Electromagnetic clutch assembly having enhanced torque throughput

• US 6,837,351 B2
• Filed: 02/28/2003
• Issued: 01/04/2005
• Est. Priority Date: 05/29/2002
• Status: Active Grant

• Current Assignee: BorgWarner Incorporated
• Original Assignee: BorgWarner Incorporated
• Inventors: Kowalsky, Christopher John, Showalter, Dan Joseph
• Primary Examiner(s): Bonck, Rodney H
• Application Number:
  US10/377,421
• Publication Number:
  US 20030221927A1
• Time in Patent Office: 676 Days
• Field of Search: 192/35, 192/70.23, 192/84.7, 192/93.A
• US Class Current: 192/35
• CPC Class Codes: F16D 27/004 with permanent magnets combined with electromagnets
• CPC Class Codes: F16D 27/115 with more than two discs, e.g. multiple lamellae

Abstract

An electromagnetic clutch assembly having a ball ramp operator provides enhanced torque throughput capability. The electromagnetic clutch assembly includes a primary or pilot friction clutch pack and a secondary or main friction clutch pack. A ball ramp operator which is actuated by the primary or pilot friction clutch pack includes a plastic washer or annulus adjacent one of the operator members. The plastic washer provides feedback which enhances the operation of the primary friction clutch pack, augments the compressive force applied to the secondary or main clutch pack and thus increases the torque throughput capability of the electromagnetic clutch assembly.

Claims

1. An electromagnetic clutch assembly comprising, in combination,

an input member and a coaxially disposed output member,

a first circular member having a plurality of camming surfaces, a second circular member adjacent said first circular member having a like plurality of camming surfaces and splined to said output member for rotation therewith,

a like plurality of load transferring balls disposed on said camming surfaces,

a circular friction member operably disposed between said first circular member and said input member,

a first clutch pack having a first plurality of first clutch plates splined to said first circular member and a second, interleaved plurality of first clutch plates splined to said input member,

an electromagnetic coil for engaging said first clutch pack, and

a second clutch pack having a first plurality of second clutch plates splined to said input member and a second, interleaved plurality of second clutch plates splined to said output member.

2. The electromagnetic clutch assembly of claim 1 further including an outer housing adapted to receive said input member and an anti-friction bearing for rotatably supporting said input member within said outer housing.

3. The electromagnetic clutch assembly of claim 1 wherein said output member defines a splined passageway, and further including an output shaft having a splined exterior surface complementary to said splined passageway in said output member.

4. The electromagnetic clutch assembly of claim 1 wherein said friction washer is fabricated of a plastic.

5. The electromagnetic clutch assembly of claim 1 further including a plurality of oil seals for sealing an interior region of said clutch assembly containing said first and said second clutch packs.

6. The electromagnetic clutch assembly of claim 1 wherein said friction washer provides controlled feedback to enhance torque throughput of said second friction clutch pack.

7. The electromagnetic clutch assembly of claim 1 wherein said washer is fabricated of a thermoplastic polyimide.

8. A torque transfer device having a pair of clutches comprising, in combination,

a rotatable input member,

a rotatable output member,

a main clutch having a first plurality of clutch plates coupled to said input member and a second plurality of clutch plates interleaved with said first plurality of clutch plates and coupled to said output member,

a cam operator having first and second members defining opposing cam surfaces, said first cam member coupled to said output member for rotation therewith,

a pilot clutch having a first plurality of clutch plates coupled to said input member and a second plurality of clutch plates interleaved with said first plurality of clutch plates and coupled to said second member of said cam operator,

an electromagnetic coil for engaging said pilot clutch, and

a friction washer operably disposed between said second member of said cam operator and said input member.

9. The torque transfer device of claim 8 further including an outer housing assembly adapted to receive said input member and an anti-friction bearing for rotatably supporting said input member in said outer housing.

10. The torque transfer device of claim 8 wherein said output member defines a splined, internal passageway, and further including an output shaft having a splined exterior complementary to said splined passageway in said output member.

11. The torque transfer device of claim 8 wherein said friction washer is fabricated of a plastic.

12. The torque transfer device of claim 8 wherein said friction washer provides controlled feedback to enhance torque throughput of said main clutch.

13. The torque transfer device of claim 8 wherein said friction washer is fabricated of a thermoplastic polyimide.

14. The torque transfer device of claim 8 further including a plurality of oil seals for sealing an interior region of said torque transfer device containing said first and said second clutches.

15. An electromagnetic clutch assembly comprising, in combination,

an input member and an output member disposed for coaxial rotation,

an electromagnetic coil,

a first cam member disposed about said output member,

a second cam member splined to said output member for rotation therewith, said cam members including means for axially separating said cam members upon relative rotation,

a friction member operably disposed between said first cam member and said input member,

a primary friction clutch having a first plurality of primary clutch plates splined to said first cam member and a second, interleaved plurality of primary clutch plates splined to said input member, and

a secondary clutch having a first plurality of secondary clutch plates splined to said input member and a second, interleaved plurality of secondary clutch plates splined to said output member.

16. The electromagnetic clutch assembly of claim 15 further including an outer housing adapted to receive said input member and an anti-friction bearing assembly for rotatably supporting said input member within said outer housing.

17. The electromagnetic clutch assembly of claim 15 wherein said output member defines a splined bore and further including an output shaft having a splined surface complementary to said splined bore in said output member.

18. The electromagnetic clutch assembly of claim 15 wherein said washer is fabricated of plastic.

19. The electromagnetic clutch assembly of claim 15 wherein said washer is fabricated of a thermoplastic polyimide.

20. The electromagnetic clutch assembly of claim 15 wherein said means for axially separating said cam member includes a plurality of opposed pairs of arcuate recesses disposed in said cam members and a like plurality of load transferring members disposed in said recesses.