Dana Corporation

John H Wall

Douglas J Clemens

Edward L Walter

A component for use in an electromagnetic friction clutch, such as a rotor assembly, and a method of manufacturing same is disclosed. The rotor assembly includes an outer annular pulley which connected to a flat annular rotor plate for concurrent rotation. The pulley is located directly radially outwardly from the rotor plate such that radial loads imposed on the pulley are transmitted directly radially inwardly through the rotor plate to a support bearing, thereby reducing or eliminating undesirable cantilever stresses. The pulley and the rotor plate are preferably formed from a single piece of injection molded material which is not magnetically permeable, such as plastic. A plurality of relatively thin, concentric annular rings formed from a magnetically permeable material is carried on the rotor plate for rotation therewith. The rotor assembly further includes an inner tube which is generally hollow and cylindrical in shape and is preferably formed from a magnetically permeable material. The inner tube is concentric with the rotor plate and extends about the inner periphery thereof. A plurality of notches is formed in one end of the inner tube to facilitate the injection molding process. Similarly, the rotor assembly includes an outer tube which is generally hollow and cylindrical in shape and is preferably formed from a magnetically permeable material. The outer tube is concentric with the rotor plate and extends about the outer periphery thereof, just inside of the pulley. A plurality of notches is also formed in one end of the outer tube to facilitate the injection molding process.

Molded plastic rotor assembly for electromagnetic friction clutch

A locating ring for positioning and supporting an electric coil within a mold for encapsulation of the coil. The locating ring comprises an annular body defining a central axis and a plurality of tabs extending generally axially from the annular body. The annular is adapted to insulate the coil from a steel shell. The tabs are adapted to position the coil within the mold. In a preferred embodiment, the tabs include a recess along a portion of the radially inner face thereof which receives the encapsulating material prevents the separation of the tabs therefrom. In an alternate embodiment, a portion of the sidewalls of each tab are tapered outwardly from the inner face to the outer face thereof. In another aspect of the invention, the body of the locating ring includes a plurality of circumferentially spaced openings extending axially therethrough which provide a number of routes by which air may be vented during the molding operation.

Locating ring for encapsulating a coil

An apparatus for precisely winding a coil of wire, either free standing or on a bobbin, includes a servo motor for rotating a spool and a wire feeding mechanism for guiding the wire onto the rotating spool. The wire feeding mechanism is mounted on a ball screw shaft connected to a stepper motor. Thus, rotation of the ball screw shaft by the stepper motor causes axial movement of the wire feeding mechanism. A wire feed angle sensor is provided on the wire feeding mechanism for generating a signal which is representative of the load angle at which the wire is wound upon the spool. A control system, such as a microprocessor or a programmable controller, is responsive to the load angle signal for controlling the operation of the stepper motor and, thus, the position of the wire feeding mechanism relative to the point of winding on the spool. As a result, a constant load angle is maintained throughout the winding process. A wire diameter sensor also generates signals to the control system. The control system is responsive to the wire diameter signal for determining the number of windings which can be made on each layer of the spool. In an alternate embodiment, the control system determines the position of a movable flange in accordance with the diameter of the wire to provide a predetermined number of windings per layer.

Apparatus for precisely winding a coil of wire

A soft start controller for regulating the engagement and disengagement of an electromagnetic clutch is disclosed. The controller includes a microprocessor which, in response to an engagement signal, causes electrical current to be provided to a coil of the clutch. A plurality of sensors are provided for generating electrical signals which are representative of various operating conditions of the clutch, such as engine load, clutch temperature and the like. These signals are selectively fed through a multiplexer and an analog to digital converter to the microprocessor. The microprocessor samples the signals generated by the sensors and controls the magnitude of the current fed to the coil of the clutch in response thereto. A plurality of manually operable start select switches are provided for selecting one of a plurality of clutch current curves stored in a memory of the microprocessor for use. Alternatively, the microprocessor may be programmed to select one of the clutch current curves in accordance with the sensed operating conditions. The microprocessor may also be responsive to the sensed operating conditions for automatically engaging or disengaging the clutch under certain conditions.

Digital control system for electromagnetic clutch

An apparatus for passing an electrical current through an electromagnetic coil to perform a resistance bonding operation is disclosed. The apparatus includes a pair of pistons which are selectively moved to clamp the leads of the coil to respective electrical terminals. The terminals are selectively connected through a switch to a source of electrical power to perform the resistance bonding operation. A pivotable cover is provided for covering the entire apparatus during the resistance bonding operation. When the cover is closed by an operator, a logic controller automatically actuates the pistons to clamp the leads of the coil to the terminals. Additional limit switches sense when the pistons have been so moved and, in response thereto, automatically close the switch to connect the electrical power supply to the terminals, thereby commencing the resistance bonding operation. The cover may be lined with a shielding material to prevent the operator from being exposed to the electromagnetic field generated by the coil during the resistance bonding operation.

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Columbia City, IN, United States of America

John H Wall