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    • 专利摘要:
    decoupler assembly to transfer torque between a shaft and an endless drive element, and, belt-alternator-start system for a vehicle. in one aspect, a decoupler assembly is provided for use between a shaft and an endless drive element that is used to drive the shaft. the decoupler assembly includes a pulley, a hub and an isolating spring which is referred to as a coiled torsion spring. both ends of the spring are at least indirectly engageable with the pulley and hub to transfer torque between them. at a minimum, one end of the spring engages an engagement structure (either on the pulley or hub) that includes a helical axial shoulder and a drive wall a. the spring transfers torque in one direction through the added wall (eg when the pulley overhangs the hub), but the spring end is not fixedly connected to the drive wall. when the hub exceeds the pulley, there is relative rotation between the spring and either the hub or the pulley, to which it is not fixedly connected. consequently, there is relative rotation between the spring end and the helical axial shoulder and the actuating wall. this causes the end of the spring to separate from the driving wall and mount to the helical axial shoulder. this causes the spring to compress axially. the coils of the spring have a selected amount of spacing so that the spring can be compressed by a selected amount axially. this establishes the amount of relative rotation (and the amount of runout) that is available between the pulley and the hub, in the situation when the hub rides the pulley.
    公开号:BR112013010006B1
    申请号:R112013010006-0
    申请日:2011-11-08
    公开日:2021-07-20
    发明作者:Patrick Marion
    申请人:Litens Automotive Partnership；
    IPC主号:
    专利说明:

    field of invention
    [001] The present invention is related to decoupler sets and, more particularly, to decoupler sets for alternators. Foundation of the invention
    [002] It is known to provide an uncoupling mechanism in an accessory such as an alternator, which is driven by a belt from an engine in a vehicle. Such a decoupling mechanism, which may be referred to as a decoupler, allows the associated accessory to temporarily operate at a speed that is different from the speed of the belt. For example, when there is a sudden stop of the belt when the belt was operating and triggering rotation of the alternator shaft, the decoupler allows the alternator shaft to continue rotating temporarily as a result of inertia, until it decelerates to a stop, as a result of drag, thereby reducing the tension on the alternator shaft. As another example, the decoupler allows the alternator shaft to rotate at a relatively constant speed, even though the engine crankshaft undergoes a cycle of decelerations and accelerations associated with the movement of the pistons.
    [003] Such a decoupler is a valuable addition to the vehicle power package. However, it can be expensive to manufacture for several reasons. An example of what increases its cost is the pulley that is included with it. On certain decouplers the pulley is typically made of steel as it is engaged with a coiled (shielded) spring that is in the decoupler. The pulley can be coated for appearance reasons. The inner surface of the pulley, however, is machined to have selected dimensions, with very tight tolerances, to provide predictability in its engagement with the coiled spring. Thus, coatings that typically have a relatively high variability in their thickness typically cannot be applied to their inner surface that engages the coiled spring. Thus, the coating process becomes more difficult and expensive than it would otherwise be. Additionally, the liner itself can be subject to scratches that could cause the entire decoupler to be rejected when inspected.
    [004] Other problems arise when a decoupler with a coiled spring is used in conjunction with a BAS (Belt-Alternator-Start) system on a vehicle. In such a system, the alternator is driven like an engine and is used to drive the belt so that the belt drives the engine crankshaft to start the engine. The coiled spring, however, prevents the alternator shaft from driving the pulley in any way, and so a separate electric clutch has been proposed to overcome this aspect. However, such clutches are expensive and complex.
    [005] There is a continuing need to reduce its cost, to improve its service life, to reduce its complexity and to simplify its manufacture. It would thus be beneficial to provide a decoupler that addresses one or more of these ongoing needs. Invention Summary
    [006] In a first aspect, the invention is directed to a decoupler assembly for use between a rotating element such as an alternator shaft, and a belt or other endless drive element, which is used to drive the rotating element. The decoupler assembly includes a pulley, a hub and a drive spring which is preferably a coiled torsion spring. Both ends of the spring can be engaged with, at least indirectly, the pulley and hub for torque transfer between them. At least one end of the spring engages a pulley or hub engagement structure that includes a helical axial shoulder and a drive wall. The spring transfers torque in one direction across the drive wall (eg when the pulley overhangs the hub), however the end of the spring is not fixedly connected to the drive wall. As a result, when the hub exceeds the pulley, relative rotation occurs between the spring and any one, the hub or the pulley, that is not fixedly connected. Consequently, there is relative rotation between the spring and the engagement structure (ie, the helical axial shoulder and the driving wall). This causes the end of the spring to separate from the driving wall and mount to the helical axial shoulder. This causes the spring to compress axially. The spring exhales have a selected amount of spacing so that the spring can be compressed by a selected amount axially. This establishes the amount of relative rotation and therefore the amount of runout that is available between the pulley and the hub in that situation, for example, in the situation when the hub rides the pulley.
    [007] In a particular embodiment of the first aspect, the invention is directed to a decoupler assembly to transfer torque between a shaft and an endless drive element. The decoupler assembly includes a hub which is adapted to be coupled to the shaft such that the shaft rotates with the hub about a centerline of rotation, a pulley rotatably coupled to the hub and which has an outer periphery. which is adapted to engage an endless drive element, a helical torsion spring concentric with the center line of rotation, and having a first axial face and a second axial face, and having a plurality of turns that are spaced apart, separated by a plurality of spaces, a first engaging structure positioned between the torsion spring and one, the hub or pulley, and a second engaging structure positioned between the torsion spring and the other of the hub and pulley. The first engaging structure includes a first helical axial shoulder for engaging the first axial face of the torsion spring. The second engagement structure includes a second axial shoulder which is engageable with the second axial face of the torsion spring. Rotation of the pulley in a first direction of rotation relative to the hub triggers the hub rotation via the torsion spring. Hub rotation in the first direction relative to the pulley generates relative rotation between the torsion spring and the first helical axial shoulder, which causes axial compression of the torsion spring between the first and second axial shoulders where the plurality of spaces is sized to provide a selected amount of torsion spring axial compression.
    [008] The decoupler assembly can be used as part of a BAS (Belt-Alternator-Start) system for a vehicle. In one embodiment, the vehicle includes an engine that has a crankshaft, a crankshaft pulley, and a belt that engages with the crankshaft pulley and an alternator. The BAS system includes a decoupler assembly that can be mounted to the alternator shaft. The decoupler assembly includes a hub which is adapted to be coupled to the shaft such that the shaft rotates together with the hub about a centerline of rotation, a pulley rotatably coupled to the hub and which has a periphery. exterior which is adapted to engage an endless drive element, a helical torsion spring concentric with the centerline of rotation and which has a first axial face and a second axial face, and which has a plurality of turns which are spaced apart. separated by a plurality of spaces, a first engaging structure positioned between the torsion spring and one of the hub and pulley and a second engaging structure positioned between the torsion spring and the other of the hub and pulley. The first engaging structure includes a first helical axial shoulder for engaging the first axial face of the torsion spring. The second engagement structure includes a second axial shoulder which is engageable with the second axial face of the torsion spring. Rotation of the pulley in a first direction of rotation relative to the hub triggers the hub rotation via the torsion spring. Hub rotation in the first direction relative to the pulley generates a relative rotation between the torsion spring and the first helical axial shoulder, which causes axial compression of the torsion spring between the first and second axial shoulders. The plurality of spaces are sized to provide a selected amount of torsion spring axial compression. Selected amount of torsion spring compression is achieved in less than 360° of hub rotation relative to pulley. Brief description of the drawings
    [009] The present invention will now be described, by way of examples only, with reference to the attached drawings, in which:
    [0010] Figure 1 is an elevation view of an engine having an accessory drive belt, a plurality of accessories and a decoupler assembly according to an embodiment of the present invention;
    [0011] Figure 2 is an exploded perspective view of the decoupler assembly shown in Figure 1;
    [0012] Figure 3 is a side sectional view of the decoupler assembly shown in Figure 1;
    [0013] Figure 4a is a side view of a portion of the decoupler assembly shown in Figure 1, in a state where the pulley is surmounting the hub of the decoupler assembly;
    [0014] Figure 4b is a side view of the portion of the decoupler assembly shown in figure 4a in a state where the hub is overcoming the decoupler assembly pulley;
    [0015] Figure 5a is an exploded perspective view of a decoupler assembly according to an alternative embodiment of the present invention;
    [0016] Figure 5b is a sectional side view of the decoupler assembly shown in Figure 5a;
    [0017] Figure 5c is a perspective view of a glove that is part of the decoupler assembly shown in Figure 5a;
    [0018] Figure 5d is a sectional view of the end of the decoupler assembly shown in Figure 5b;
    [0019] Figure 6a is a graph illustrating the response of a prior art decoupler assembly to variable torque;
    [0020] Figure 6b is a graph illustrating the response of a decoupler assembly according to an alternative embodiment of the present invention for variable torque;
    [0021] Figures 7a-7g are curves illustrating tests and test results conducted on a prior art decoupler assembly with a coiled spring clutch and a decoupler assembly in accordance with an embodiment of the present invention;
    [0022] Figure 8a is an exploded perspective view of a decoupler assembly according to an alternative embodiment of the present invention;
    [0023] Figure 8b is a side sectional view of the decoupler assembly shown in Figure 8a;
    [0024] Figure 9 is a sectional side view of a cartridge for use with a decoupler assembly in accordance with an alternative embodiment of the present invention;
    [0025] Figure 10 is a sectional side view of a cartridge for use with a decoupler assembly in accordance with an alternative embodiment of the present invention;
    [0026] Figure 11 is a sectional side view of a cartridge for use with a decoupler assembly in accordance with an alternative embodiment of the present invention;
    [0027] Figure 11a is a perspective view of a detail of the cartridge shown in Figure 11;
    [0028] Figure 12 is a side sectional view of a decoupler assembly according to an alternative embodiment of the present invention; and
    [0029] Figure 12a is a perspective view of a detail of the decoupler assembly shown in Figure 12. Detailed description of the invention
    [0030] Reference is made to figure 1 which shows an engine 10 for a vehicle. The motor 10 includes a crankshaft 12 which drives an endless drive element which may be, for example, a belt 14. Through the belt 14 the motor 10 drives a plurality of accessories 16 (shown in broken outlines), such as as an alternator and a compressor. Each fitting 16 includes an input drive shaft 15 with a pulley 13 thereon, which is driven by belt 14. A decoupler assembly 20 is provided, in lieu of a pulley, between belt 12 and input shaft 15 of either one or more of the belt driven attachments 16. The decoupler assembly 20 transfers torque between the belt 14 and the shaft 15, but automatically decouples the shaft 15 from the belt 14 when the belt 14 decelerates relative to the shaft 15. Additionally, The decoupler assembly 20 allows the speed of belt 14 to oscillate relative to shaft 15. Thus, oscillations in belt speed that are the result of oscillations in crankshaft speed (an inherent property of internal combustion piston engines) are dampened. by decoupler assembly 20 and as a result, stresses that would otherwise be incurred by shaft 15 and component 16 are reduced.
    [0031] Referring to figures 2 and 3, the decoupler assembly 20 includes a hub 22, a pulley 24, a first bearing element 26, a second bearing element 27 and an isolation spring 28.
    [0032] Hub 22 can be adapted to mount to accessory shaft 15 (figure 1) in any suitable manner. For example, hub 22 may have a shaft mounting opening 36 therethrough which is used to mount hub 22 to the end of shaft 15 for joint rotation of hub 22 and shaft 15 around a centerline. THE.
    The pulley 24 is rotatably coupled to the hub 22. The pulley 24 has an outer surface 40 that is configured to engage the belt 14. The outer surface 40 is shown as having grooves 42. The belt 14 can thus be a multiple V-belt. It will be understood, however, that the outer surface 40 of the pulley 24 may have any other suitable configuration, and the belt 14 need not be a multiple V-belt. For example, pulley 24 could have a single groove and pulley 14 could be a single V-belt or pulley 24 could have a generally flat portion for engaging a flat belt 14. Pulley 24 further includes an interior surface 43. of some prior art decoupler assemblies, the inner surface 43 of the pulley 24 does not engage a one-way clutch spring and, as a result, the pulley 24 need not be made of a material that resists abrasion or wear from such a spring. of clutch. The pulley 24 can thus be made of any suitable material, such as a polymeric material such as a phenolic type or a nylon 6 reinforced with up to 50% glass. As a result, the pulley can be injection molded and can easily have any suitable finish applied to it. Also, the material can be a selected color, so the pulley is a selected color for appearance purposes, without the need for painting. Paint or some similar coating is required for metal pulleys, however it is susceptible to scratches which can reveal the base material below, leading to a rejection of the assembly during the inspection process. A polymeric pulley, however, even if scratched, remains the same color as the color extends through the entirety making it, therefore, less susceptible to rejection than being scratched. This reduced potential for rejection reduces the overall average cost of manufacturing the pulley. Furthermore, a polymeric pulley 24 can be significantly less expensive to manufacture than a coated steel pulley, due to the lower cost of materials and elimination of the coating step. Additionally, since the pulley 24 is not engaged with a wound spring, the inner surface 43 of the pulley 24 need not be formed to very tight tolerances. In contrast, prior art pulleys that directly engage a clutch spring may, in some cases, require strict dimensional control over the inner surface of the pulley that engages the clutch spring so that the clutch spring operates as designed.
    [0034] The pulley 24 may nevertheless be made of a metallic material such as steel or aluminium. Even when made of steel, however, pulley 24 can be less expensive than some prior art pulleys used in decoupler assemblies. For example, the pulley 24 can be made from a turning and forming process, as necessary to achieve a pulley shape. Such a pulley is described in US Patent number 4,273,547.
    [0035] If made of a polymeric material or a metallic material, the pulley 24 can be made lighter than some prior art pulleys, as it is not necessary to withstand the stresses associated with engagement with a wound spring. Furthermore, it is not necessary to have the tight tolerances associated with some prior art pulleys, and thus similar wall thicknesses can be selected with the aim of lightness and with less emphasis on ensuring the ability to provide tight tolerances on their interior surface. This reduced weight translates to reduced rotational inertia, which can result in reduced energy consumption associated with its rotation. This translates to reduced emissions and/or increased fuel economy for the vehicle in which it is employed.
    [0036] The first bearing element 26 rotatably supports the pulley 24 on the hub 22 at a first axial (proximal) end 44 of the pulley 24. The first bearing element 26 can be any suitable type of bearing element such as a bush. In cases where it is a bushing, it can be made of 4-6 nylon or for some applications it could be PX9A, which is made by DSM in Birmingham, Michigan, USA, or some other suitable polymeric material, and it can be molded directly over pulley 24 in a two-stage molding process in modalities where a molded pulley is supplied. In such a case, the bearing could be inserted into a mold cavity and the pulley 24 could be molded onto the bearing 26. Instead of a polymeric bushing, a metallic bushing (eg bronze) could be provided, which can be inserted into a mold cavity for the pulley molding process in a similar manner to the bearing mentioned above. The first bearing element 26 could alternatively be a bearing (e.g. a ball bearing, or a roller bearing).
    [0037] The second bearing element 27 is positioned at a second axial distal end of the pulley 24, so as to rotatably support the pulley 24 on a pulley support surface 48 of the hub 22. The second bearing element 27 can be any suitable type of bearing element, such as a ball bearing, a roller bearing, or a bushing.
    [0038] The isolation spring 28 is provided to accommodate oscillations in the speed of the belt 14 with respect to the axis 15. The isolation spring 28 may be a helical torsion spring having a first helical end 50 that meets an actuating wall that meets. extends radially 52 (figure 4a) and a first helical axial face 63 which is engaged with a first helical axial shoulder 51 on hub 22 (figures 4a and 4b). Isolation spring 28 has a second helical end 53 (Fig. 3) which engages a radially extending drive wall 54 on pulley 24 and a second helical axial face 65 which is engaged with a second helical axial shoulder 67.
    [0039] In the embodiment shown, the isolation spring 28 has a plurality of turns 58 between the first and second ends 50 and 53. The turns 58 are preferably spaced apart, separated by a plurality of spaces 69 (figure 4a) and the spring of insulation 28 is preferably under a selected amount of axial compression to ensure that first and second helical ends 50 and 53 of spring 28 are secured to helical axial shoulder 51 and drive walls 52 and 54, respectively.
    [0040] The first helical axial shoulder 51 and the first drive wall 52 may together be referred to as a first engagement structure. The second helical axial shoulder 67 and the second drive wall 54 may together be referred to as a second engagement structure.
    [0041] Rotation of the pulley 24 in a first direction of rotation with respect to the hub 22 triggers the rotation of the hub 22 through the torsion spring 28. Rotation of the hub 22 in the first direction with respect to the pulley 24 generates relative rotation between the spring of torsion 28 and the first helical axial shoulder 51, which causes axial compression of the torsion spring 28 between the first and second axial shoulders 51 and 67. The plurality of spaces 69 are sized to provide a selected amount of axial compression of the torsion spring 28 when the decoupler assembly 20 is in an idle state.
    [0042] The isolation spring 28 can be made of any suitable material such as a suitable spring steel. Isolation spring 28 can have any suitable cross-sectional shape. In the figures, the isolation spring 28 is shown as having a rectangular cross-sectional shape, which endows it with a relative torsional strength (i.e. spring constant) for a given occupied volume. A suitable spring constant can be obtained with other cross sectional shapes, such as circular cross sectional shape or square cross sectional shape. This can be advantageous in the sense that it can reduce the cost of the isolating spring as compared to one made of wire which has a rectangular cross section.
    [0043] During use when the pulley 24 is being driven by the belt 14, the pulley 24 drives the rotation of the alternator shaft or any other accessory shaft through engagement of the torsion spring 28 with the first and second drive walls 52 and 54 During a transient event, such as when the engine stops, pulley 24 will be stopped by belt 24, but alternator shaft 15 will continue to rotate for a short period of time. As shown in figures 4a and 4b, hub 22 will rotate with shaft 15, which will bring first actuating wall 22 away from end 50 of spring 28. Helical axial face 51 also rotates with hub 22, and when it rotates, it pushes the axial face 63 of the spring 28 partially proximally (figure 4b), thereby compressing the spring 28 axially. This continues until: shaft 15 stops rotating due to frictional forces or hub 22 rotates enough to trigger axial compression of spring 28 until all coils 58 contact each other, at which point spring 28 locks. that is, no further axial compression is possible, and it no longer allows the hub 22 to further exceed the pulley 24. In the embodiment shown in Figures 4a and 4b there is a selected relative angle between the hub 22 and the pulley 24, at which the spring 28 hangs. This means that the decoupler 20 provides less than 360° of relative movement of the hub 22 relative to the pulley 24. The particular amount of relative movement available before the spring locks can be selected, however, based on the size of the spaces 69. In particular, the amount of relative movement available can be selected to receive the amount needed for most situations. It has been determined that under some circumstances there is less than 70° of relative motion between hub and pulley in a decoupler. Thus, if the amount of relative movement available is selected to be greater than approximately 70°, then various circumstances could be handled by decoupler 20. It will be noted that the amount of relative movement before spring lock could be selected to be any amount up to 360°, or even more in some modes. In a particular embodiment the amount of relative motion available is less than approximately 360°, and more preferably less than approximately 350°.
    [0044] The sizing of spaces 69 can be selected so that there is sufficient clearance to prevent spring 28 from locking, even if there is a full 360° relative rotation by hub 22 relative to pulley 24.
    [0045] Reference is made to figures 5a, 5b, which show a decoupler assembly 129 which is similar to the decoupler assembly 20, but includes a device for damping oscillations, transferring through spring 28, for example, from pulley 24 to hub 22 , and also includes a device to limit the amount of torque that the spring 24 must handle by itself. In the embodiment shown in Figures 5a, 5b, a separate carrier 130 is provided between spring 28 and pulley 24. Carrier 130 may be made of any suitable material, such as a polymeric material. Carrier 130 can be fixedly connected in rotation to pulley 24 by means of a key, a press fit, a groove, or any other suitable structure. A key 131, which is integrated with pulley 24, is shown engaged with a keyway 133 in carrier 130 in Figure 5d. Carrier 130 may have the second engaging structure thereon. When spring 28 expands during use, it may expand enough to scrape against a damping surface 132 on carrier 130. When this occurs, some damping occurs when there are differences in speed between spring 28 and pulley 24.
    [0046] As shown in figures 5a, 5b, and 5c, there is a sleeve 134. The sleeve 134 may be in contact with the inner surface of the pulley 24, but may be unconnected to it (ie, the sleeve 134 may be capable of movement relative to the pulley 24). Glove 134 can have any suitable structure. For example, in the embodiment shown, the sleeve 134 is a full approximately cylindrical shape, as shown in Figure 5c. In another embodiment, the sleeve 134 may be shaped like a spiral spring. In yet another embodiment, the sleeve 134 may be in the form of a complete cylinder. Sleeve 134 surrounds spring 28 and limits the amount of radial expansion that is available to spring 28. If a torque that is sufficiently large is applied across spring 28, spring 28 will expand sufficiently to engage sleeve 134. As shown in Figures 5a, 5b, the sleeve 134 is engaged with the inner surface of the pulley 24, and thus, once the spring 28 engages the sleeve 134, the spring 28 cannot expand further radially. Any larger torque applied through spring 28 is then supported by sleeve 134. In this way, sleeve 134 limits the amount of torque that spring 28 needs to handle by itself. Furthermore, the engagement of spring 28 with sleeve 134, and sleeve 134 with the inner surface of pulley 28, act to dampen oscillations that are transmitted through spring 28. Sleeve 134 can be made of any suitable material, such as a plastic material, eg nylon, or a metal, eg steel. In embodiments in which sleeve 134 is provided, it may simply "float" axially between carrier 130 and an analogous portion 136 on hub 22.
    [0047] As shown in Figures 5a, 5b, the decoupler assembly 129 further includes a retainer 138 that captures the bearing element 27. Also, as shown in Figures 5a, 5b, the bearing element 26 is shown as a bush 140 that is positioned radially between pulley 24 and hub 22 and which is also positioned axially between pulley 24 and carrier 130.
    [0048] Reference is made to figures 8a, 8b, which show a decoupler assembly 150 according to yet another embodiment of the present invention, which may be similar to decoupler assembly 129, but which includes another device for damping oscillations. In the decoupler assembly 150 the bearing element 27 is a bushing 152, not a ball bearing. Bushing 152 is positioned radially between hub 22 and pulley 24 is also positioned axially between the distal end of hub 22 and retainer shown at 154. Bushing 152 provides additional cushioning to decoupler assembly 150 as compared to cushioning provided in decoupler assembly 129.
    [0049] Reference is made to figure 9 which shows a cartridge 160 that can be used during assembly of the decoupler assembly. Cartridge 160 may consist of a carrier associated with pulley 162, a sleeve 164 and a carrier associated with hub 166. The three components 162, 164, 166 can be assembled together and held together with spring 28 (not shown in this figure) captured therein, by means of a robot or an assembly line operator, and can all be mounted together on the hub shown at 168. The carrier associated with hub 166 may rest on a support surface 170 of hub 168. extends in a keyway (similar to that shown in figure 5d) on the support surface 170 can be provided. A similar arrangement can be provided between pulley 24 and carrier 162. Bearing elements to support pulley 24 in the hub are not shown but could be provided.
    [0050] Reference is made to Figure 10, which shows a cartridge 180 which may be similar to cartridge 160, except that cartridge 180 includes only two components: a carrier associated with pulley 182 that can be keyed, for example, with pulley 24, and a carrier associated with hub 184, which includes a sleeve portion shown at 186, which is keyable to a support surface 189 on the hub shown at 188. Bearing elements for supporting pulley 24 on the hub are not shown, however could be provided.
    [0051] Reference is made to Figure 11, which shows a cartridge 190 that may be similar to cartridge 180, except that the carriers associated with the pulley and associated with the hub shown at 192 and 194, respectively, are connected together by a clamp or clamp connection. similar shown at 196. Clamp connection 196 holds cartridge 190 together for easy transport and handling by an assembly line worker or robot during decoupler assembly fabrication. Once the cartridge 190 is mounted on the hub shown at 198, the carriers associated with the pulley and associated with the hub 192 and 194 can be disconnected from each other by any suitable device. For example, as shown in Figure 11, rotation of the two carriers 192, 194 relative to one another can slide the two clamp elements shown at 200 and 202 apart so that they no longer overlap, allowing the spring 28 to push. the two carriers 192 and 194 separate (spring 28 may be in compression when the two carriers 192, 194 are clipped together). During use the two carriers 192 and 194 should remain sufficiently separated so that they might not have any significant risk of rejoining. Bearing elements to support pulley 24 in the hub are not shown but could be provided.
    [0052] Reference is made to Figure 12 which shows a decoupler assembly 210 according to another embodiment of the present invention. In decoupler assembly 210, the first engaging structure includes a helical axial shoulder 212 on the hub shown at 214, which engages a first axial end 216 of a carrier associated with hub 218. Carrier 218 is engaged with spring 28 for joint rotation with he. A drive wall shown at 220 in Figure 12a, on hub 214, engages a corresponding wall 222 on carrier 218. relation to carrier 218 compresses spring 28 (not shown in this figure) axially so as to permit overcoming in a manner similar to that described here elsewhere. A sleeve is shown at 224 and a carrier associated with the pulley is shown at 226. Bearing elements to support the pulley 24 on the hub are not shown but could be provided.
    [0053] During the use of a decoupler assembly in accordance with at least some of the modalities described above, it can be seen that the damping force, that is, the friction force is, at least in part, dependent on the axial force exerted by the spring 28. In such embodiments, when spring 28 is axially compressed by rotation of the first engagement surface, the axial force exerted by spring 28 increases, and thus the damping force provided by the decoupler assembly increases.
    [0054] Damping has been described as being provided by a carrier in conjunction with a friction surface associated with the hub. It will be appreciated that some or substantially all of the damping may be provided in conjunction with a friction surface provided with or associated with the pulley.
    [0055] As shown and described in some embodiments, both the first and second engagement structures include helical drive walls and axial shoulders, so that the spring 28 is not fixedly connected to either end of the hub or pulley. Alternatively, it is possible, however, to fixedly connect one end of the spring 28 to the pulley or hub, and leave the other end of the spring not fixedly connected between the hub or pulley. The unconnected end of spring 28 can be in the hub or it can be in the pulley.
    [0056] In a typical (not overriding) insulator of the prior art, both the first and second ends of the torsion spring are fixedly connected to the hub and pulley, respectively, being bent to form ends that engage slots in the hub and pulley. Figure 6a illustrates the response curve 70 of such a prior art isolator. As can be seen, a first part 72 of curve 70 shows the linear relationship between the relative angle between the hub and pulley and the torque transferred through the torsion spring. When the pulley drives the hub, for example, the torque applied by the pulley through the spring to the hub can be considered positive and the angular change associated with it can be considered to be positive. As torque increases, the relative angle increases relatively linearly.
    [0057] In the insulator modeled in Figure 6a, a sleeve was provided which provides a restriction on the maximum amount of radial expansion that the torsion spring can undergo during use. The second part of the curve shown at 74 illustrates what happens when the spring expands and is constrained by the sleeve. As can be seen, the torque increases almost vertically with essentially no change in the relative angle of the hub and pulley. As can be seen from the curved portion 76, when the transferred torque is reduced, the relative angle essentially reduces, mirroring the second portion of the curve 74. As the spring moves away towards the inside of the sleeve, the reduction in relative angle between the hub and pulley is relatively linear and parallel to the first part of the curve 72. As can be seen in 78, when the hub drives the pulley, for example, when it pulls the pulley to rotate during engine stop, the ends of the spring they move past the rest position and are no longer pushed towards each other to be pulled by the hub and away from each other, which is considered a negative angular change. During this transition, however, a tip can be seen on the curve. This tip occurs when the ends of the spring fit into the slots and are no longer pushed to be pulled. Repeated passage through this region of the graph during insulator use can eventually lead to noise and/or leakage and failure of the hub and/or pulley spring. It can be seen that a similar transition region 80 may exist in part of the curve which illustrates the transition from when the hub pulls the pulley to when the pulley pushes the hub, which again contributes to wear, noise and failure of the spring of the hub and/or pulley during use.
    [0058] In general, an insulator that has both ends of the spring fixedly connected to the hub and pulley benefits enormously from a sleeve as it helps to extend the life of the spring. More specifically, when the spring expands radially, that is, when it transfers torque, the ends of the spring that are held in position are tensioned. Repeated end tensioning can eventually cause spring failure at these points due to fatigue. A sleeve improves this situation by restricting how much the spring can expand radially, however this restricts the isolation the spring is able to provide. In contrast, both ends of spring 28, in at least some of the embodiments shown and described here, are not fixedly connected to the hub and pulley. As a result, spring 28 is not subjected to these aforementioned stresses. As a result, spring 28 can operate without a sleeve, so as to have a greater range of torque that it can handle while, in this way, providing isolation without risk of fatigue and failure at its ends. If a sleeve is provided (as shown in Figures 5a-5c, for example) the sleeve may have greater spacing from spring 28 than would be practical for the spring in the prior art insulator described above, due to the risk of fatigue and failure.
    [0059] Figure 6b shows a curve 81 illustrating the response of the decoupler 20 during use without a glove. The first parts of the curve shown at 82 and 88 may be very similar to the parts 72 and 78 at the curve 70 in Figure 6a. As can be seen when the curve passes in region 90 from a situation where the pulley drives the hub to a situation where the hub exceeds the pulley, the curve then extends horizontally illustrating that there is angular displacement without torque transfer in portion 92 This illustrates when the first end of the spring 50 separated from the drive wall 52. Eventually, if the overrun extended long enough, the hub and pulley could reach a relative angle at which the spring 28 locks, i.e., does not there are spaces remaining between turns 58 and the torque could increase in the negative direction essentially without any change in relative angle, as seen in 94. As can be seen from turn 81 there are no spikes that occur when the spring passes between the hub past the pulley and between the pulley surmounting the hub. This is because, at a minimum, one end of the spring is not fixedly connected to the hub or pulley with which it is engageable.
    Figures 7a-7g illustrate a comparison of the decoupler 20 with a prior art decoupler that includes a one-way wound spring clutch. The graph in Figure 7a shows a steady state test that was performed on both the decoupler 20 and the decoupler with the coiled spring. In this test a sinusoidal torsional vibration was applied to the decouplers, where the applied torque was 2000 Nm+/-300Nm, at a frequency of 21.7 Hz as shown by curve 93. Figure 7b shows the performance of the decoupler of the previous technique with the coiled spring. The curve shown at 95 is the torque applied by the pulley. The curve shown at 96 is the torque applied to the hub. As can be seen, the torque on the hub is phase shifted in time and is lower than the torque applied to the pulley. Figure 7c shows the performance of decoupler 20. The curve shown at 98 is the torque applied by pulley 24. The curve shown at 100 is the torque applied to hub 22. As can be seen, here also the torque in hub 22 is offset in phase in time and is lower than the torque applied to the pulley 24.
    [0061] Figure 7d is a graph that illustrates the performance of the decoupler of the prior art under a first type of transient condition during motor start. The speed of the pulley is represented by curve 102 and the speed of the hub is represented by curve 104. As can be seen, in the region taken as an example 106 there are situations where the speed of the hub is greater than the speed of the pulley, i.e., the hub is surpassing the pulley. Figure 7e is an analogous graph for the decoupler 20. The speed curve of the pulley is shown at 108 and the speed curve of the hub is shown at 110. As can be seen in the regions taken as an example 112, here also the hub overcomes pulley at certain points during engine start.
    [0062] Figure 7f illustrates the response of the decoupler of the prior technique during another transient condition that is the motor stop. Pulley speed and hub speed are represented by curves 114, 116, respectively. As can be seen, the coiled spring allows for a relatively long period of break-in, approximately 0.4 seconds by the hub relative to the pulley as shown in region 118. Figure 7g illustrates the response of the decoupler 20 during engine stall. Pulley speed and hub speed are represented by curves 120 and 122, respectively. As can be seen, the hub repeatedly outruns the pulley for shorter periods of time (see regions 124) during stopping, somewhat mirroring performance during a start situation. While this may in some situations allow a chirping chirp to be emitted due to some degree of belt slippage, in many situations the belt chirping is impeded and in any case if belt chirping is present, the overall stresses on the pulley, the shaft and belt are reduced compared to an arrangement without any insulation or decoupling.
    [0063] A particularly advantageous application for the decoupler assemblies described here is part of a BAS (Belt-Alternator-Start) system for the engine 10. A BAS system starts the engine by turning the crankshaft through the belt instead of through of a starter motor. The belt is driven by the alternator which is energized to operate as an engine on a temporary basis. In such situations, a prior art decoupler, which is equipped with a one-way wound spring clutch, could be operable, since the clutch could prevent the hub from driving the pulley. To overcome this, some systems have been proposed, whereby an electrically actuated clutch is provided, which is actuated during engine start where the hub must actuate the pulley. Such an arrangement can work, but it can be relatively expensive and relatively complex, it can occupy a relatively large space in the already congested engine bays of many vehicles. In contrast, the decoupler assemblies described here, which lock the spring 28 up to 360° of relative rotation between the hub and pulley, automatically allow the hub to drive the pulley and therefore do not require a complex and expensive electrically driven clutch.
    [0064] It can be seen that the decoupler assemblies described here provide some resilience while eliminating the cost and complexity associated with a wound spring and the precisely machined pulley associated with it. In addition to the reduced cost of manufacturing the pulley, there are other advantages provided by the decoupler assembly described here. For example, in decouplers that include coiled springs that engage the pulley's inner surface, it is difficult to efficiently change the design to accommodate a larger pulley. If the pulley inner diameter is changed, then the wound spring needs to be changed and the design will potentially have to be revalidated. If the pulley inner diameter is not changed, although the outer diameter is increased, then the pulley becomes unnecessarily heavy. In contrast, the decoupler assemblies described here need not employ a coiled spring and therefore can easily accommodate an increase in both the outside diameter and the inside diameter of the pulley.
    [0065] While the above description constitutes a plurality of embodiments of the present invention, it will be appreciated that the present invention is susceptible to other modifications and changes without departing from the proper meaning of the accompanying claims.



    权利要求:
    Claims (18)
    [0001]
    1. Decoupler assembly to transfer torque between a shaft and an endless drive element, said decoupler assembly characterized in that it comprises: a hub that is adapted to be coupled to the shaft, in such a way that the shaft rotates together with the hub around a centerline of rotation; a pulley rotatably coupled to the hub, the pulley having an outer periphery that is adapted to engage the endless drive element; a helical torsion spring concentric with the centerline of rotation, which has a first axial face and a second axial face and which has a plurality of turns that are spaced apart, separated by a plurality of spaces; a first engagement structure positioned between the torsion spring and between the hub or pulley wherein the first engaging structure includes a first helical axial shoulder for engaging the first axial face of the torsion spring; and a second engagement structure positioned between the torsion spring and between the hub or pulley, wherein the second engagement structure includes a second axial shoulder engageable with the second axial face of the torsion spring, wherein rotation of the pulley in a first direction of rotation in relation to the hub drives the rotation of the hub through the torsion spring and in which rotation of the hub in the first direction in relation to the pulley generates relative rotation between the torsion spring and the first helical axial shoulder which causes axial compression of the torsion spring between the first and second axial shoulders, in which the plurality of spaces are sized to provide a selected amount of axial compression of the torsion spring so that there is a selected finite amount of relative rotation available between the hub and the pulley before spring lock caused by elimination of axial compression spaces.
    [0002]
    2. Decoupler assembly according to claim 1, characterized in that the selected amount of compression of the torsion spring is achieved in less than 360° of rotation of the hub in relation to the pulley.
    [0003]
    3. Decoupler assembly according to claim 1, characterized in that the selected amount of axial compression of the torsion spring generates a selected increase in friction force on the first helical axial shoulder.
    [0004]
    4. Decoupler assembly according to claim 1, characterized in that the torsion spring has a first helical end and a second helical end in which the first engagement structure includes a first radial shoulder and the second engagement structure includes a second radial shoulder, wherein the generally radial first and second shoulders are positioned to at least indirectly engage the first and second helical ends, respectively, during pulley rotation in the first direction of rotation relative to the hub and wherein the first radial shoulder is spaced from the first helical end during rotation of the hub in the first direction of rotation with respect to the pulley.
    [0005]
    5. Decoupler assembly according to claim 1, characterized in that the torsion spring has a first helical end and a second helical end and the first engagement structure includes a first radial shoulder that is engageable with the first helical end of the spring and the second engagement structure is rotatably fixed, connected with the second helical end of the spring.
    [0006]
    6. Decoupler assembly according to claim 1, characterized in that the first coupling structure is integrated with the pulley and the second coupling structure is integrated with the hub.
    [0007]
    7. Decoupler assembly according to claim 1, characterized in that the first engagement structure is integrated with the hub and the second engagement structure is integrated with the pulley.
    [0008]
    8. Decoupler assembly according to claim 1, characterized in that it further comprises a carrier positioned between the second helical end of the torsion spring and between the hub or pulley, in which the second engagement structure is integrated with the carrier .
    [0009]
    9. Decoupler assembly, according to claim 1, characterized in that it also comprises a bearing positioned between the pulley and the hub.
    [0010]
    10. Decoupler assembly according to claim 1, characterized in that it comprises a bushing positioned between the pulley and the hub.
    [0011]
    11. Decoupler assembly according to claim 1, characterized in that it comprises a sleeve positioned radially on the outside of the torsion spring and which has a selected coefficient of friction.
    [0012]
    12. Decoupler assembly according to claim 1, characterized in that the selected amount of compression of the torsion spring is achieved in more than approximately 50° of rotation of the hub in relation to the pulley.
    [0013]
    13. Decoupler assembly according to claim 1, characterized in that the selected amount of compression of the torsion spring is achieved in more than approximately 70° of rotation of the hub in relation to the pulley.
    [0014]
    14. Decoupler assembly according to claim 1, characterized in that it further comprises a carrier positioned between the first helical end of the torsion spring and the other of the hub and pulley in which the first engagement structure is integrated with the carrier .
    [0015]
    15. Decoupler assembly according to claim 1, characterized in that it further comprises: a first carrier positioned between the first helical end of the torsion spring and between the hub or pulley, and a second carrier positioned between the second helical end of the torsion spring and between hub or pulley.
    [0016]
    16. Decoupler assembly, according to claim 15, characterized in that the first carrier is fixedly mounted to the hub or pulley and the first coupling structure is integrated with the first carrier.
    [0017]
    17. Decoupler assembly according to claim 15, characterized in that the first carrier is fixedly mounted to the torsion spring and the first carrier engages the first helical axial shoulder.
    [0018]
    18. Belt-alternator-start system for a vehicle, the vehicle including an engine that has a crankshaft and that has a crankshaft pulley and a belt that engages with the crankshaft pulley and an alternator, the belt-alternator-start system being characterized in that it comprises: a decoupler assembly that can be mounted on the alternator shaft and in which the decoupler assembly includes: a hub that is adapted to be coupled to the shaft in such a way that the shaft rotates in assembly with the hub about a centerline of rotation; a pulley rotatably coupled to the hub, the pulley having an outer periphery which is adapted to engage the endless drive element; a helical torsion spring concentric with the centerline of rotation and having a first axial face and a second axial face and having a plurality of turns that are spaced apart, separated by a plurality of spaces; a first engagement structure positioned between the torsion spring and between the hub or pulley, wherein the first engaging structure includes a first helical axial shoulder for engaging the first axial face of the torsion spring; and a second engagement structure positioned between the torsion spring and between the hub or pulley, in which the second engagement structure includes a second axial shoulder engageable with the second axial face of the torsion spring, in which rotation of the pulley in a first direction of rotation in relation to the hub drives the rotation of the hub through the torsion spring and in which rotation of the hub in the first direction in relation to the pulley generates relative rotation between the torsion spring and the first helical axial shoulder, which causes axial compression of the torsion spring between the first and second axial shoulders, in which the plurality of spaces are sized to provide a selected amount of torsion spring axial compression, in which the selected amount of torsion spring compression is achieved in less than 360° of rotation of the hub in relation to the pulley, so that the selected amount of axial compression corresponds to a spring lock caused by the elimination of the compression spaces not axial.
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    同族专利:
    公开号 | 公开日
    WO2012061930A1|2012-05-18|
    EP2638304A1|2013-09-18|
    CA2814548C|2018-06-26|
    BR112013010006A2|2020-10-27|
    CA3000102A1|2018-04-03|
    KR101880318B1|2018-07-19|
    EP2638304B1|2019-03-13|
    CA2814548A1|2012-05-18|
    US20150226309A1|2015-08-13|
    CN103221704B|2016-05-18|
    KR20130138255A|2013-12-18|
    US20130237351A1|2013-09-12|
    US9518646B2|2016-12-13|
    US9046133B2|2015-06-02|
    EP2638304A4|2017-10-25|
    CN103221704A|2013-07-24|
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    法律状态:
    2020-11-10| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|
    2020-12-01| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|
    2021-07-06| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|
    2021-07-20| B16A| Patent or certificate of addition of invention granted [chapter 16.1 patent gazette]|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 08/11/2011, OBSERVADAS AS CONDICOES LEGAIS. |
    优先权:
    申请号 | 申请日 | 专利标题
    US41149310P| true| 2010-11-09|2010-11-09|
    US61/411493|2010-11-09|
    US61/411,493|2010-11-09|
    PCT/CA2011/001245|WO2012061930A1|2010-11-09|2011-11-08|Decoupler assembly having limited overrunning capability|
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