Electric fan clutch

• US 6,129,193 A
• Filed: 08/26/1998
• Issued: 10/10/2000
• Est. Priority Date: 08/29/1997
• Status: Expired due to Fees

• Current Assignee: American Cooling Systems LLC
• Original Assignee: American Cooling Systems LLC
• Inventors: Link, Larry Ray
• Primary Examiner(s): Marmor, Charles A.
• Assistant Examiner(s): PANG, ROGER L
• Application Number:
  US09/140,511
• Time in Patent Office: 776 Days
• Field of Search: 192/84.1, 192/84.2, 192/84.31, 310/92, 310/62, 310/63, 310/103, 310/156, 310/187
• US Class Current: 192/84.1
• CPC Class Codes: B60H 1/3222 characterised by the compressor driving arrangements, e.g. clutches, transmissions or multiple drives B60H1/3208, B60H1/3226 take precedence
• CPC Class Codes: F01P 7/048 using electrical drives
• CPC Class Codes: F01P 7/081 using clutches, e.g. electro-magnetic or induction clutches
• CPC Class Codes: F04B 35/002 driven by internal combustion engines
• CPC Class Codes: F04D 25/022 comprising a yielding coupling, e.g. hydraulic a magnetic coupling F04D25/026
• CPC Class Codes: F04D 25/026 with a magnetic coupling
• CPC Class Codes: H02K 1/30 using intermediate parts, e.g. spiders
• CPC Class Codes: H02K 49/06 of the synchronous type H02K49/10 takes precedence

Abstract

A magnetic slip clutch system that can be used tin a number of different applications where a slip clutch is desired to be used; and particularly, to applications where the clutch is desired to be fully disengaged, i.e., free-wheeling, fully engaged to transmit 100% of the power, or coupled in a modulated or slip manner for transmission of a variable amount of power. The torque transfer is modulated by controlling the electric power to the clutch.

Claims

1. A magnetic slip clutch comprising:

a frame having a rotational support;

a driving member mounted on the rotational support;

magnetic field, driving elements mounted on the driving member and comprising a series of coils to be energized for creating magnetic fields;

a driven member mounted for rotation on the rotational support;

magnetic field, driven elements separated by an air gap from the series of coils and comprising magnetizable elements without coils which become part of the magnetic fields being generated across the air gap with energization of the series of coils on the driving elements, the magnetizable elements without coils being mounted on the driven member to be magnetically coupled to and driven by the magnetic field, driving elements to rotate the driven member; and

an electrical control circuit connected to supply-modulated electrical power to modulate the energization of the coils and thereby the magnetic field being generated by the magnetic field, driving elements and thereby varying the torque transfer between the driving member and the driven member between substantially no torque transfer to full torque transfer.

2. A magnetic slip clutch in accordance with claim 1, wherein the driven magnetic field elements are metal bars of magnetizable material without coils being wound thereabout and being magnetized across the air gap by the series of coils on the magnetic field, driving elements.

3. A magnetic slip clutch in accordance with claim 2 wherein the magnetic field, driving elements comprise electromagnet coils which are connected to the electrical control circuit.

4. A magnetic slip clutch in accordance with claim 3 including a pulsing circuit to energize the electromagnets in timed sequence to the position of electromagnet coils relative to position of the magnetic field driven elements.

5. A magnetically driven clutch comprising:

a plastic mount connected to a stationary part of the vehicle and having a central hub for the clutch;

a first rotatable plastic member mounted for rotation and carrying an energizable magnetic field;

bearings on the central hub mounting the first rotatable plastic member for rotation about the central hub;

a series of coils mounted on the first rotatable plastic member for connection to an electrical source to be energized to provide the energizable magnetic field;

a second rotatable driven plastic member mounted for rotation relative to the first rotatable member;

magnetic elements on the driven plastic member to be magnetically coupled to the energizable magnetic field to rotate the driven plastic member; and

plastic fan blades on the driven plastic member for being driven by a magnetic clutch formed by the energizable magnetic field and the magnetic elements.

6. A driven, magnetic field and fan blade assembly for a magnetic clutch comprising:

a rotatable, plastic driven member having a body with a central rotational axis;

the body being cup-shaped with a radially extending wall extending radially outwardly and substantially normal to the central rotational axis;

an outer rim supporting portion on the radially extending wall;

an annular rim section on the plastic driven body attached to the outer rim supporting portion and protecting substantially normal to the radially extending wall;

a free end on the annular rim section opposite an end attached to the outer rim supporting portion of the radially extending wall;

a plurality of spaced, magnetic members mounted on the plastic driven member which carries the spaced, magnetic members in a circular path about the rotational axis;

the rim section having its free end located outwardly to allow the rim section to cover the spaced, magnetic members located beneath the rim section; and

plastic fan blades mounted on the rotatable, plastic, cup-shaped body and rotatable with the outer, magnetic members in a circular path about the rotational axis.

7. A magnetic clutch in accordance with claim 6, wherein the magnetic members are molded in situ, in the plastic member.

8. A magnetic driven field assembly in accordance with claim 6 wherein:

raised ribs are molded integrally with the plastic member; and

the raised ribs project outwardly from the plastic member to rotate and to move air to draw heat from the plastic member.

9. A magnetically driven field assembly in accordance with claim 6 wherein,

a honeycomb section is integrally formed on the plastic driven member to reduce the weight thereof and to provide rigidity and to provide heat dissipation.

10. A magnetically driven field assembly in accordance with claim 6 wherein the magnetic driven members comprise a circular series of metal bars of unmagnetized metal embedded in situ, in an outer, annular rim portion of the plastic member.

11. A magnetic field assembly in accordance with claim 6 wherein the plastic fan blades are integrally molded with the plastic of the plastic driven member.

12. A driven magnetic field assembly in accordance with claim 6 wherein the driven member has ribs, and the ribs are aligned with torque lines being endured by the plastic member as it is driven and rotates the plastic fan blades.

13. A driven magnetic field assembly in accordance with claim 6 wherein a ribbed intermediate portion extends radially between the ribbed, central hub and the annular rim section of the plastic member.

14. A driven magnetic field assembly in accordance with claim 6 wherein the driven plastic member comprises a plastic body which weighs less than five pounds.

15. A driving pulley assembly for a magnetic clutch comprising:

a rotatable, magnetic field member rotatable about a central axis;

a plurality of spaced, magnetic members mounted on the field member to magnetically couple to and to drive magnetic field members;

a driving plastic member for carrying the magnetic field member and for rotating the magnetic field member about the central axis;

an outer, annular rim portion on the plastic member;

a fan belt drive portion on the outer rim portion to be driven by a fan belt;

the clutch being a fan clutch, and the plastic member comprising;

a honeycomb section on the fan belt annual ring of the plastic member;

an inner, small diameter hub on the plastic member mounting the same for rotation by the fan belt; and

a honeycomb section on the hub to strengthen the same.

16. A driving pulley assembly for a magnetic clutch comprising:

a rotatable, magnetic field member rotatable about a central axis;

a plurality of spaced, magnetic members mounted on the field member to magnetically couple to and to drive magnetic field members;

a driving plastic member for carrying the magnetic field member and for rotating the magnetic field member about the central axis;

an outer, annular rim portion on the plastic member;

at least one fan belt, grooved portion on the outer rim portion to be driven by a fan belt;

the plastic driving member comprising;

an outer, larger diameter, sheave portion having the annular grooved rim portion thereon;

a smaller diameter hub portion projecting forwardly from and integrally joined to the larger diameter sheave portion; and

strengthening ribs on a radially-extending side of the larger diameter sheave portion extending to the hub portion to cause air flow with rotation of the driving member to radiate heat and to strengthen the plastic driving member.

17. A driving pulley assembly for a magnetic clutch comprising:

a rotatable, magnetic field member rotatable about a central axis;

a plurality of spaced, magnetic members mounted on the field member to magnetically couple to and to drive magnetic field members;

a driving plastic member for carrying the magnetic field member and for rotating the magnetic field member about the central axis;

an outer, annular rim portion on the plastic member;

at least one fan belt, grooved portion on the outer rim portion to be driven by a fan belt;

the magnetic driving members are electromagnets and further comprising;

a series of rings in the form of flat discs having radial faces abutted against each other;

aligned openings are provided in the radial faces of the flat discs; and

the electromagnets comprise coils of wires wound through the openings in the abutted flat discs.

18. A magnetically driven clutch comprising:

a driving member mounted for rotation about an axis and mounted on a stationary mount;

an annular ring on the driving member for being driven by a belt;

magnetic field, driving members mounted on the plastic driving member for creating magnetic fields;

a driven member mounted on the stationary mount for rotation about the rotational axis of the driving member;

first, magnetic, field driven members mounted on the driven member to be magnetically coupled to and driven by the magnetic field, driving members to rotate the driven member at a rotational velocity of substantially less than the rotation velocity of driving member; and

an electrical generator having a portion mounted on the driving member and rotated by the driving member to generate electrical power for the magnetic clutch.

19. A magnetic clutch in accordance with claim 18 wherein the electrical generator comprises a first series of stationary magnetic coils receiving a trickle current;

and

a series of electromagnetic coils carried on the driving member for rotation past magnetic driven members as the driving member is rotated.

20. A magnetic clutch in accordance with claim 18 wherein the electrical generator generates AC current;

and

a rectifier converts the AC current to DC current for the electromagnetic clutch coils on the driving member.

21. A magnetic clutch in accordance with claim 18 wherein a pulsing circuit provides pulsed current for energizing the electromagnetic coils.

22. A magnetic clutch in accordance with claim 18 wherein a sensing device senses the position of the driving member relative to the driven member and times the energization and de-energization of the electromagnetic coils.