Dana Corporation

Warner Electric Technology, Inc.

Warner Electric Brake & Clutch Company

Dwight E Booth

Daniel L DeYoung

Gerry N Lippincott

Kalvin G VanLaningham

Mark E Blakeman

Robert A Olsen

Paul A Larson

David C Gustin

Douglas J Clemens

James M Heim

Stewart B Dobson

James A Licari

Michael L Cory

Robert D Keller

Joel W Hable

Thomas P Roll

Steven A Kruger

Kalvin G Van Laningham

Brian A Taylor

John C Carlson

An electromagnetic clutch in which an annulus of sound dampening material is sandwiched between an armature disc and a hub assembly, particularly a web portion thereof. The annulus and web coact to define a constrained-layer damping system for reducing noise when the armature disc is snapped into engagement with the rotor of the clutch, slipping prior to lockup, while the armature is magnetically locked to the rotor, and also during slipping and disengagement of the armature disc. The design provides a reduced axial-length package relative to prior armature assemblies incorporating constrained-layer techniques.

Sound damping armature assembly for an electromagnetic coupling

An armature assembly for a selectively engageable and disengageable electromagnetic coupling is provided. The armature assembly includes a hub having a central axis that is disposed radially outwardly, and mounted for rotation with, a shaft used to drive an air-conditioning compressor. The assembly also includes a resiliently flexible spider disposed radially outwardly of the hub. The spider is fixed against rotation relative to the hub, but is able to flex axially relative to the hub at a hinge. The armature assembly further includes an annular armature disc disposed radially outwardly of the hub and connected to a first side of the spider. Finally, the armature assembly includes a counterweight disposed on a second side of the spider. The counterweight may be integral with the spider or connected to the hub. An armature assembly in accordance with the present invention balances the dynamic loads present in the electromagnetic coupling without substantially affecting the living hinge of the resiliently flexible spider. The armature assembly is also able to retain the armature disc in the event of a failure of the spider.

Electromagnetic coupling armature assembly with counterweight

An electromagnetically actuated friction clutch includes a rotatably driven input gear. A rotatable armature is connected to the input gear and includes a friction face and nitrocarburized outer surfaces. A pole piece has a pole face for engaging the friction face of the armature and nitrocarburized outer surfaces. An electromagnet generates an electromagnetic field to shift the armature from a disengaged position to an engaged position wherein the friction face of the armature and the pole face of the pole piece are frictionally engaged. An output shaft is driven by the input gear when the armature is in the engaged position. The nitrocarburized outer surfaces of the armature and the pole piece resist wear, while interior portions of the armature and pole piece direct magnetic flux flow along a desired path.

Nitrocarburized component for an electromagnetic friction clutch assembly

An electromagnetic clutch in which an annulus of sound damping material is sandwiched between an armature disc and a backing ring. The annulus and the backing ring coact to define a constrained-layer damping system for reducing noise when the armature disc is snapped into engagement with the rotor of the clutch and also during slipping and disengagement of the armature disc.

Sound-damping armature assembly for an electromagnetic coupling

An electromagnetic armature assembly includes a spider made of resiliently yieldable plastic and carrying an annular armature plate. A mounting disc is insert molded into the spider and is adapted to be assembled with a tubular hub mountable on a rotatable shaft. The mounting disc enables the armature assembly to be mounted on various types of hubs, either with no change to the armature assembly or with very little change.

Electromagnetic coupling armature assembly adaptable to various types of

The preferred field assembly includes a field shell of generally T-shaped radial cross-section and molded of powdered metal, a plastic bobbin for supporting a multiple turn winding, and a plastic bobbin ring which covers part of the field shell and which helps hold the bobbin in assembled relation with the field shell. The bobbin is formed with a terminal block for supporting electrical leads which extend along grooves in the outboard face of one flange of the bobbin and which, together with the end portions of the winding, extend into potting cavities in the outboard face of the bobbin flange. The bobbin ring includes a cap which interfits with the terminal block to retain the leads. Various embodiments of field shells, bobbins and bobbin rings are disclosed.

Field assembly for an electromagnet

An armature disc is attached to a resilient plastic spider by angularly spaced rivets. To prevent the spider from striking the disc and creating a buzzing noise, spacer pads are formed integrally with the spider adjacent the rivets and establish an axial gap of substantial width between the disc and the spider along arcs located between the rivets. The heads of the rivets are located in countersunk holes in the spider and pull axially through the plastic of the spider to release the armature disc from the spider if the spider becomes excessively hot as a result of slippage of the coupling. A metal washer on the hub of the coupling prevents the hot disc, when released, from dropping onto and melting a central sleeve portion of the spider.

Armature assembly for an electromagnetic coupling

One face of a coupling disc (i.e., the armature or rotor) of an electromagnetic coupling such as a clutch or brake is formed with a plurality of radially spaced and circumferentially extending grooves. The other face of the disc is formed with a plurality of radially spaced rows of circumferentially extending slots which communicate with the grooves so as to form air gaps completely through the disc. In the preferred embodiment, each groove is circumferentially continuous while each row of slots is defined by circumferentially spaced slots which are separated by short bridges. By virtue of forming the grooves in the disc, only a small thickness of material need be removed from the disc in order to form the slots.

Electromagnetic coupling discs and method of making the same

An armature assembly for an electromagnetic clutch includes a plastic spider having a central sleeve which is joined to a central driven hub by insert molding. A circular web is molded integrally with and extends radially from the sleeve and carries an annular armature disc which is adapted to coact with the electromagnetic rotor of the clutch. When the clutch is energized, the web flexes adjacent the sleeve in the manner of a living hinge to enable the armature disc to move axially into engagement with the rotor. Upon de-energization of the clutch, the resilient memory of the plastic retracts the armature disc from the rotor. In addition to eliminating the need for separate springs and other components, the plastic spider provides torsional and acoustical dampening.

The non-working face of a coupling disc (i.e., the armature or rotor) of an electromagnetic coupling such as a clutch or brake is formed with radially spaced rows of angularly spaced grooves separated by radially extending bridges. The grooves terminate short of the working face of the disc and delineate magnetic poles in the disc. In some embodiments, radially spaced rows of grooves also are formed in the working face of the disc. In still other embodiments, excess metal resulting from rolling of the grooves in the non-working face of the disc is used to form integral locating flanges or the like adjacent the disc.

Electromagnetic coupling disc

A method of forming slots in the coupling disc (e.g., the armature or rotor) of an electromagnetic coupling such as a clutch or brake. The method is carried out by effecting relative movement between the coupling disc and a laser beam in such a manner as to cause the beam to trace the perimeter of the slot to be formed and to cut a slug of material from the disc. Also disclosed are coupling discs in which opposing side walls of the slots converge toward one another and in which the side walls are concentric but obliquely inclined.

A method of forming slots in the metal coupling disc (e.g., the armature or rotor) of an electomagnetic coupling such as a clutch or brake. The method is carried out by effecting relative movement between the coupling disc and a laser beam to cause the beam to melt portions of the disc and thereby form slots through the disc. The laser beam is defocused relative to the disc in order to enable a relatively low powered laser beam to form relatively wide slots in the disc. A pressurized jet of gas is directed against the disc immediately adjacent the beam and acts to blast metal from the slots and assist in the formation of wide slots.

Method of making an electromagnetic coupling disc

A method of forming non-magnetic barriers in the coupling disc (e.g., the armature or rotor) of an electromagnetic coupling such as a clutch or brake. The method is carried out by moving the disc relative to a laser beam which cuts a slot through the disc. In one embodiment, the slot is filled throughout its entire length by non-magnetic material, the filling being effected by continuously advancing a non-magnetic wire toward the laser beam to cause the wire to be melted by the beam and to flow into the newly formed slot. In another embodiment, the wire is advanced intermittently to form short non-magnetic bridges beween relatively long slots.

Method of forming a coupling disc for an electromagnetic coupling

A control unit and method for operating a gap-type electromagnetic clutch or brake is provided which reduces audible chatter, screeching caused by belt slippage and related wear and tear on the driving and driven components. The operating winding of the clutch or brake is energized to cause the gap between an armature and rotor to close, energization of the winding is then reduced to initially reduce the torque coupling between the armature and rotor and finally energization of the winding is gradually increased to full energization so as to provide a gradually increasing torque coupling between the armature and rotor.

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Janesville, WI, United States of America

Dwight E Booth