is, therefore, a primary object of the present invention to provide an improved harmonic drive configured as a linear actuator suitable for automotive brake caliper applications in brake by wire systems, which overcomes known shortfalls of existing devices without adding to part count, manufacturing complexity, cost or reduced robustness. 
     SUMMARY OF THE INVENTION 
     Generally, the present invention fulfills the forgoing needs by providing, in one aspect thereof, a robust, compact harmonic drive linear actuator, suitable for application as a piston in the brake caliper assembly of an automotive brake by wire system. The linear actuator provides the benefits of having high force output with virtually no inertia and zero back-drivability while decreasing the component count, weight and cost in a compact, easily packagable and robust design. 
     The presently inventive harmonic drive actuator includes a first annular member defining a longitudinal axis which lies on a plane perpendicular to the longitudinal axis, and wherein the first annular member is relatively flexible along a direction which lies in the plane. A second member is substantially coaxially aligned with the first member and also lies on the plane. The first and second members define opposed substantially cylindrical surfaces, which are fixed for non-relative rotation about the longitudinal axis. Finally, means are provided for flexing the first annular member into at least two spaced-apart points of contact between the surfaces and for sequentially flexing the first annular member to rotate the at least two points of contact circumferentially about the longitudinal axis. The surfaces define cooperating thread-forms thereon which selectively engage to effect relative axial displacement between the first and second members in response to sequential flexure of the first annual member. This arrangement provides a high force, low cost, simple linear actuator, which is compact and easily packaged within the envelope of a traditional automotive brake caliper. 
     According to another aspect of the invention, the second member is relatively rigid and lies on the plane perpendicular to the longitudinal axis. This allows the cylindrical surface defined by the second member to be formed by a structural member to facilitate packaging of the linear actuator. 
     According to another aspect of the invention, the linear actuator further includes means to limit axial displacement of one of the annular members with respect to an adjacent grounded member. Furthermore, the other annular member defined means for urging a load in at least one direction parallel to the longitudinal axis. This feature further enhances adaptability and packaging of the inventive harmonic drive actuator. 
     According to still another aspect of the invention, the means for flexing the first annular member is operable to effect selective bi-directional relative longitudinal displacement between the first and second annular members. This enhances operating speed and ensures against inadvertent lock-up of an associated brake system. 
     According to yet another aspect of the invention, the second annular member defines a rigid, generally cup-shaped member, and the first annular member as well as the means for flexing the first annular member are disposed substantially within the second annular member. This arrangement enhances robustness by protecting the moving parts as well as miniaturization of the linear actuator. 
     According to still yet another aspect of the invention, the means for flexing the first annular member is responsive to an electrical control signal, and is operative to effect radial disengagement of the thread-forms in response to the absence of the control signal, whereby the first and second members are freely axially displaceable with respect to one another. This arrangement has the advantage of providing a “fail silent” operation whenever the actuator is not energized, eliminating many adverse potential failure modes. 
     Application of the invention is particularly advantageous for use in brake caliper assemblies for passenger vehicles. Such an apparatus comprises a brake caliper for applying a clamp load along an actuation axis, a piston slidably disposed in a bore concentric with the axis for applying the clamp load, and a harmonic drive linear actuator disposed for acting upon the piston and an opposed substantially grounded caliper surface. Preferably, elements of the linear actuator are conjoined with the piston. This arrangement provides a robust, high force compact brake actuator. 
     These and other features and advantages of this invention will become apparent upon reading the following specification, which, along with the drawings, describes preferred and alternative embodiments of the invention in detail. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The present invention will now be described, by way of example, with reference to the accompanying drawings, in which: 
         FIG. 1 , is a broken, sectional view of the preferred embodiment of a harmonic drive linear actuator employed within a brake by wire system of an automotive vehicle; 
         FIG. 2 , is a cross-sectional view of the harmonic drive linear actuator of  FIG. 1 , on an enlarged scale; 
         FIG. 3 , is a cross-sectional view taken on lines  3 - 3  of  FIG. 2 ; 
         FIG. 4 , is a cross-sectional view taken on lines  4 - 4  of  FIG. 2 ; and 
         FIG. 5 , is a cross-sectional view similar to that of  FIG. 4 , but where the harmonic drive linear is de-activated. 
     
    
    
     Although the drawings represent embodiments of the present invention, the drawings are not necessarily to scale and certain features may be exaggerated in order to illustrate and explain the present invention. The exemplification set forth herein illustrates an embodiment of the invention, in one form, and such exemplifications are not to be construed as limiting the scope of the invention in any manner. 
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     The present invention is intended for application in varied automotive vehicle applications and will be described in that context. It is to be understood, however, that the present invention could also be successfully applied in many other applications. Accordingly, the claims herein should not be deemed limited to the specifics of the preferred embodiment of the invention described hereunder. 
     Referring to  FIG. 1 , a preferred environment and application of the present invention within the brake system of a passenger vehicle is illustrated. A brake caliper apparatus  10  may include mounting means (not illustrated) for grounding or securing the caliper apparatus  10  to the chassis of a motor vehicle in a manner well known in the art. The caliper apparatus  10  consists of a one-piece cast iron body  12  having an actuator housing portion  14  and an integral brake pad positioning/support portion  16 . In application, the body  12  is disposed adjacent the radially outermost portions of a brake disc  18  which is mounted for rotation with an associated vehicle wheel (not illustrated). 
     Caliper apparatus  10  supports and positions opposed outer and inner brake pads  20  and  22 , respectively, which are positioned to straddle and selectively engage outer and inner surfaces  24  and  26 , respectively, of brake disc  18 . Outer brake pad  20  is mounted on a rightwardly facing thrust surface  28  of support portion  16  and inner brake pad  22  is mounted on a leftwardly facing thrust surface  30  of a piston  32 . Piston  32  is slip fit within a blind bore  34  formed within housing portion  14  of body  12 , opening leftwardly toward brake disc  18 . 
     As will be described in detail herein below, a harmonic drive linear actuator  36  is disposed within bore  34  and is operable to displace the piston  32  and inner brake pad  22  bi-directionally along a longitudinal axis designated A-A. As illustrated in  FIG. 1 , brake caliper apparatus  10  is in a released or non-braking condition, wherein the brake pads  20  and  22  are axially displaced a small distance from surfaces  24  and  26  of brake disc  18 . In this condition, brake disc  18  is free to rotate about its axis of rotation (not illustrated), which is substantially parallel to actuation axis A-A. 
     When braking of a host vehicle is desired, a vehicle braking control system  38  applies a control signal via a line  40  to provide electrical power to linear actuator  36 . Linear actuator  36  then drives the piston  32  and brake pad  22  leftwardly along axis A-A, causing brake pads  20  and  22  to apply opposed clamping forces upon surfaces  24  and  26 , respectively, of brake disc  18 . The amount of force applied by the linear actuator  36  will translate through thrust surfaces  28  and  30  to control the frictional braking forces applied to the brake disc  18  by the brake pads  20  and  22 . 
     Blind bore  34  is defined by a cylindrical wall surface  42  which is concentric with axis A-A, and an end wall surface  44  which is normal to axis A-A. Piston  30  is generally cylindrical in shape and dimensioned for a precise slip-fit within bore  34 . Due to the harsh environment in which the present invention is applied, it is contemplated that a flexible seal will be provided between the piston  32  and the housing portion  14  to prevent the ingress of brake system related debris, environmental contamination or moisture. 
     Referring to  FIGS. 1 and 2 , piston  32  and linear actuator  36  are integrally formed as a single subassembly, which, in the preferred application, is substantially entirely disposed within bore  34  of body  12  of caliper system  10 . Piston  32  is generally cup-shaped, comprising a cylindrical head portion  46  and a circumferential skirt portion  48  integrally formed therewith. The outer surface of head portion  46  forms thrust surface  30 . A keyway  50  is formed in the outer surface of skirt portion  48 , which extends the entire axial length thereof. Keyway  50  mates with a radially inwardly directed guide ridge  52  formed in wall surface  42  of bore  34 . Keyway  50  and guide ridge  52  cooperate to prevent relative rotation and limit piston  32  to axial displacement within bore  34 . 
     The inner surfaces of head portion  46  and skirt portion  48  of piston  32  define a rightwardly opening cylindrical cavity  54 . The inner surface  56  of skirt portion is formed as a succession of concentric, equally dimensioned V-grooves  58 , which are flat walled, and form an overall “sawtooth” configuration with a constant trough-to-trough axial dimension designated “X”. Collectively, the V-grooves are designated as a thread-form with zero pitch. The inner surface  60  of head portion  46  establishes an axial limit of travel for linear actuator  36  as will be described herein below. The entire piston  32  is constructed of machined steel or other suitable material producing a robust, substantially rigid structure. 
     Referring to  FIGS. 2-4 , the structure and operation of linear actuator  36  are illustrated. In addition to the skirt portion  48  of piston  32 , the linear actuator  36  includes an electromagnetic actuator assembly  62  and a flexible annular member  64  disposed generally concentrically within cavity  54  of piston  32 . Electromagnetic actuator assembly  62  includes an armature body  66  fixedly mounted to a splined end of an axially elongated support member  68 . The opposite end of support member  68  is affixed to a base plate  70 . Base plate  70  is disc-shaped having an outer circumferential surface  72  dimensioned similarly to piston skirt portion  48  for slip-fit within bore  34  of brake caliper  10  ( FIG. 1 ). In application, the large leading (right-hand as viewed in  FIG. 2 ) surface  74  of base plate  70  abuts end wall surface  44  of caliper bore  34  to distribute braking forces and to maintain precise axial alignment of linear actuator  36  within bore  34 . A keyway  76  is formed in circumferential surface  72 , which registers with guide ridge  52 . Thus configured, electromagnetic actuator assembly  62 , including support member  68  and base plate  70 , is grounded or fixed from relative rotation with respect to the brake caliper  10 . 
     Armature body  66  is generally spool-shaped, including integral leading and trailing radially outwardly extending flange portions  78  and  80 , respectively, and a reduced diameter central body portion  82 . A plurality of electrical coils or windings  84  are insulatively disposed within central body portion  82  and are each electrically in-circuit with control system  38  via lines  40  ( FIG. 1 ) to define a discrete number of circumferentially arranged poles. 
     Flexible annular member  64  is an open-ended cylinder, which is carried by actuator assembly  62 . Annular member  64  is a bonded composite of a thick-walled inner ring  86  formed of relatively flexible material, and a relatively thin-walled outer ring  88  having ferro-magnetic properties. Annular member  64  is dimensioned whereby its effective inner diameter is somewhat greater than that of the central body portion  82  of armature body  66 , but somewhat lesser than the effective outer diameter of flange portions  78  and  80 . Annual member  64  is axially straddled by flange portions  78  and  80  and has an axial dimension to establish a slip-fit therebetween. Thus configured, annular member  64  is captured and carried by electromagnetic actuator assembly  62 , having no relative freedom of travel in either axial direction and limited relative radial freedom of travel. 
     Referring to  FIGS. 1 and 2 , the outer ring  88  of flexible annular member  64  has an outer surface  90  in which is defined a thread-form  92 . Thread-form  92  is illustrated as a dual helix with a constant trough-to-trough dimension designated “X”. Thus, the pitch of thread-form  92  will result in a relative axial displacement between piston  32  and flexible annular member  64  of “2X” in single 360° point of contact rotation. It is contemplated, however, that differing combinations of thread-forms  58  and  92  can be applied depending upon such variables as clamping force requirements, actuation speed, range of axial displacement, overall diameter of the piston, and the like, as will be apparent to one skilled in the art in light of the present specification. 
     As best viewed in  FIG. 5  where annular member  64  is in a relaxed position, i.e. when none of the electrical coils  84  are electrically energized, member  64  assures a substantially round configuration. Insodoing, a radial space  94  is established between the radially innermost portion of V-grooves/thread-form  58  of surface  56  of skirt portion  48  and the radially outermost portion of thread-form  92  of outer surface  90  of annular member  60 . In this condition, the flexible annular member  64  and electromagnetic actuator assembly  62  is entirely mechanically de-coupled from the piston  32 , and the piston  32  is free for unrestrained axial movement within bore  34  of brake caliper  10 . This releases any brake clamping forces the caliper assembly  10  may have been applying upon the brake disc  18 . 
     Keyways  50  and  76  are continuously engaged with guide ridge  52  independent of their respective axial position within bore  34  of brake caliper. Thus, they are mutually rotatively fixed. 
     The outer circumferential surface of the central body portion  82  of armature body  66  defines a plurality of axially elongated, radially outwardly directed tapered cogs  96  integrally formed therewith. Likewise, the inner circumferential surface of inner ring  86  of flexible annular member  64  defines a plurality of axially elongated, radially inwardly directed tapered cogs  98  integrally formed therewith. The cogs  96  and  98  are complimentarily shaped and circumferentially distributed and interdigitated, as best illustrated in  FIG. 5 . The cogs prevent relative rotation between electromagnetic actuator assembly  62  and flexible annular member  64 , while permitting the limited radial displacement therebetween as described herein above. The axial end surfaces of the cogs  96  and  98  also increase the effective surface area for transferring linear actuator generated axial clamping forces between the electromagnetic actuator assembly  62  and the flexible annular member  64 . 
     Referring to  FIGS. 2-4 , the harmonic drive linear actuator functions by selectively energizing opposed coil pairs within actuator assembly  62 . For example, if an opposed pair of coils  84   a  and  84   b  are energized, they create a magnetic field which attracts nearby portions of the flexible annular member  64 , causing it to distend from the relaxed condition depicted in  FIG. 5  into the elongated or egg-shaped configuration of  FIG. 4 . In  FIG. 4 , the portions of the flexible member  64  are drawn radially inwardly into intimate contact with the outer peripheral surface of central body portion  82  of armature body  66  and are rotatively locked together by the engagement of cooperating cogs  96  and  98 . Simultaneously, opposed (by 90°) portions of the flexible member  64  are deformed radially outwardly into intimate contact with inner surface  56  of skirt portion  48  of piston  32 . This engagement can be supplemented by magnetic repulsion of adjacent reverse polarized coils  84   c  and  84   d.    
     When flexible annular member  64  is distended as illustrated in  FIGS. 1-4 , opposed segments of the tread-form  92  momentarily engage adjacent segments of V-grooves/thread-form  58  to axially lock the flexible annular member  64  with the skirt portion  48 . The areas of engagement are depicted in  FIG. 3  as opposed arcuate segments  100 . Whenever the coils  84  are de-energized, the flexible member  64  returns to the configuration depicted in  FIG. 5  due to the resiliency of its construction. 
     The electrical control of harmonic motors and actuators is well known. For example, U.S. Pat. No. 6,664,711 B2 and U.S. Patent Application 2005/0253675 A1 describe harmonic motors and electrical controllers therefore which can be adopted for use with the present invention. U.S. Pat. No. 6,664,711 B2 and U.S. 2005/0253675 A1 are hereby incorporated herein by reference as an exemplary teaching of one possible approach. It is to be understood that they reflect only one of many possible control strategies. Furthermore, other methodologies for sequentially flexing the flexing member such as mechanical, electrical or electromagnetic could be implemented without departing from the spirit of the invention. 
     In summary, the piston  32  and linear actuator are locked together for relative non-rotation. When the electrical coils  84  are sequentially energized, the localized opposed areas of contact of the opposed thread-forms “walks around” the circumference of the linear actuator  36 , and thereby axially advancing or retracting the piston  32  with respect to the brake caliper body  10 . The inventive linear actuator therefore has very low inertia, excellent back-drivability, a lowered part count (compared to a ball-screw approach) for reliable operation and high linear force output. 
     The only inertia in the device is in the internal actuator employed for flexing or deforming the “flex-tube”. Preferably, this is accomplished electro-magnetically, to virtually eliminate related moving parts. This allows almost instantaneous direction reversal of the linear actuator  36 . The zero back-driveability is achieved by effecting disengagement of the piston  32  with the actuator  36  whenever power is lost, thereby allowing the piston to float. 
     The structure of the present invention is extremely simple, including only an actuator, a flex-tube and a piston. 
     The linear displacement of the actuator is effectively one thread width per revolution. The gain of the actuator can be changed simply by changing the pitch or lead angle of one or both of the thread-forms  58  and  92 . 
     As an analogy, the present invention operates as a “nut” and “bolt”, with the exception that they are in contact in only a limited number of opposing points. The flexible annular member  64  serves as an out-of-round “nut” which preferably contacts the mating “bolt” in only two points, which are 180° apart. The load capacity or limit is effectively reduced as a result of the reduced surface contact area between the “bolt” and out-of-round “nut”. However, this can be accommodated by thickening the “nut” in its axial dimension, i.e. increasing the number of threads and thus the number of thread segments which are engaged with the “bolt” at any given time. As a next step, the threads of the out-of-round “nut are cut as a succession of concentric grooves which are perpendicular to the axis. Assuming that the lead angle and contact circumference is compatible, if the “nut” is turned, the same axial displacement will occur. Finally, instead of spinning the “nut”, the “nut” is held stationary and deformed by changing the minor axis of orientation. In other words, the “nut” is sequentially squeezed, first at a 12 o&#39;clock orientation, then a 1 o&#39;clock orientation, then a 2 o&#39;clock orientation, and so on. Because the “nut” cannot move axially or linearly, the “bolt” will be displaced axially, but without relative rotation. 
     It is to be understood that the invention has been described with reference to specific embodiments and variations to provide the features and advantages previously described and that the embodiments are susceptible of modification as will be apparent to those skilled in the art. 
     Furthermore, it is contemplated that many alternative, common inexpensive materials can be employed to construct the basic constituent components. Accordingly, the forgoing is not to be construed in a limiting sense. 
     The invention has been described in an illustrative manner, and it is to be understood that the terminology, which has been used is intended to be in the nature of words of description rather than of limitation. 
     Obviously, many modifications and variations of the present invention are possible in light of the above teachings. For example, mechanical, hydraulic or other prime movers can be employed to affect the sequenced flexure of the first annular member. It is, therefore, to be understood that within the scope of the appended claims, wherein reference numerals are merely for illustrative purposes and convenience and are not in any way limiting, the invention, which is defined by the following claims as interpreted according to the principles of patent law, including the Doctrine of Equivalents, may be practiced otherwise than is specifically described.