Abstract:
An actuator device adapted to move an object. The actuator device includes a motor connectable with a power source and a rotatable member coupled to the motor for rotation about a central axis. The actuator device also includes a swivel arm positioned on the rotatable member for rotation about the central axis relative to the rotatable member. The swivel arm receives movement from a driving portion of the rotatable member. Further, the actuator device includes a cable coupling the swivel arm with the object, whereby the object is movable in response to movement of the swivel arm.

Description:
RELATED APPLICATIONS  
       [0001]    The present application claims the benefit of co-pending Provisional Patent Application Serial No. 60/392,165, filed on Jun. 27, 2002, which is hereby incorporated by reference. 
     
    
     
       FIELD OF THE INVENTION  
         [0002]    This invention relates generally to actuator devices, and more particularly to actuator devices providing linear motion.  
         BACKGROUND OF THE INVENTION  
         [0003]    Conventional actuator devices usually comprise some variation of a housing containing a movable piston with an attached rod therein. The rod usually extends outside of the housing and attaches to the object being actuated. A separate, remotely located power source is typically fluidly connected to the housing to provide a compressed fluid to the housing to move the piston and the rod. Conduit or hose is typically utilized to provide the fluid connection between the power source and the housing. Such a conventional actuator device may include a hydraulic or pneumatic cylinder, in combination with a hydraulic pump or an air pump, respectively.  
           [0004]    Such conventional actuators may be configured, sometimes in combination with additional structure, to push or pull an object, tilt an object, open and close an object, clamp and/or grip an object, and raise and lower an object.  
         SUMMARY OF THE INVENTION  
         [0005]    The present invention provides, in one aspect, an actuator device adapted to move an object. The actuator device includes a motor connectable with a power source and a rotatable member coupled to the motor for rotation about a central axis. The actuator device also includes a swivel arm positioned on the rotatable member for rotation about the central axis relative to the rotatable member. The swivel arm receives movement from a driving portion of the rotatable member. Further, the actuator device includes a cable coupling the swivel arm with the object, whereby the object is movable in response to movement of the swivel arm.  
           [0006]    The present invention provides, in another aspect, an actuating system including an actuator device coupled to an object. The actuator device includes a motor connectable with a power source, a rotatable member coupled to the motor for rotation about a central axis, a protrusion extending from and positioned on the rotatable member a distance from the central axis, a swivel arm receiving movement from the protrusion and being positioned on the rotatable member for rotation relative to the rotatable member about the central axis, and a cable coupled to the swivel arm. The object is coupled to the actuator device by the cable. The cable is moved in response to rotation of the swivel arm to move the object.  
           [0007]    The present invention provides, in yet another aspect, an actuating system including an actuator device coupled to a lever of a clutch/brake assembly. The actuator device includes a motor connectable with a power source, a rotatable member coupled to the motor for rotation about a central axis, a protrusion extending from the rotatable member and positioned on the rotatable member a distance from the central axis, a swivel arm positioned on the rotatable member for rotation relative to the rotatable member about the central axis, the swivel arm receiving movement from the protrusion, and a cable coupled to the swivel arm for movement in response to movement of the swivel arm. The lever of the clutch/brake assembly is selectively actuated to engage and disengage the clutch/brake assembly. The cable is coupled to the lever to engage and disengage the clutch/brake assembly in response to movement of the cable.  
           [0008]    Other features and aspects of the present invention will become apparent to those skilled in the art upon review of the following detailed description, claims and drawings. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0009]    In the drawings, wherein like reference numerals indicate like parts:  
         [0010]    [0010]FIG. 1 is a front perspective view of an actuator device with a portion of the outer structure removed to reveal a portion of the inner structure;  
         [0011]    [0011]FIG. 2 a  is a top view of the actuator device of FIG. 1, illustrating the actuator device in a first position;  
         [0012]    [0012]FIG. 2 b  is a top view of the actuator device of FIG. 1, illustrating the actuator device in a second position;  
         [0013]    [0013]FIG. 2 c  is an enlarged view of a portion of the actuator device of FIG. 1.  
         [0014]    [0014]FIG. 3 is a partial sectional view of the actuator device of FIG. 1.  
         [0015]    [0015]FIG. 4 is an example schematic wiring diagram utilized with the actuator device of FIG. 1;  
         [0016]    [0016]FIG. 5 is a top view of a mower deck, illustrating the actuator device of FIG. 1 coupled to a clutch/brake assembly selectively driving mower blades in the mower deck;  
         [0017]    [0017]FIG. 6 is a top view of a mower deck, illustrating the actuator device of FIG. 1 coupled to an idler pulley selectively tensioning a belt of a pulley system to selectively drive mower blades in the mower deck; and  
         [0018]    [0018]FIG. 7 is a side view of a mower deck coupled to a riding lawnmower, illustrating the actuator device of FIG. 1 coupled to the mower deck to raise and lower the mower deck relative to the riding lawnmower. 
     
    
       [0019]    Before features of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangements of components set forth in the following description or illustrated in the drawings. The invention is capable of other constructions and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limited.  
       DETAILED DESCRIPTION  
       [0020]    With reference to FIG. 1, the actuator device  10  includes a low-torque, high-speed electric motor  14  driving a speed-reducing gearbox  18 . The gearbox  18  converts the motor&#39;s speed and torque input to a suitable speed and torque output via an output shaft  22 . In the illustrated construction of the device  10 , the gearbox  18  is configured to provide a five-stage speed reduction utilizing spur gears. Alternatively, in other constructions of the device  10 , more or fewer stages may be utilized to achieve a different speed reduction. Also, other gear train designs may be utilized to achieve a desired speed reduction.  
         [0021]    The gearbox  18  is mounted to a housing  26 , which contains both mechanical and electrical components. The output shaft  22  extends into the housing  26  and couples to a rotatable member in the form of a timing wheel  34  that selectively imparts movement to a swivel arm  38 . In the illustrated construction (see FIGS. 2 a - 2   b ), the output shaft  22  defines a non-circular cross section, such that upon being inserted through a matching aperture (not shown) in the timing wheel  34 , torque is transmittable from the output shaft  22  to the timing wheel  34 . Alternatively, in other constructions of the device  10 , the timing wheel  34  may be coupled to the output shaft  22  by an interference fit, a locking collar, or by welding, among other conventional methods. The swivel arm  38  is positioned in mating contact with the timing wheel  34  and is coupled to the output shaft  22  for rotation relative to the output shaft  22 .  
         [0022]    The timing wheel  34  is concentrically mounted with the output shaft  22  and includes a projection  46  extending from the top surface of the timing wheel  34 . The projection is positioned on the timing wheel  34  a radial distance from the output shaft  22 . In the illustrated construction of FIGS. 2 a - 2   b , the projection  46  is configured in a cylindrical shape. Alternatively, the projection  46  may be configured in any number of shapes. The projection  46  contacts a side surface  50  of the swivel arm  38  and imparts rotational movement to the swivel arm  38  upon rotation of the timing wheel  34 . The swivel arm  38  co-rotates with the output shaft  22  when driven by the projection  46 , however, the swivel arm  38  is not rotatably fixed to either the output shaft  22  or the timing wheel  34 . The swivel arm  38  is free to rotate about the output shaft  22  and rotate relative to the output shaft  22 . The swivel arm  38  includes a projection  54  extending from the top surface of the swivel arm  38  and positioned at a radial distance from the output shaft  22 . In the illustrated construction, the projection  54  is configured in a cylindrical shape, however, the projection  54  may be configured in any of a number of different shapes.  
         [0023]    A combination of microswitches  58 ,  62  and timing marks  66 ,  70  on the timing wheel  34  control activation of the motor  14 . In the illustrated construction, the timing marks  66 ,  70  are in the form of timing grooves  74 ,  78  formed in the timing wheel  34 . As shown in FIGS. 2 a - 3 , a first microswitch  58  is paired with a first timing groove  74  to deactivate the motor  14  when the timing wheel  34  reaches a first position (shown in FIG. 2 a ), in which a cable  80  attached to the swivel arm  38  is extended from the housing  26 . Likewise, a second microswitch  62  is paired with a second timing groove  78  to deactivate the motor  14  when the timing wheel  34  reaches a second position (shown in FIG. 2 b ), in which the cable  80  is retracted into the housing  26 . In the illustrated construction (see FIG. 2 c ), the first and second microswitches  58 ,  62  are triggered by depressing or releasing respective first and second buttons  82 ,  86 . The first timing groove  74  includes a leading edge  90  and a trailing edge  94  with respect to the direction of rotation of the timing wheel  34 . The second timing groove  78  also includes a leading edge  98  and a trailing edge  102  with respect to the direction of rotation of the timing wheel  34 . The first microswitch  58 , therefore, is triggered by the first timing groove  74  when the first button  82  encounters the leading edge  90  of the first timing groove  74 . Likewise, the second microswitch  62  is triggered by the second timing groove  78  when the second button  86  encounters the leading edge  98  of the second timing groove  78 . The first and second timing grooves  74 ,  78  are formed in the timing wheel  34  such that the timing wheel  34  rotates about 175° from the first position (see FIG. 2 a ) to the second position (see FIG. 2 b ). The first and second timing grooves  74 ,  78  may be formed in the timing wheel  34  by any conventional machining process, or may be integrally formed with the timing wheel  34 .  
         [0024]    Alternatively, timing bumps (not shown) may be used in place of the timing grooves  74 ,  78  to trigger the microswitches  58 ,  62 . Also, the grooves  74 ,  78  or bumps may be placed along any radial or axial position of the timing wheel  34  rather than the illustrated positions in FIGS. 2 a - 3 . Further, any type of position indicator and/or sensor may be used in place of the timing grooves  74 ,  78  and microswitches  58 ,  62 . In another construction of the device (not shown), for example, strips of reflective material adhered to the timing wheel  34  in combination with light sensors positioned adjacent the timing wheel  34  may selectively activate and deactivate the motor  14 . In yet another construction of the device (not shown), for example, individual magnets coupled to the timing wheel  34  in combination with magnetic pick-up sensors or Hall-effect sensors can selectively activate and deactivate the motor  14 .  
         [0025]    The first and second microswitches  58 ,  62 , in addition to the motor  14 , are electrically connected to an electrical circuit  106  that controls operation of the device  10 . Such an electrical circuit  106  is schematically illustrated in FIG. 4. The electrical circuit  106  includes a combination of relays and switches to control operation of the device  10 . The illustrated electrical circuit  106  shows the device  10  interfacing with the components, relays, and switches of a typical riding lawnmower, however, the device  10  may be used in other host vehicles or as part of a fixed structure.  
         [0026]    A 3-position momentary switch  10  is utilized in combination with a relay  114  to activate and deactivate the device  10 . As used herein, “activating” the device  10  includes activating the motor  14  to drive the timing wheel  34  from the first position to the second position. Also, “deactivating” the device  10  includes activating the motor  14  to drive the timing wheel  34  from the second position to the first position. The momentary switch  110  is wired to interface with the microswitches  58 ,  62  in combination with switches of the host vehicle, such as a seat switch  118  or transaxle switch  122  of the riding lawnmower. The seat switch  118  deactivates the device  10  if a rider is not detected on the seat of the riding lawnmower, or the rider leaves the seat while operating the lawnmower. The transaxle switch  122  can deactivate the device  10  upon switching from a forward gear to reverse or neutral. Both the seat switch  118  and the transaxle switch  122 , in combination with the device  10 , enhance the safety features of the riding lawnmower. For example, if the device  10  is deactivated at any time due to either the seat switch  118  or transaxle switch  122  being triggered, the momentary switch  110  requires the rider to reset the relay  114  before once again activating the device  10 . By resetting the relay  114 , this forces the rider to intentionally reactivate the device  10 , rather than by accident. Alternatively, any electrical switch performing similar or different functions as the momentary switch  110  may be used. Also, any combination of switches and/or relays may be used to control operation of the device  10 .  
         [0027]    The housing  26  includes a groove  126  formed in one side of the housing  26  such that the groove  126  extends from the interior of the housing  26  to the exterior of the housing  26 . A cable jacket  130  enclosing the steel cable  80  is positionable within the groove  126  such that one end of the cable  80  extends into the interior of the housing  26 . The end of the cable  80  inside the housing  26  includes an eyelet  138  fixed thereto for engaging the projection  54 . Alternatively, the cable  80  may be coupled to the projection  54  by any of a number of different methods, including being threaded through an aperture (not shown) in the projection  54  and crimping a bulb (not shown) on the end of the cable  80  to secure the cable  80  to the projection  54 . Further, the cable  80  may alternatively be coupled directly to the swivel arm  38 . The end of the cable  80  opposite the end configured with the eyelet  138  is coupled to a resilient member  142  providing a biasing tensile force to the cable  80 . The resilient member  142  may be an integral component of an object being actuated by the device  10 , or the resilient member  142  may be configured as a separate, stand-alone component, such as a spring  146  illustrated in FIGS. 2 a - 2   b.    
         [0028]    A cover  150  is coupled to the housing  26  to secure the jacket  130  in the groove  126  and to protect the interior components in the housing  26 . In the illustrated construction, the cover  150  is fastened to the housing  26  using conventional fasteners (not shown). Also, the cover  150  is configured with a mounting portion  154  that may be formed in any of a number of different configurations for mounting the device  10 .  
         [0029]    During operation of the device  10 , the motor  14  is selectively activated to drive the gearbox  18 , output shaft  22 , and timing wheel  34 . The gearbox  18  is designed to provide a clockwise rotation of the output shaft  22  and timing wheel  34  when viewed from the top of the device  10  (see FIGS. 2 a - 2   b ). Alternatively, the gearbox  18  may provide a counterclockwise rotation to the output shaft  22  and timing wheel  34 . Upon rotation of the timing wheel  34 , the projection  46  contacts the side surface  50  of the swivel arm  38  and imparts rotational movement to the swivel arm  38  for co-rotation with the timing wheel  34 . The rotation of the swivel arm  38  causes movement of the cable  80  relative to the housing  26 . Further, when viewed from the exterior of the housing  26 , the cable  80  appears to experience substantially linear movement. In the illustrated construction of the device  10 , the cable  80  experiences about 1.5 inches of linear movement upon the timing wheel  34  and swivel arm  38  rotating from the first position to the second position. Alternatively, the timing wheel  34  and swivel arm  38  may be sized accordingly to provide more or less linear movement to the cable  80 .  
         [0030]    As shown in FIG. 2 a , the timing wheel  34  is initially shown in the first position with the cable  80  extended from the housing  26 . To activate the device  10 , the motor  14  is activated by the electrical circuit  106  to drive the timing wheel  34  in a clockwise direction, such that the projection  46  on the timing wheel  34  imparts rotation to the swivel arm  38  (shown in phantom in FIG. 2 a ), causing the cable  80  to retract within the housing  26  against the bias of the resilient member  142 .  
         [0031]    The motor  14  will continue to drive the timing wheel  34  until the first microswitch  58  is triggered by the first button  82  encountering the leading edge  90  of the first timing groove  74 , at which time the motor  14  is deactivated. However, once the motor  14  is deactivated, the timing wheel  34  will continue to rotate until internal and external resistance on the motor  14  causes the timing wheel  34  to stop rotating. Such external resistance on the motor  14  may include the biasing forces of the resilient member  142  and/or resistance imparted on the motor  14  by the object being actuated. The first timing groove  74  is formed about 15° along the timing wheel circumference to allow ample time and space for the timing wheel  34  to decelerate and completely stop rotating after the first button  82  initially encounters the leading edge  90  of the first timing groove  74  to deactivate the motor  14 . Forming the first timing groove  74  about 15° along the timing wheel circumference allows the first button  82  to remain in the first timing groove  74  while the timing wheel  34  decelerates after deactivation of the motor  14  (see FIG. 2 c ). For example, if the first timing groove  74  was not long enough, the first button  82  of the first microswitch  58  would encounter the leading edge  90  of the first timing groove  74 , therefore triggering the first microswitch  58  to deactivate the motor  14 , then the first button  82  would encounter the trailing edge  94  of the first timing groove  74  and trigger the first microswitch  58  to reactivate the motor  14 , since the first timing groove  74  was not long enough to allow the timing wheel  34  to decelerate and completely stop rotating. The first timing groove  74  must be sized accordingly to allow ample time and space for the motor  14  (and timing wheel  34 ) to stop rotating so that the motor  14  remains deactivated. However, depending on the motor manufacturer, more or less time and/or space may be required to allow the motor  14  to stop rotating. As a result, more or less than about 15° along the timing wheel circumference may be required for the first timing groove  74 .  
         [0032]    Upon deactivation of the device  10  (shown in FIG. 2 b ) by the electrical circuit  106 , the device  10  “powers itself off” by activating the motor  14  to cause the timing wheel  34  to drive the swivel arm  38  past a centerline  158  defined by the jacket  130 . Once the swivel arm  38  passes through the centerline  158 , the bias of resilient member  142  withdraws the cable  80  from the housing  26  and quickly rotates the swivel arm  38  with respect to the timing wheel  34  back to the first position. The timing wheel  34  continues to rotate until the second button  86  encounters the leading edge  98  of the second timing groove  78  to trigger the second microswitch  62  to deactivate the motor  14 , at which time the timing wheel  34  is returned to the first position (shown in FIG. 2 a ).  
         [0033]    The same requirements exist for the second timing groove  78  as the first timing groove  74 . The second timing groove  78  requires about 35° along the timing wheel circumference to allow ample time and space for the timing wheel  34  to decelerate and completely stop rotating after the second button  86  initially encounters the leading edge  98  of the second timing groove  78  to deactivate the motor  14 . The second timing groove  78  requires more space along the timing wheel circumference because the external resistance on the motor  14  is substantially less when the timing wheel  34  rotates from the second position to the first position (i.e., the biasing forces of the resilient member  142  are not working against the rotation of the timing wheel  34 ). In effect, the motor  14 , when not loaded by the cable  80  and the resilient member  142 , will “free-wheel” after it is deactivated until internal and external resistance on the motor  14  causes it to stop rotating. The second timing groove  78  must be sized accordingly to allow ample time and space for the motor  14  (and timing wheel  34 ) to stop rotating so that the motor  14  remains deactivated. However, depending on the motor manufacturer, more or less time and/or space may be required to allow the motor  14  to stop rotating. As a result, more or less than about 35° along the timing wheel circumference may be required for the second timing groove  78 .  
         [0034]    As shown in FIG. 5, an actuating system  162  may include the device  10  actuating a clutch/brake assembly  166  in a mower deck  170  carried by a riding lawnmower. When activated, the device  10  is operable to engage the clutch/brake assembly  166 , and when deactivated, the device  10  is operable to disengage the clutch/brake assembly  166 . A typical clutch/brake assembly  166  may be found in U.S. Pat. No. 5,570,765. As shown in FIG. 5, the clutch/brake assembly  166  is operable to selectively drive and brake mower blades (not shown) in a mower deck. When the clutch/brake assembly  166  is engaged, a rotating input disc linearly engages an output disc to rotate and drive the mower blades of the mower deck  170 . The output disc is normally resiliently biased toward the brake member, so when the clutch/brake assembly  166  is disengaged, the output disc is urged back against the brake member to initiate braking of the mower blades. The clutch/brake assembly  166  is engaged and disengaged via an internal cam assembly, the cam assembly having a lever  174  protruding from an opening in the clutch/brake assembly housing to actuate the internal cam assembly. In some clutch/brake assemblies  166 , a linear force of about 50 pounds is required to actuate and maintain the lever in a position engaging the clutch/brake assembly  166 .  
         [0035]    The spring  146  is coupled between the steel cable  80  and the lever  174  to provide a window of adjustment of the force applied to the lever  174 . Upon activation of the device  10 , the cable  80  is retracted into the housing  26 , causing the spring  146  to stretch and the lever  174  to pivot. The spring  146  can be sized (both length and stiffness), according to the amount of retraction of the cable  80 , to provide a desired force on the lever  174 . In the illustrated actuating system  162 , once a linear force of about 50 pounds is achieved in the spring  146 , the lever  174  is caused to pivot and engage the clutch/brake assembly  166 . After the lever  174  pivots, the spring  146  will continue to stretch until the cable  80  is retracted the amount governed by the timing wheel  34  and swivel arm  38 . The device  10  may be configured to provide a somewhat slow, and steady engagement of the clutch/brake assembly  166  to prevent jarring impact forces as a result of rapidly engaging the clutch/brake assembly  166 . Also, the device  10  may be configured to disengage the clutch/brake assembly  166  very quickly, such that the response time to deactivating the device  10  to disengaging the clutch/brake assembly  166  is less than about 0.1 seconds.  
         [0036]    As shown in FIG. 6, another actuating system  178  may include the device  10  actuating an idler pulley  182  to engage a belt  186  of a pulley system of a mower deck  194  carried by a riding lawnmower. When activated, the device  10  is operable to engage the idler pulley  182  such that the idler pulley  182  tensions the belt  186  so that torque may be transferred from a driving pulley  198  to driven pulleys  202  in the system  178 , thereby engaging mower blades in the mower deck  194 . When deactivated, the device  10  is operable to disengage the idler pulley  182  from the belt  186 , such that the idler pulley  182  loosens the belt  186  so the belt  186  slips on the pulleys  198 ,  202  and does not transfer torque from the driving pulley  198  to the driven pulleys  202 , thereby disengaging the mower blades in the mower deck  194 . Like the system  162  of FIG. 5, a spring  146  may be utilized in the system  178  of FIG. 6 to adjust the force applied to the idler pulley  182  by the device  10 . Further, the device  10  may be configured in the system  178  of FIG. 6 to provide a slow engagement of the idler pulley  182  and a rapid disengagement, like the device  10  in the system  162  of FIG. 5.  
         [0037]    As shown in FIG. 7, yet another actuating system  206  may include the device  10  raising and lowering a mower deck  210  carried by a riding lawnmower. When activated, the device  10  is operable to raise the mower deck  210  such that mower blades in the mower deck are displaced upwardly relative to the riding lawnmower. When deactivated, the device  10  is operable to lower the mower deck  210  such that the mower blades are displaced downwardly relative to the riding lawnmower. Similar to the system  162  of FIG. 5 and the system  178  of FIG. 6, a spring  146  may be utilized in the system  206  of FIG. 7 to adjust the force applied to the mower deck  210  by the device  10 . Further, the device  10  may be configured in the system  206  of FIG. 7 to raise or lower the mower deck  210  slowly, or raise or lower the mower deck  210  quickly. Further, the timing wheel  34  may define more than two positions (e.g., the first position and the second position), such that multiple mower heights of the mower deck  210  are possible.