Patent Publication Number: US-2022235831-A1

Title: Teeter-totter strut clutch assembly with unintended-deployment-preventing features

Description:
TECHNICAL FIELD 
     The present disclosure relates to clutch assemblies and, more particularly, to clutch assemblies having teeter-totter struts. 
     BACKGROUND 
     Unintended deployment of locking members employed in clutch assemblies due to shock load is problematic because a shock load force may cause the locking members to be deployed and/or engaged, and may cause undesirable operatioMnSn and/or damage to the clutch assembly. In some clutch assemblies, a solenoid may include a plunger that acts on a strut for purposes of engaging the strut, and in other clutch assemblies the strut operates independently of a solenoid. In either case, if a solenoid spring fails and a shock load occurs, the plunger is free to move thus resulting in unintended deployment of the strut. In another example of unintended deployment, if a strut spring fails, then the strut can freely move toward an engagement face during a shock load. As will be discussed in detail below, the inventors developed designs to prevent such unintended deployment of struts. 
     SUMMARY 
     A clutch assembly includes a pocket plate having a pocket and a teeter-totter strut retained in the pocket. The teeter-totter strut is pivotable to an engaged position in which an engagement face of the teeter-totter strut extends out from the pocket. The teeter-totter strut is pivotable from the engaged position to a disengaged position in which the engagement face of the teeter-totter strut extends within the pocket. The clutch assembly is configured so that when a shock load force acts on the teeter-totter strut, the teeter-totter strut is prevented from moving into the engaged position. 
     A clutch assembly includes an electromechanical component having an actuator and a pocket plate having a pocket with a pivotable teeter-totter strut therein. The teeter-totter strut, in response to the actuator acting on the teeter-totter strut, pivots to an engaged position in which an engagement face of the teeter-totter strut extends out from the pocket plate. The teeter-totter strut, in response to an absence of the actuator acting on the teeter-totter strut, pivots from the engaged position to a disengaged position in which the engagement face of the teeter-totter strut does not extend out from the pocket plate. The teeter-totter strut is configured so that, when a shock load force acts on the teeter-totter strut, the teeter-totter strut prevents movement into the engaged position. 
     A torque locking mechanism for preventing back driving of a rotary stage including a notch plate configured for rotation about a rotational axis includes a coupling face of the notch plate oriented to face axially along the axis and having a set of locking formations angularly spaced about the axis. Each of the locking formations defines a load-bearing surface adapted for abutting engagement with a load-bearing surface of a teeter-totter strut. The torque locking mechanism further includes (i) a pocket plate having the teeter-totter strut and (ii) an electromechanical component having an actuator. The teeter-totter strut is moveable towards the coupling face to a locked position in response to the actuator acting on the teeter-totter strut. The teeter-totter strut abuttingly engages one of the locking formations to prevent rotation of the notch plate in one direction about the rotational axis in the locked position. At least one of the pocket of the pocket plate or the teeter-totter strut is configured so that when a shock load force acts on the teeter-totter strut, the teeter-totter strut is prevented from moving into the engaged position. While the rotary stage is rotating, the teeter-totter strut is in an unlocked position and after the rotary stage ceases rotating, the teeter-totter strut moves into the locked position to prevent the rotary stage from back driving. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective schematic view of various components of a torque locking mechanism or assembly including a locking member in its retracted, unlocked position; 
         FIG. 2  is a perspective schematic view of the various components of the torque locking mechanism or assembly but with the locking member in its engaged, locked position; 
         FIG. 3  is an exploded perspective view of the various components of the torque locking mechanism or assembly; 
         FIG. 4  is an enlarged, perspective, schematic view of a pocket plate or coupling member of the torque locking mechanism or assembly; 
         FIG. 5  is an enlarged, perspective, schematic view of a teeter-totter strut or locking member of the torque locking mechanism or assembly; 
         FIG. 6  is an enlarged, perspective, schematic view of a retainer or cover plate of the torque locking mechanism or assembly; 
         FIG. 7  is a top plan view of the pocket plate or coupling member; 
         FIG. 8  is a sectional view taken along lines  8 - 8  of  FIG. 7  of the pocket plate or coupling member; 
         FIG. 9  is an enlarged, perspective, schematic view of a subassembly including the pocket plate or coupling member, the strut or locking member (in its active and inactive states), the cover or retainer plate, and the threaded fasteners which hold the subassembly together; 
         FIG. 10  is a view, partially broken away and in cross-section, of the torque locking mechanism or assembly in its inactive or unlocked position; 
         FIG. 11  is a view, partially broken away and in cross-section, of the torque locking mechanism or assembly in its active or locked position; 
         FIG. 12  is a schematic view of a shock load applied upward to a locking member in the form of a teeter-totter strut having enhanced features for preventing unintended deployment of the strut due to shock load; 
         FIG. 13  is a schematic view of a shock load applied downward to the teeter-totter strut having enhanced features for preventing unintended deployment of the strut due to shock load; 
         FIG. 14  is a schematic view of a shock load applied upward to the teeter-totter strut having enhanced features for preventing unintended deployment of the strut due to shock load; and 
         FIG. 15  is a schematic view of a shock load applied downward to the teeter-totter strut having enhanced features for preventing unintended deployment of the strut due to shock load. 
     
    
    
     DETAILED DESCRIPTION 
     Detailed embodiments of the present disclosure are disclosed herein; however, it is to be understood that the detailed embodiments are merely exemplary of the present disclosure 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 particular 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 disclosure. 
     The teachings herein provide a torque lock mechanism for an electromechanical system. The electromechanical system may be used in vehicular and non-vehicular applications to slow, stop, and/or prevent movement of a moving component. 
     The torque lock mechanism is a clutch assembly having a normally off teeter-totter strut that is actuated by an actuator. In accordance with embodiments of the present disclosure, the teeter-totter strut has enhanced features for preventing its unintended deployment due to shock load. Other types of clutch assemblies which may have teeter-totter struts having such enhanced features include dynamic controllable clutches (DCC), mechanical diode (MD) one-way clutches, and controllable mechanical diode (CMD) two-way clutches. 
     Referring now to  FIGS. 1 and 2 , there are illustrated various components of a torque locking mechanism  16  including a locking member or teeter-totter strut (“strut”)  18  in its retracted, unlocked position and its engaged, locked position, respectively. The strut  18  is also shown in its retracted position in  FIG. 10  and in its engaged position in  FIG. 11 . The strut  18  is shown in both of its positions in  FIG. 9 . 
     Referring now to  FIGS. 1-3 and 10-11 , the torque locking mechanism  16  includes at least a portion of a notch plate  20 . The notch plate  20  is configured for rotation about a rotational axis  26 . The notch plate  20  has a face  21  oriented to face radially with respect to the rotational axis  26 . The notch plate  20 , for instance, is a component of a rotary stage of an electromechanical system. 
     The portion of the notch plate  20  which forms part of the torque locking mechanism  16  comprises a coupling face  24  which faces axially along the rotational axis  26 . The coupling face  24  has a set of locking formations in the form of notches  28  which form a notch profile in the notch plate  20 . The notches  28  are angularly spaced about the rotational axis  26 . Each notch  28  defines a load-bearing surface  30  (labeled in  FIGS. 10 and 11 ) adapted for abutting engagement with a load-bearing surface  32  of the strut  18 . 
     Referring to  FIGS. 1-4 and 7-11 , there is illustrated a coupling member in the form of a pocket plate, generally indicated at  34 , which serves as a housing for the strut  18 . The pocket plate  34  has a coupling face  35  with a pocket  40  which defines a load bearing shoulder  37 . The strut  18  is biased by a return spring  36  disposed within a spring pocket  38  within the larger pocket  40  towards its unlocked position (shown in  FIGS. 1 and 10 ). 
     The strut  18  pivotally moves within its pocket  40  and is retained therein by a cover or retainer plate, generally indicated at  42 . The cover plate  42  is secured to the pocket plate  34  by a plurality of threaded fasteners such as bolts or screws  44  which extend through holes in the cover plate  42  and into the pocket plate  34 . The cover plate  42  includes a slit  43  which allows the strut  18  to extend therethrough. The strut  18  further includes wings  41  that prevent the strut  18  from completely leaving its pocket  40 . 
     The pocket plate  34  is secured to a housing  45  of an electromechanical component such as a solenoid, generally indicated at  47 , via apertured attachment flanges  46  of the pocket plate  34  and apertured attachment flanges of the housing  45 . Threaded fasteners (not shown) fasten the solenoid  47  to the pocket plate  34 . 
     The solenoid  47  includes an armature  52  (shown in  FIGS. 10-11 ) and an excitation coil  54  which, when energized, causes an actuator in the form of a push pin  56  (i.e., a type of actuator) to linearly move with the armature  52  (the pin  56  being mounted for movement at one end of the armature  52 ) from its position shown in  FIG. 10  to its position shown in  FIG. 11 . Because a distal end  58  of the pin  56  is in close proximity to a lower surface  60  of the strut  18  as shown in  FIG. 10 , translational movement of the pin  58  upward to its uppermost position (shown in  FIG. 11 ), causes the strut  18  to pivot upwardly in its pocket  40  against the biasing action of its strut return spring  36 . When the excitation coil  54  is de-energized, the armature  52  and its pin  56  move downwardly via the biasing action of a solenoid spring (not shown) which extends between an end part  62  of the solenoid  47  and a distal end  64  of the armature  52 . 
     As described above, the electromechanical component or solenoid  47  forms part of the torque locking mechanism  16 . The solenoid  47  is normally off (i.e., the coil  54  is de-energized). The coil  54  is then energized and the pin  56  moves the strut  18  into one of the notches  28  in the notch profile in the notch plate  20 . The rotary stage is then released, and torque is applied to the strut  18  thereby locking the notch plate  20  from rotating in one direction about the rotational axis  26 . Electrical current is then removed from the coil  54  since the strut  18  is held in its extended, locked position by torque. 
     Teeter-Totter Single Strut Insert (SSI) with Shock Load Engagement Prevention 
     The locking member or teeter-totter strut (“strut”)  18  has enhanced features for preventing unintended deployment of the strut  18  due to shock load. As described, the strut  18  is utilized in an electromechanical system utilizing a normally off solenoid  47  with return spring, the pocket plate  34 , the strut return spring  36 , and the cover plate  42 . The system is designed for the push pin  56  to push directly on the strut  18  during engagement. When the system is disengaged, the strut  18  is returned to the “off” position via the strut return spring  36 , and the solenoid  47  is returned via an internal solenoid spring. 
     One consideration when working with an electromechanical system is the implications which a shock load or G-forces can have on the system. A shock load is the force on an object when the object suddenly accelerates or decelerates. In the case of a vehicle when the vehicle goes over a bump, glances off a curb, or is in a collision, a shock load is witnessed by most if not all components in a vehicle. When such an event occurs, the strut  18  in the case of a normally off with solenoid deployment may engage due to this load. 
     The strut  18  in accordance with embodiments of the present disclosure has enhanced features for preventing unintended deployment of the strut  18  due to shock load. Such enhanced features will be described with reference to  FIGS. 12-15 . In general, by utilizing the center of mass (CoM) (or center of gravity (CoG)) of the strut  18  and pivot points, the motion of the strut  18  can be arrested preventing deployment. 
       FIG. 12  is a schematic view of a shock load applied upward (i.e., in the direction of engagement of the engagement face) to the strut  18  having the enhanced features for preventing unintended deployment of the strut  18  due to shock load. For purposes of this description, shock loads are in and out of plane with the strut  18  as shown  FIGS. 12 and 13 . With a conventional teeter-totter strut geometry, the CoM is slightly forward of the pivot point (i.e., toward the strut engagement face). This causes the strut to want to tip up or engage. When a strut unintendedly engages, the event may be damaging. In order to prevent the tendency for the strut  18  to want to engage, the CoM has been moved through geometry changes to behind the pivot point, or towards the location of the strut return spring  36 . By moving the CoM, the moment at the pivot point yields a negative value, meaning the tip of the strut  18  will tend to rotate away from engagement. 
     If, during the shock load event, the solenoid pin  56  were able to move and contact the strut  18 , then this configuration could prevent the pin  56  from being able to move the strut  18  according to the following equations: 
       ΣM≤0
 
       Σ M =(( F   SP   *−D   SP to Pivot )+( G   Force   *M   ST   *−D   CoM to Pivot ))+( G   Force   *M   Pin   *D   Pivot to Pin )
 
     where F SP  is the spring force, D SP to Pivot  is the distance from the spring force to the pivot point, G Force  is the impact load in Gs, M ST  is the mass of the strut, D CoM to Pivot  is the distance from the CoM of the strut to the pivot point, M Pin  is the mass of the pin, and D Pivot to Pin  is the distance from the pivot point to the pin contact point on the strut. 
       FIG. 13  is a schematic view of a shock load applied downward (i.e., in the direction of disengagement of the engagement face) to the strut  18  having the enhanced features for preventing unintended deployment of the strut  18  due to shock load. With the configuration of a teeter-totter strut, a downward force relative to the pivot point in the bottom of the pocket can cause the strut to attempt to engage. To ensure that the strut  18  will not engage, the pivot point in the bottom of the pocket is located to the left (toward the return spring  36 ) of the CoM of the strut. This again results in a negative moment about the pivot point thus causing the tip of the strut  18  to want to move away from the engagement. 
     The following equations are applicable with respect to the enhanced design features that are the subject of  FIG. 13 : 
       ΣM≤0
 
       Σ M =(( F   SP   *−D   SP to Pivot )+(− G   Force   *M   ST   *−D   CoM to Pivot ))
 
     where F SP  is the spring force, D SP to Pivot  is the distance from the spring force to the pivot point, G Force  is the impact load in Gs, M ST  is the mass of the strut, and D CoM to Pivot  is the distance from the CoM of the strut to the pivot point. 
     In order to adjust the CoM of the strut  18  there are several geometric changes which can be made. These include, but are not limited to, lengthening, widening, and/or thickening the strut  18 . The mentioned changes would take place on the side of the ears of the strut  18  which contact the strut return spring  36 . In contrast to this, the opposite changes can be made to the side of the strut  18  which contacts the solenoid pin  56  and have the same result (shortening, narrowing, and/or thinning the strut). In addition, strut pocket geometry can utilize features such as bumps in the pocket  40  and tapered pocket bottoms to create a pivot for downward shock loads. For upward shock loads, the ears of the strut  18  are used as a pivot point. 
     The enhanced features of the strut  18  (i.e., “single strut insert (SSI) with shock-load prevention”) in accordance with embodiments of the present disclosure for preventing unintended deployment of the strut  18  due to shock load are further described as follows. A primary idea of the enhanced features is to design the SSI such that during a shock load in either of the axial directions (+/−) the strut  18  will be unable to deploy based on physics. In this regard, a first sub-idea is to place the center of gravity (CoM) of the strut  18  behind the pivot pin (toward the strut return spring) for a shock load toward the notch engagement surface. A second sub-idea is to alter the pocket geometry such that the CoM of the strut  18  acts on an inclined surface forcing it down in the pocket for a shock load away from the notch engagement surface. 
     1 st  Sub-Idea: CoM of Strut.  FIG. 14  is in relation to the first sub-idea. With the CoM positioned toward the strut return spring, the moments are additive. Through a moment balance, if M is greater than 0, then the tendency of the strut  18  is to remain in the retracted position. By positioning the CoM, increasing mass of the strut, and appropriate spring force, the strut  18  can withstand the shock-load if the solenoid return spring were to fail. 
     Benefits of the first sub-idea may include the following. Reduces the occurrence/detection in the design failure mode and effect analysis (DFMEA). With a severity of ten, reduction of occurrence and detection is desired to lower the risk priority number (RPN). Yields a physics-based solution which can be tested physically and through computer-aided engineering (CAE) to prove the validity of the design. Reduces the spring force in the solenoid and the strut return spring. Depending on force balance the solenoid spring may be reduced because the retention of the solenoid pin is not critical to prevention of deployment. The strut return spring can be reduced if solenoid spring is maintained, this results in less force needed from the solenoid. 
     2 nd  Sub-Idea: Strut Pocket Geometry.  FIG. 15  is in relation to the second sub-idea. The strut pocket is recessed (away from the strut return spring). The angled surface is to exist from behind the CoM—an alternative is to have a bump behind the CoM (small circle). When a downward G-force is exerted the force acts at the CoM, thus due to the angle or bump the tendency is for the portion of the strut  18  to the right of the pivot point will continue to move downward in the retracted position. The pivot moves from strut ears to the point of recess or bump. The CoM is placed in front of the pivot. 
     Benefits of the second sub-idea may include the following. Reduce the occurrence/detection in the DFMEA. With a severity of ten, reduction of occurrence and detection is desired to lower the RPN. Yields a physics-based solution which can be easily analyzed and drive down DFMEA values. Reduce the spring force in the solenoid and the strut return spring. Depending on force balance the solenoid spring could be reduced because the retention of the solenoid pin is not critical to prevention of deployment. The strut return spring can be reduced if the solenoid spring is maintained, this results in less force needed from the solenoid. 
     In sum, the first and second sub-ideas incorporate a physics-based solution to G-loading into the SSI. Through positioning of the CoM of the strut and utilizing pocket geometry to change the pivot point based on direction of impact, the effects of G-loading can be eliminated regarding strut deployment. During a+G-load (direction of strut deployment) the CoM is positioned toward the return spring, behind the pivot, to cause additional retraction forces in conjunction with the return spring. During a−G-load (direction of strut disengagement) a bump or recess in the pocket is to be added to promote the tip of the strut to move toward a farther disengaged position. Due to the position of the CoM to the original pivot location, a−G-load would result in strut deployment if the return spring is compromised or incorrectly specified. By adding the recess to the pocket or the bump, the pivot point is moved, and the strut tends to stay in the retracted position. 
     The enhanced features of the strut  18  are applicable to any other teeter-totter strut having a normally off position that is actuated by some type of actuator. For exemplary purposes, the actuator described herein is the pin  56  of the solenoid  47 . However, the teeter-totter strut  18  with the enhanced design features for preventing unintended deployment of the strut due to shock load may be utilized in other assemblies such as dynamic controllable clutches (DCC), mechanical diode (MD) one-way clutches, and controllable mechanical diode (CMD) two-way clutches having actuators for actuating struts retained in pocket plates. The package simply has to have the ability to shift the CoM toward the strut spring, along with having the ability to axially fit a bump or recessed strut tip into the pocket, as described herein. 
     As described, a consideration when working with an electromechanical system is the implications which a shock load or G-forces can have on the system. The enhanced design features of the strut  18  use two methods to prevent unintended engagement based on geometry and physics. The first method utilizes center of mass (CoM) to prevent unintended engagement of the strut  18  under shock loading. The CoM of the strut  18  is positioned such that it is biased toward the spring side of the strut behind the pivot line. With the CoM being biased in this direction, during a shock load the force acts at the CoM, thus resulting in a retraction force rather than extension. The second method utilizes moment arms to prevent engagement during solenoid spring failure. The strut spring and geometry are utilized to prevent unintended engagement in the event that the solenoid spring fails to maintain the armature position. The mass of the pushpin armature and force application location are such that the strut return spring force and CoM combine to resist the impact from the pushpin assembly. 
     Finally, the subject matter of this application is presently disclosed in conjunction with several explicit illustrative embodiments and modifications to those embodiments, using various terms. All terms used herein are intended to be merely descriptive, rather than necessarily limiting, and are to be interpreted and construed in accordance with their ordinary and customary meaning in the art, unless used in a context that requires a different interpretation. And for the sake of expedience, each explicit illustrative embodiment and modification is hereby incorporated by reference into one or more of the other explicit illustrative embodiments and modifications. As such, many other embodiments, modifications, and equivalents thereto, either exist now or are yet to be discovered and, thus, it is neither intended nor possible to presently describe all such subject matter, which will readily be suggested to persons of ordinary skill in the art in view of the present disclosure. Rather, the present disclosure is intended to embrace all such embodiments and modifications of the subject matter of this application, and equivalents thereto, as fall within the broad scope of the accompanying claims.