Electromagnetic brake for a multiple-ratio power transmission in a vehicle powertrain

• US 7,318,515 B2
• Filed: 06/02/2005
• Issued: 01/15/2008
• Est. Priority Date: 01/20/2004
• Status: Expired due to Fees

• Current Assignee: Eaton Intelligent Power Limited (Eaton Corporation PLC.)
• Original Assignee: Eaton Corp. (Wisconsin) (Eaton Corporation PLC.)
• Inventors: Hornbrook, Michael J., Schenkel, John A.
• Primary Examiner(s): Lorence; Richard M
• Application Number:
  US11/143,069
• Publication Number:
  US 20050217966A1
• Time in Patent Office: 957 Days
• Field of Search: 192/84.94
• US Class Current: 192/222
• CPC Class Codes: F16D 2121/20 using electromagnets
• CPC Class Codes: F16D 2123/00 Multiple operation forces
• CPC Class Codes: F16D 67/02 Clutch-brake combinations
• CPC Class Codes: F16D 67/06 electromagnetically actuated
• CPC Class Codes: F16H 2003/123 using a brake

Abstract

An electromagnetic brake, including an electromagnetic brake actuator coil surrounding a power input shaft for a multiple-ratio transmission in a vehicle powertrain, is disclosed. An electromagnetic flux flow path for the actuator coil is electromagnetically isolated from the power input shaft and other elements of the powertrain thereby avoiding residual magnetization.

Claims

1. An electromagnetic brake in combination with a vehicle powertrain for a wheeled vehicle, the powertrain comprising an engine, a multiple-ratio power transmission having a housing enclosing multiple-ratio gear elements, a power output shaft driveably connected to vehicle traction wheels, a power input shaft driveably connected to the multiple-ratio gear elements and a master clutch selectively connecting the power input shaft to the engine, the master clutch being enclosed by a master clutch housing forming a part of the transmission housing, the electromagnetic brake comprising:

an electromagnetic brake stator coil housing secured to the transmission housing, the stator coil housing enclosing a stator coil surrounding the power input shaft and defining with the coil housing an electromagnetic pole face;

an armature brake plate having a hub portion secured to the power input shaft, an outer peripheral portion of the brake plate being secured to an armature plate disposed adjacent the brake stator coil; and

means for electrically energizing the brake stator coil to effect frictional engagement of the armature plate with the pole face as an electromagnetic flux flow path is established around the coil through the stator coil housing and the outer peripheral armature brake plate portion, the radial spacing of the stator coil from the power input shaft being sufficient to locate the flux flow path radially outward from the power input shaft to avoid magnetizing the power input shaft, whereby the power input shaft is isolated electromagnetically from the flux flow path.

2. The combination set forth in claim 1 wherein the armature brake plate is flexible, the peripheral portion of the armature plate being spaced from the pole face to define an air gap.

3. The combination set forth in claim 1, wherein the means for electrically energizing the brake stator coil includes a controller for effecting engagement of the electromagnetic brake by energizing the stator coil in response to powertrain operating variables when the master clutch is disengaged whereby the power input shaft is decelerated at the initiation of a ratio change by the gear elements thereby effecting a smooth gear ratio change in a reduced ratio change time.

4. An electromagnetic brake in combination with a vehicle powertrain for a wheeled vehicle, the powertrain comprising an engine, a multiple-ratio power transmission having a housing enclosing multiple-ratio gear elements, a power output shaft driveably connected to vehicle traction wheels, a power input shaft driveably connected to the multiple-ratio gear elements and a master clutch selectively connecting the power input shaft to the engine, the master clutch being enclosed by a master clutch housing forming a part of the transmission housing, a bearing rotatably supporting the power input shaft in a bearing support wall of the transmission housing, the electromagnetic brake comprising:

an electromagnetic brake stator coil housing secured to the transmission housing; and

an armature brake plate secured to the power input shaft, an outer peripheral portion of the brake plate being secured to an armature plate disposed adjacent the brake stator coil housing;

the stator coil housing enclosing a stator coil surrounding the power input shaft and defining with the coil housing an electromagnetic pole face as an electromagnetic flux flow path is established around the coil through the stator coil housing and the peripheral portion, the radial spacing of the stator coil from the power input shaft being sufficient to locate the flux flow path radially outward from the power input shaft to avoid magnetizing the power input shaft and the bearing, whereby the power input shaft and the bearing are isolated electromagnetically from the flux flow path.

5. The combination set forth in claim 4 wherein the armature brake plate is flexible, the armature plate being spaced from the pole face to define an air gap, a hub portion of the armature brake plate being connected driveably to the power input shaft, the armature brake plate having radially disposed arms connecting the peripheral portion to the power input shaft thereby restricting radial flux flow through the armature brake plate.

6. The combination set forth in claim 4 including a controller for effecting engagement and release of the electromagnetic brake by energizing the stator coil in response to powertrain operating variables when the master clutch is disengaged whereby the power input shaft is decelerated at the initiation of a ratio change by the gear elements thereby effecting a smooth gear ratio change in a reduced ratio change time.

7. An electromagnetic brake in combination with a vehicle powertrain for a wheeled vehicle, the powertrain comprising an engine, a multiple-ratio power transmission having a housing enclosing multiple-ratio gear elements, a power output shaft driveably connected to vehicle traction wheels, a power input shaft driveably connected to the multiple-ratio gear elements and a master clutch selectively connecting the power input shaft to the engine, the master clutch being enclosed by a master clutch housing forming a part of the transmission housing, the master clutch comprising a clutch release bearing surrounding the power input shaft, the electromagnetic brake comprising:

an electromagnetic brake stator coil housing secured to the transmission housing, the stator coil housing enclosing a stator coil surrounding the power input shaft and defining with the coil housing an electromagnetic pole face;

an armature brake plate having a hub portion secured to the power input shaft, an outer peripheral portion of the brake plate being secured to an armature plate disposed adjacent the brake stator coil housing; and

means for electrically energizing the brake stator coil to effect frictional engagement of the armature plate with the pole face as an electromagnetic flux flow path is established around the coil through the stator coil housing and the peripheral portion, the radial spacing of the stator coil from the power input shaft being sufficient to locate the flux flow path radially outward from the power input shaft to avoid magnetizing the power input shaft and the armature brake plate hub portion, whereby the power input shaft and the armature brake plate hub portion are isolated electromagnetically from the flux flow path.

8. The combination set forth in claim 7 wherein the armature brake plate is flexible, the armature plate being spaced from the pole face to define an air gap.

9. The set forth in claim 7, wherein the means for electrically energizing the brake stator coil includes a controller for effecting engagement and release of the electromagnetic brake by energizing the stator coil in response to powertrain operating variables when the master clutch is disengaged whereby the power input shaft is decelerated at the initiation of a ratio change by the gear elements thereby effecting a smooth gear ratio change in a reduced ratio change time.

10. An electromagnetic brake in combination with a vehicle powertrain for a wheeled vehicle, the powertrain comprising an engine, a multiple-ratio power transmission having a housing enclosing multiple-ratio gear elements, a power output shaft driveably connected to vehicle traction wheels, a power input shaft driveably connected to the multiple-ratio gear elements, a master clutch selectively connecting the power input shaft to the engine, the master clutch being enclosed by a master clutch housing forming a part of the transmission housing, a bearing rotatably supporting the power input shaft in a bearing support wall of the transmission housing, the master clutch comprising a clutch release bearing surrounding the power input shaft, the electromagnetic brake comprising:

an electromagnetic brake stator coil housing secured to the transmission housing; and

an armature brake plate secured to the power input shaft, an outer peripheral portion of the brake plate being secured to an armature plate disposed adjacent the brake stator coil housing;

the stator coil housing enclosing a stator coil surrounding the power input shaft and defining with the coil housing an electromagnetic pole face as an electromagnetic flux flow path is established around the coil through the stator coil housing and the peripheral portion whereby the power input shaft, the power input shaft bearing and the master clutch release bearing are isolated electromagnetically from the flux flow path, the radial spacing of the stator coil from the power input shaft being sufficient to locate the flux flow path radially outward from the power input shaft to avoid magnetizing the power input shaft, the power input shaft bearing and the clutch release bearing.

11. The combination set forth in claim 10 wherein the armature brake plate is flexible, the armature plate being spaced from the pole face to define an air gap.

12. The combination set forth in claim 10 including a controller for effecting engagement and release of the electromagnetic brake by energizing the stator coil in response to powertrain operating variables when the master clutch is disengaged whereby the power input shaft is decelerated at the initiation of a ratio change by the gear elements to effect a smooth gear ratio change in a reduced ratio change time.

13. The combination set forth in claim 10 wherein the power input shaft bearing comprises a bearing cap surrounding the power input shaft, the bearing cap being secured to the transmission housing, the bearing cap being isolated electromagnetically from the flux flow path.

14. The combination set forth in claim 11 wherein the armature brake plate comprises a hub connected driveably to the power input shaft, and flexible radial arms connecting the hub to the peripheral portion, the radial arms restricting flow of magnetic flux in a magnetic flux field from the stator coil to the hub.