Patent Publication Number: US-2023141381-A1

Title: Coupling assembly with detent mechanism

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of U.S. Provisional Application No. 63/276,880, filed Nov. 8, 2021. The disclosure of the above application is incorporated herein by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The invention generally relates to a vehicle power train or drive system; and, more specifically, a system and mechanism for controlling coupling assembly. 
     2. Description of Related Art 
     In automotive technology, existing motor vehicle drive trains use coupling assemblies, including controllable or selectable one-way clutches. These coupling assemblies can be electromagnetically operated and magnetically controlled. 
     SUMMARY OF THE INVENTION 
     A coupling assembly includes a first coupling mechanism and a second coupling mechanism. The coupling assembly further includes an actuation mechanism with a carriage movable between a first, second, and third position. A detent assembly holds the carriage in one of the first, second, and third positions. 
     Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein: 
         FIG.  1    is a cross-sectional schematic side view of a coupling assembly in accordance with one example of the present invention for coupling components in a first position. 
         FIG.  2    is a cross-sectional schematic side view of the coupling assembly of  FIG.  1    in a second position. 
         FIG.  3    is a cross-sectional schematic side view of the coupling assembly of  FIG.  1    in a third position. 
         FIG.  4    is a cross-sectional schematic side view of an alternative example of the coupling assembly in a first position. 
         FIG.  5    is a cross-sectional schematic side view of the coupling assembly of  FIG.  4    in a second position. 
         FIG.  6    is a cross-sectional schematic side view of the coupling assembly of  FIG.  4    in a third position. 
         FIG.  7    is a cross-sectional schematic side view of another alternative example of the coupling assembly in a first position. 
         FIG.  8    is a cross-sectional schematic side view of the coupling assembly of  FIG.  7    in a second position. 
         FIG.  9    is a cross-sectional schematic side view of the coupling assembly of  FIG.  7    in a third position. 
         FIG.  10    is a cross-sectional view of the coupling assembly of  FIG.  1    taken on lines 10-10. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or its uses. 
     Examples of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimized to show details of the components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting but merely as a representative basis for teaching one skilled in the art to variously employ the present invention. 
     The figures illustrate a coupling device or assembly, generally seen at  10 . The coupling device or assembly  10  can be used in place of a traditional dog-clutch/synchronizer in a DCT (dual-clutch transmission), AMT (automated manual transmission), or others. 
     The coupling device or assembly  10  includes a first coupling mechanism  12  and a second coupling mechanism  14 . The first and second coupling members  12 ,  14  may be selectable one-way clutches. A selectable one way clutch can produce a mechanical connection between rotating or stationary components in one or both directions and can overrun in one or both directions and allows the selection of different modes. A selectable one-way clutch can either be static, one race of the clutch does not rotate, or dynamic, both clutch races can rotate. 
       FIG.  10    shows an example of the first coupling mechanism  12  as a selectable one-way clutch that includes a pocket plate  16  and a notch plate  18 . The pocket plate  16  and notch plate  18  are supported for relative rotation about a common axis  20 . The pocket plate  16  includes a shaft or gear connection, illustrated as splines  22 . The pocket plate  16  includes a plurality of pockets  24 . The notch plate  18  connected to a shaft/gear (not shown) includes a plurality of notches  26 . The first coupling mechanism  12  includes a locking member or strut  28  in each pocket  24 . When the locking member or strut  28  extends radially outward of the pocket plate  16 , it engages the notch  26  on the notch plate  18 , coupling the pocket plate  16  to the notch plate  18  and preventing relative rotation between the pocket plate  16  and notch plate  18  in at least one direction. 
     Similar to the first coupling mechanism  12 , the second coupling mechanism  14  is also a selectable one-way clutch that includes a pocket plate  30  and a notch plate  32 . Like the pocket plate  16 , the pocket plate  30  includes a shaft or gear connection, illustrated as splines  34 . The pocket plate  30  and notch plate  32  are supported for relative rotation about the common axis  20 . The pocket plate  30  includes a plurality of pockets  36 . The notch plate  32 , connected to a shaft/gear (not shown), includes a plurality of notches  38 . The second coupling mechanism  14 , includes a locking member or strut  40  in each pocket  36 . When the locking member or strut  40  extends radially outward of the pocket plate  30 , it engages the notch  38  on the notch plate  32 , coupling the pocket plate  30  and the notch plate  32  and preventing relative rotation between the pocket plate  30  and notch plate  32  in at least one direction. 
     The preceding description of a coupling device or assembly  10  is one example illustrating the locking member or strut  28 ,  40  orientation. For example, as shown, when actuated, the struts extend radially in a direction transverse to the direction of the common axis  20 . In another example, the locking member or strut  28 ,  40  may extend axially in the direction of the common axis  20 . 
     An actuation mechanism, generally seen at  42 , moves the locking member or strut  28 ,  40  to an extended position, radially outward of its respective pocket plate  16 ,  30 , as shown in  FIG.  10   . As illustrated, the actuation mechanism includes a fixed or stationary linear actuator or stator  44 . The stator  44  includes three stator coil bays  46 ,  48 ,  50 . The actuation mechanism  42  further includes a translator assembly  51 . The translator assembly  51  includes a linear actuator or translator  52  and a translator plunger  54  supported on a carriage  56 . The carriage  56  is supported adjacent to the pocket plates  16 ,  30  for reciprocal motion in the direction of the longitudinal or common axis  20 . In one example, the carriage  56  moves along the outer circumferential surface  58  of the respective pocket plates  16 ,  30 . The disclosed example shows the individual pocket plates  16 ,  30  sandwiched together, having a common outer circumferential surface  58 . The individual pocket plates  16 ,  30  could be formed as an integral, one-piece unit with a first set of pockets  24  and a second set of pockets  36 . 
     In one example, the actuation mechanism  42  may include a three-position linear actuator movable between a first, second, and third position. Each position may correspond to an operating state or mode. For example, the translator assembly  51  may be placed at a first or left-hand position wherein the translator plunger  54  engages the struts  28  of the pocket plate  16  of the first coupling mechanism  12 ; a second or middle, which may be referred to as a neutral position, in which the translator plunger  54  is spaced from and located between the first coupling mechanism  12  and the second coupling mechanism  14  wherein the translator plunger does not engage the struts  28 ,  40  of the respective pocket plates  16 ,  30 ; and a third or right-hand position wherein the translator plunger  54  engages the struts  40  of the pocket plate  30  of the second coupling mechanism  14 . The disclosure is for illustrative purposes; the operating state or mode of each of the three positions may vary. For example, the second or middle, neutral position need not be a non-engaged, neutral state or mode. Instead, the second or middle, neutral position may be an engaged state or mode. 
     In another embodiment, any of the three positions can be a non-engaged position. For example, the first position can be a non-engaged state or mode, while the second and third positions are engaged states or modes or some combination thereof. While a non-engaged, neutral position state or mode is disclosed as the second or middle position, the non-engaged, neutral position state or mode can be on the far left or far right and not the middle position. 
     Following are various examples of a detent mechanism that holds or secures the translator assembly  51  in the middle position regardless of the operating state or mode, irrespective of the use, state, or mode, of the middle position. 
       FIGS.  1 - 3    illustrate the position of the translator assembly  51 , including the translator  52 , translator plunger  54 , and carriage  56 , and correspondingly, engagement or disengagement between the translator plunger  54  and struts  28 ,  40 . The stator  44  and respective stator coil bays  46 ,  48 ,  50  provide magnetic control forces that magnetically bias the translator assembly  51 , including the translator  52 , translator plunger  54 , and carriage  56  into one of three positions. 
       FIG.  1    illustrates the first position, placing the left-hand clutch or first coupling mechanism  12  in a lock state or mode. The translator assembly  51  is positioned on the left-hand side adjacent to the stator coil bay  46 . The translator plunger  54  contacts and urges the strut  28  radially outward into engagement with the notch  26  of the notch plate  18  and coupling the pocket plate  16  to the notch plate  18 . 
       FIG.  2    illustrates the second position, an in-between or middle position, wherein both the left-hand clutch or first coupling mechanism  12  and the right-hand clutch or second coupling mechanism  14  are in an open or unlocked state or mode. The second position, an in-between or middle position, is located between or in the middle of the first and second positions. As shown in  FIG.  2   , the translator plunger  54 , positioned between the left-hand clutch or first coupling mechanism  12  and the right-hand clutch or second coupling mechanism  14  and adjacent to the stator coil bay  48 , is spaced from and does not contact the struts  28 ,  40 . 
       FIG.  3    illustrates the third position, placing the right-hand clutch or second coupling mechanism  14  in a lock state or mode. The translator assembly  51  is positioned on the right-hand side adjacent to the stator coil bay  50 . The translator plunger  54  contacts and urges the strut  40  radially outward into engagement with the notch  38  of the notch plate  32  and coupling the pocket plate  30  to the notch plate  32 . 
     Energizing a particular stator coil bay  46 ,  48 ,  50  of the stator  44  moves the carriage  56  to one of the first, second, and third positions. Upon actuation/energizing the stator  44 , the translator assembly  51  tends to overshoot when traveling from the left side, or first coupling mechanism  12 , the first position, or from the right side, or second coupling mechanism  14 , third position, to the second position, the in-between or middle position. This may create a non-synchronous engagement on the other outside or opposite position if the overshoot causes the translator assembly  51  to extend too far past the middle position. 
       FIGS.  1 - 3    illustrate one example of the detent mechanism. The detent mechanism includes a mechanical detent assembly  60 . The mechanical detent assembly  60  includes a detent ball  62  biased radially outwardly by a spring  64 . The spring  64  and detent ball  62  cooperate to form a spring-loaded ball located in a bore  66 . The bore  66  extends radially inward from the outer circumferential surface  58  of the respective pocket plates  16 ,  30 . The carriage  56  includes a detent recess  68  having a semispherical/concave shape.  FIG.  2    shows the translator assembly  51 , including the translator  52 , translator plunger  54 , and carriage  56  in the second or middle, neutral position, wherein the spring  64  pushes detent ball  62  into the detent recess  68 , which holds the carriage  56  stationary.  FIG.  1    illustrates the translator assembly  51  in the first position—left-hand clutch/first coupling mechanism  12  in lock state. In the first position, the translator plunger  54  engages the struts  28 . To move the carriage  56  left, in the direction of the arrow  70 , the stator  44 , through stator coil bay  46 , generates an axial force in the direction of the arrow  70 , sufficient to overcome the radial detent force generated by the spring  64  and detent ball  62  on the carriage  56 . When the axial force reaches a predetermined level, the semispherical/concave shape of the detent recess  68  acts as a cam surface and pushes the detent ball  62  inwardly, compressing the spring  64  whereby the carriage  56  continues to move to the left until it reaches a stop surface  72  on the pocket plate  16  with the detent ball  62  engaging an inner circumferential surface  78  of the carriage  56 . 
     As the stator  44  and stator coil bay  48  operate to return the translator assembly  51 , including the translator  52 , translator plunger  54 , and carriage  56  from the first position or left-hand positon shown in  FIG.  1    to the second or middle, neutral position shown in  FIG.  2   , the detent ball  62  reengages the detent recess  68  to catch and hold the carriage  56  in the second or middle, neutral position. 
       FIG.  3    illustrates the translator assembly  51  in the third position—right-hand clutch or second coupling mechanism  14  in lock state. In the third position, the translator plunger  54  engages the struts  40 . To move the carriage  56  right, in the direction of the arrow  74 , the stator  44 , through stator coil bay  46 , generates an axial force in the direction of the arrow  74 , sufficient to overcome the radial detent force generated by the spring  64  and detent ball  62  on the carriage  56 . As shown in  FIG.  4   , when the axial force reaches a predetermined level, the semispherical/concave shape of the detent recess  68  acts as a cam surface and pushes the detent ball  62  inwardly, compressing the spring  64 , whereby the carriage  56  continues to move to the right until it reaches a stop surface  76  on the pocket plate  30 . 
     As the stator  44  and stator coil bay  48  operate to return the translator assembly  51 , including the translator  52 , translator plunger  54 , and carriage  56  form the third or right-hand position shown in  FIG.  3    to the second or middle, neutral position shown in  FIG.  2   , the detent ball  62  reengages the detent recess  68  to catch and hold the carriage  56  in the second or middle, neutral position. 
       FIGS.  4 - 6    illustrate a second example of a detent mechanism. The detent mechanism includes a mechanical detent assembly  80 , including a wave spring  82  having a radially outwardly extending crest  84 . The wave spring  82  rests on the respective outer circumferential surface  58  of the pocket plates  16 ,  30 , wherein the crest  84  engages the semispherical or concave detent recess  68 .  FIG.  5    shows the translator assembly  51 , including the translator  52 , translator plunger  54 , and carriage  56  in the second or middle, neutral position with the crest  84  of the wave spring  82  in the detent recess  68  and holding the carriage  56  stationary.  FIG.  4    illustrates the translator assembly  51  in the first or left-hand position—left-hand clutch/first coupling mechanism  12  in lock state. In the first position, the translator plunger  54  engages the struts  28 . To move the carriage  56  left, in the direction of the arrow  70 , the stator  44 , through stator coil bay  46 , generates an axial force in the direction of arrow  70 , sufficient to overcome the radial detent force generated by the wave spring  82  on the carriage  56 . When the axial force reaches a predetermined level, the semispherical/concave shape of the detent recess  68  and the crest  84  of the wave spring  82  act as cam surfaces, pushing the crest  84  of the wave spring  82  inwardly, flattening the wave spring  82  whereby the carriage  56  continues to move to the left until it reaches a stop surface  72  on the pocket plate  16 . 
     As the stator  44  and stator coil bay  48  operate to return the translator assembly  51 , including the translator  52 , translator plunger  54 , and carriage  56  from the first or left-hand position shown in  FIG.  4    to the second or middle, neutral position shown in  FIG.  5   , the crest  84  of the wave spring  82  engages the detent recess  68  to catch and hold the carriage  56  in the second or middle, neutral position. 
     When moving the translator assembly to the right, in the direction of the arrow  74 , the axial force in the direction of the arrow  74  overcomes the radial detent force generated by the wave spring  82  on the carriage  56 , flattening the wave spring  82 , whereby the carriage moves to the right until it reaches the stop surface  76  on the pocket plate  30 . 
     As the stator  44  and stator coil bay  48  operate to return the translator assembly  51 , including the translator  52 , translator plunger  54 , and carriage  56  from the third or right-hand position shown in  FIG.  6    to the second or middle, neutral position shown in  FIG.  5   , the crest  84  of the wave spring  82  engages the detent recess  68  to catch and hold the carriage  56  in the second or middle, neutral position. 
       FIGS.  7 - 9    illustrate a third example of a detent mechanism. The detent mechanism includes a mechanical detent assembly  90 . The mechanical detent assembly includes a friction member  92  in a bore  94 . As illustrated, the friction member  92  extends outwardly above the radial or circumferential surface  58  of the first and second pocket plates  16 ,  30 .  FIG.  8    shows the translator assembly  51 , including the translator  52 , translator plunger  54 , and carriage  56  in the second or neutral position wherein the entire radial or contact surface  96  of the friction member  92  contacts the carriage  56  and holds the carriage  56  stationary.  FIG.  7    illustrates the translator assembly  51  in the first position—left-hand clutch/first coupling mechanism  12  in lock state. In the first position, the translator plunger  54  engages the struts  28 . To move the carriage  56  left, in the direction of the arrow  70 , the stator  44 , through stator coil bay  46 , generates an axial force in the direction of arrow  70 , sufficient to overcome the frictional force generated by the friction member  92  on the carriage  56 . Depending upon the dimensions/size/surface area of the radial or contact surface  96  of the friction member  92  contacting the carriage  56 , the carriage  56  may clear, or be spaced from, the friction member  92 . When the axial force reaches a predetermined level and overcomes the frictional force generated by the friction member  92  on the carriage  56 , the carriage  56  continues to move to the left until it reaches a stop surface  72  on the pocket plate  16 . 
     As the stator  44  and stator coil bay  48  returns the translator assembly  51 , including the translator  52 , translator plunger  54 , and carriage  56  from the first or right-hand position shown in  FIG.  7    to the second or middle, neutral position shown in  FIG.  8   , the friction member  92  operates to hold the carriage  56  in the second or middle, neutral position. 
       FIG.  9    illustrates the translator assembly  51  in the third position—right-hand clutch/first coupling mechanism  12  in lock state. In the third position, the translator plunger  54  engages the struts  40 . To move the carriage  56  right, in the direction of the arrow  74 , the stator  44 , through stator coil bay  50 , generates an axial force in the direction of arrow  74 , sufficient to overcome the frictional force generated by the friction member  92  on the carriage  56 . Depending upon the dimensions/size/surface area of the radial or contact surface  96  of the friction member  92  contacting the carriage  56 , the carriage  56  may clear, or be spaced from, the friction member  92 . When the axial force reaches a predetermined level and overcomes the frictional force generated by the friction member  92  on the carriage  56 , the carriage  56  continues to move to the right until it reaches a stop surface  76  on the pocket plate  30 . 
     As the stator  44  and stator coil bay  48  returns the translator assembly  51 , including the translator  52 , translator plunger  54 , and carriage  56  from the third or right-hand position shown in  FIG.  9    to the second or middle, neutral position shown in  FIG.  8   , the friction member  92  operates to hold the carriage  56  in the second or middle, neutral position. 
     In a further example, a spring located in the bore  94  may urge the friction member  92  radially outward and increase the frictional force generated on the carriage  56 . In addition, the material of the friction member, for example, a plastic material, may vary to vary the frictional force generated. The size or surface area of the radial or contact surface  96  of the frictional member  92  engaging the carriage  56  also varies the frictional force. In a further embodiment, the frictional member  92  could be a brush or other member that acts on the carriage  56  to control the movement of the carriage  56  and, correspondingly, the translator assembly  51 . 
     Further embodiments may include springs, tension or compression springs attached to the translator assembly  51 , or one or more of the translator  52 , translator plunger  54 , and carriage  56  to control movement relative to the respective pocket plates  16 ,  30 . 
     The detent feature of the foregoing embodiments reduces overshoot of the translator assembly  51  when the translator  52 , translator plunger  54 , and carriage  56  move from the first position to the second or middle position—neutral position. The detent mechanisms keep the translator assembly  51  from over traveling—traveling past the in-between or middle position and potentially engaging the second coupling mechanism  14  when disengaging the first coupling mechanism  12 . For example, the detent mechanism prevents overshoot whereby the translator plunger  54  could potentially engage struts  40  of the pocket plate  30  of the second coupling mechanism  14  when the actuation mechanism  42  operates to disengage or move the translator assembly from the first position to the second position. 
     While the foregoing explains the detent mechanisms used when disengaging the first coupling mechanism  12 , moving from the first position to the second position—in between or middle position, the same applies when disengaging the second coupling mechanism  14 , moving from the third position to the second position—in between or middle position. 
     A mechanical detent, for example, a location of higher friction in the middle of the travel, a solid bump detent that slows down the translator, brushes that slow down the translator, or wave springs to provide a detent feature. The mechanical detent may eliminate the potential of a 3-position linear actuator from overshooting when moving from an end position to the middle position. A linear actuator could be used where standard synchronizers are used today in vehicle transmissions, where the outside positions are locked states, and the middle position is an unlocked state. 
     Each of the first, second, and third positions of the linear actuator, positions of the translator assembly  51 , may be associated with different operating states or modes of the clutch assembly. For example, none of the three positions need to position the translator in a neutral or non-engaged state or mode. In addition, the neutral or non-engaged state or mode may be associated with the far left, first position, or the far right, third position, and not the middle, second position. 
     As set forth herein, the actuation mechanism  42  includes a mechanical detent assembly  60  that holds the translator assembly  51  in a predetermined position associated with different operating states or modes. 
     While examples or exemplary embodiments are described above, these embodiments are not intended to describe all possible forms of the present invention. The words used in the specification are words of description rather than limitation. It is understood that various changes may be made without departing from the spirit and scope of the present invention. Additionally, the features of various implementing embodiments may be combined to form further embodiments of the present invention. 
     The description of the invention is merely exemplary in nature; thus, variations that do not depart from the gist of the invention are intended to be within the scope of the invention.