Camshaft phaser with two one-way wedge clutches

This application claims the benefit under 35 U.S.C. §119(e) of U.S. Provisional Patent Application No. 61/980,913, filed Apr. 17, 2014, which application is incorporated herein by reference in its entirety.

The present disclosure relates to a camshaft phaser with two-way wedge clutches. In particular, the two-way wedge clutches are used to transmit rotation of a stator to a rotor while accounting for oscillating torsional forces transmitted to the rotor by a camshaft. The two-way wedge clutches are also used to advance and retard the phase of the rotor with respect to the stator.

It is known to use fluid pressure in chambers created by respective portions of a stator and a rotor for a camshaft phaser to maintain and shift a rotational position of the rotor with respect to the stator. This known technique involves complicated hydraulic systems and controls.

According to aspects illustrated herein, there is provided a camshaft phaser, including a rotatable stator including a radially inner side with first and second grooves; rotatable rotor arranged to non-rotatably connect to a camshaft and including a radially outer surface including first plurality of circumferentially disposed ramps, a respective radially outermost surface of each ramp in the first plurality of circumferentially disposed ramps extending further in a radially outer direction along a first circumferential direction; and second plurality of circumferentially disposed ramps, a respective radially outermost surface of each ramp in the second plurality of circumferentially disposed ramps extending further in a radially outer direction along a second circumferential direction, opposite the first circumferential direction; a first wedge plate including a third plurality of circumferentially disposed ramps engaged with the first plurality of circumferentially disposed ramps and first radially outermost portion at least partially disposed in the first groove; and second wedge plate including fourth plurality of circumferentially disposed ramps engaged with the second plurality of circumferentially disposed ramps; and second radially outermost portion at least partially disposed in the second groove.

According to aspects illustrated herein, there is provided a camshaft assembly, including camshaft phaser including: stator; rotor including first plurality of circumferentially aligned ramps; and second plurality of circumferentially aligned ramps offset from the first plurality of ramps in a first axial direction; first and second wedge plates radially disposed between the rotor and the stator; and camshaft non-rotatably connected to the rotor. In a drive mode: the stator is arranged to receive first torque and to rotate in a first direction; the assembly is arranged to operate in successive cycles of a first phase followed by a second phase; in the first phase the first wedge plate non-rotatably connects the stator and the rotor while the second wedge plate is rotatable with respect to the stator; and in the second phase, the second wedge plate non-rotatably connects the stator and the rotor while the first wedge plate is rotatable with respect to the stator.

According to aspects illustrated herein, there is provided a method of phasing a camshaft, including: engaging a radially outermost portion of a first wedge plate with a stator for a camshaft phaser; engaging a first plurality of ramps on the first wedge plate with a second plurality of ramps on a rotor for the camshaft phaser; engaging a radially outermost portion of a second wedge plate with the stator; engaging a third plurality of ramps on the second wedge plate with a fourth plurality of ramps on the rotor; rotating the stator in a first direction; rotating, via contact with the stator, the first wedge plate in the first direction; transmitting first torque in the first direction from a camshaft to the rotor; rotating the rotor a first circumferential distance in the first direction with respect to the stator; sliding the second plurality of ramps along the first plurality of ramps to displace the first wedge plate radially outward; non-rotatably connecting the rotor, the first wedge plate, and the stator; transmitting second torque in a second direction, opposite the first direction, from the camshaft to the rotor; rotating the rotor a second circumferential distance in the second direction with respect to the stator; sliding the fourth plurality of ramps along the third plurality of ramps to displace the second wedge plate radially outward; and non-rotatably connecting the rotor, the second wedge plate, and the stator.

Various embodiments are disclosed, by way of example only, with reference to the accompanying schematic drawings in which corresponding reference symbols indicate corresponding parts, in which:

FIG. 1 is a perspective view of a cylindrical coordinate system demonstrating spatial terminology used in the present application;

FIG. 2A is a front view of a camshaft phaser with two-way wedge clutches;

FIG. 2B is a rear view of the camshaft phaser in FIG. 2A ;

FIG. 3 is a perspective exploded view of the camshaft phaser in FIGS. 2A and 2B ;

FIG. 4 is a front perspective view of a rotor for the camshaft phaser in FIGS. 2A and 2B ;

FIG. 5 is a rear perspective view of the rotor for the camshaft phaser in FIGS. 2A and 2B ;

FIG. 6A is a front view of one wedge plate for the camshaft phaser in FIGS. 2A and 2B ;

FIG. 6B is a rear view of another wedge plate for the camshaft phaser in FIGS. 2A and 2B ;

FIG. 7A is a cross-sectional view generally along line 7 - 7 in FIG. 2A with a locking pin assembly in a disengaged mode;

FIG. 7B is a cross-sectional view generally along line 7 - 7 in FIG. 2A with a locking pin assembly in an engaged mode;

FIG. 8A is a cross-sectional view generally along line 8 - 8 in FIG. 2B with a locking pin assembly in a disengaged mode;

FIG. 8B is a cross-sectional view generally along line 8 - 8 in FIG. 2B with a locking pin assembly in an engaged mode;

FIG. 9 is a perspective view of two camshaft phasers, as shown in FIGS. 2A and 2B , connected to respective cam shafts;

FIG. 10 is a front view of a stator for the camshaft phaser in FIGS. 2A and 2B .

At the outset, it should be appreciated that like drawing numbers on different drawing views identify identical, or functionally similar, structural elements of the disclosure. It is to be understood that the disclosure as claimed is not limited to the disclosed aspects.

Furthermore, it is understood that this disclosure is not limited to the particular methodology, materials and modifications described and as such may, of course, vary. It is also understood that the terminology used herein is for the purpose of describing particular aspects only, and is not intended to limit the scope of the present disclosure.

Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood to one of ordinary skill in the art to which this disclosure belongs. It should be understood that any methods, devices or materials similar or equivalent to those described herein can be used in the practice or testing of the disclosure.

FIG. 1 is a perspective view of cylindrical coordinate system 10 demonstrating spatial terminology used in the present application. The present application is at least partially described within the context of a cylindrical coordinate system. System 10 includes longitudinal axis 11 , used as the reference for the directional and spatial terms that follow. Axial direction AD is parallel to axis 11 . Radial direction RD is orthogonal to axis 11 . Circumferential direction CD is defined by an endpoint of radius R (orthogonal to axis 11 ) rotated about axis 11 .

To clarify the spatial terminology, objects 12 , 13 , and 14 are used. An axial surface, such as surface 15 of object 12 , is formed by a plane parallel to axis 11 . Axis 11 is coplanar with planar surface 15 ; however it is not necessary for an axial surface to be coplanar with axis 11 . A radial surface, such as surface 16 of object 13 , is formed by a plane orthogonal to axis 11 and coplanar with a radius, for example, radius 17 . Surface 18 of object 14 forms a circumferential, or cylindrical, surface. For example, circumference 19 forms a circle on surface 18 . As a further example, axial movement is parallel to axis 11 , radial movement is orthogonal to axis 11 , and circumferential movement is parallel to circumference 19 . Rotational movement is with respect to axis 11 . The adverbs “axially,” “radially,” and “circumferentially” refer to orientations parallel to axis 11 , radius 17 , and circumference 19 , respectively.

FIG. 2A is a front view of camshaft phaser 100 with two-way wedge clutches.

FIG. 2B is a rear view of camshaft phaser 100 in FIG. 2A .

FIG. 3 is a perspective exploded view of camshaft phaser 100 in FIGS. 2A and 2B .

FIG. 4 is a front perspective view of a rotor for camshaft phaser 100 in FIGS. 2A and 2B .

FIG. 5 is a rear perspective view of the rotor for camshaft phaser 100 in FIGS. 2A and 2B . The following should be viewed in light of FIGS. 2 through 5 . Phaser 100 includes: axis of rotation AR, rotatable stator 102 , rotatable rotor 104 , and wedge plates 106 and 108 . Rotor 104 is arranged to non-rotatably connect to a camshaft (discussed further below) and includes radially outer surface 112 with circumferentially disposed ramps 114 and 116 . Ramps 114 are separated from ramps 116 in axial direction AD 1 . Stator 102 is rotatable in circumferential directions CD 1 and CD 2 . Wedge plates 106 and 108 are frictionally engaged with stator 102 and rotate with the rotor except as noted below.

Radially outermost surface 118 of ramps 114 extend further in radially outer direction RD 1 along circumferential direction CD 2 . That is, radial distance 120 increases along direction CD 2 . Radially outermost surface 122 of ramps 116 extend further in radially outer direction RD 1 along circumferential direction CD 1 . That is, radial distance 124 increases along direction CD 1 .

FIG. 6A is a front view of wedge plate 106 for camshaft phaser 100 in FIGS. 2A and 2B .

FIG. 6B is a rear view of wedge plate 108 for camshaft phaser 100 in FIGS. 2A and 2B . The following should be viewed in light of FIGS. 2 through 6B . Wedge plate 106 includes circumferentially disposed ramps 126 engaged or engageable with ramps 114 . Wedge plate 108 includes circumferentially disposed ramps 128 engaged with or engageable with ramps 116 . Radially innermost surface 130 of ramps 126 extend further in radially inner direction RD 2 along circumferential direction CD 1 . That is, radial distance 132 decreases along direction CD 1 . Radially innermost surface 134 of ramps 128 extend further in direction RD 2 along circumferential direction CD 2 . That is, radial distance 136 decreases along direction CD 2 .

FIG. 7A is a cross-sectional view generally along line 7 - 7 in FIG. 2A with a locking pin assembly in a disengaged mode.

FIG. 7B is a cross-sectional view generally along line 7 - 7 in FIG. 2A with a locking pin assembly in an engaged mode. The following should be viewed in light of FIGS. 2 through 7B . In an example embodiment, stator 102 includes grooves 138 and 140 . Radially outermost portion 106 A of wedge plate 106 is at least partially disposed in groove 138 and frictionally engaged with groove 138 . Radially outermost portion 108 A of wedge plate 108 is at least partially disposed in groove 140 and frictionally engaged with groove 140 . Due to the frictional engagement between wedge plates 106 and 108 and grooves 138 and 140 , respectively, wedge plates 106 and 108 rotate with the stator except as noted. In an example embodiment (not shown), grooves 138 and 140 are formed in respective annular components formed separately from stator 102 and fixedly connected to stator 102 .

Rotor 104 includes locking pin assembly 142 with locking pin 144 . Pin 144 is displaceable in axial direction AD 1 to engage wedge plate 106 and non-rotatably connected rotor 104 and wedge plate 106 . In an example embodiment, assembly 142 includes spring 146 urging pin 144 in direction AD 2 into the disengaged mode shown in FIG. 7A . In an example embodiment, hydraulic pressure via channel 148 overcomes spring 146 and displaces pin 144 in direction AD 1 , for example into pocket 150 in plate 106 so that assembly 142 is in the engaged mode shown in FIG. 7B .

FIG. 8A is a cross-sectional view generally along line 8 - 8 in FIG. 2B with a locking pin assembly in a disengaged mode.

FIG. 8B is a cross-sectional view generally along line 8 - 8 in FIG. 2B with a locking pin assembly in an engaged mode. The following should be viewed in light of FIGS. 2 through 8B . Rotor 104 includes locking pin assembly 152 with locking pin 154 . Pin 154 is displaceable in axial direction AD 2 to engage wedge plate 108 and non-rotatably connected rotor 104 and wedge plate 108 . In an example embodiment, assembly 152 includes spring 156 urging pin 154 in direction AD 1 into the disengaged mode shown in FIG. 8A . In an example embodiment, hydraulic pressure via channel 158 overcomes spring 156 and displaces pin 154 in direction AD 2 , for example into pocket 160 in plate 108 so that assembly 152 is in the engaged mode shown in FIG. 8B . Although pockets 150 and 160 are shown, openings in wedge plates 106 and 108 can be used to engage pins 144 and 154 , respectively.

FIG. 9 is a perspective view of camshaft phasers 100 A and 100 B as shown in FIGS. 2A and 2B , connected to cam shafts 202 and 204 , respectively. The discussion regarding phaser 100 is applicable to phasers 100 A and 100 B. Typically one of cam shafts 202 and 204 is for an intake valve train and the other of cam shafts 202 and 204 is for an exhaust valve train. Phasers 100 A and 100 B are rotated by chain (simplified chain model—chain sprockets are shown) BL, typically driven by a crankshaft for an engine of which the camshafts and phasers are a part. The following discussion is applicable to both of phasers 100 A and 100 B; however phaser 100 A is referenced in the discussion that follows.

Phaser 100 A is configured to operate in at least three modes: a drive mode; a phase advance mode; and a phase retard mode. In the drive mode, the stator receives rotational torque from chain or belt BL, for example in direction CD 1 . Due to the interaction of rotor 104 and wedge plates 106 or 108 , rotation of stator 102 in direction CD 1 is transmitted to rotor 104 and rotor 104 rotates in phase with stator 102 , within the context of the torsional forces (explained below) from camshaft 202 , as follows. The operation in drive mode can be divided into first and second phases. In the first phase, stator 102 , wedge plate 106 , and rotor 104 are non-rotatably connected to transmit rotation of the stator to the rotor and wedge plate 108 is rotatable with respect to stator 102 . Thus, rotation and torque is transmitted by wedge plate 106 and not wedge plate 108 . In the second phase, stator 102 , wedge plate 108 , and rotor 104 are non-rotatably connected to transmit rotation of the stator to the rotor and wedge plate 106 is rotatable with respect to stator 102 . Thus, rotation and torque is transmitted by wedge plate 108 and not wedge plate 106 .

The non-rotatable engagement of stator 102 , wedge plate 106 , and rotor 104 is due to, for example, ramps 126 sliding up ramps 114 in direction CD 2 . Since distance 120 increases in direction CD 2 and distance 132 decreases in direction CD 1 , wedge plate 106 is forced radially outward and rotationally locks with stator 102 and rotor 104 . In particular, ramps 114 and 126 are frictionally and compressively locked and outer portion 106 A is frictionally and compressively locked in groove 138 .

The non-rotatable engagement of stator 102 , wedge plate 108 , and rotor 104 is due to, for example, ramps 128 sliding up ramps 116 in direction CD 1 . Since distance 124 increases in direction CD 1 and distance 136 decreases in direction CD 2 , wedge plate 108 is forced radially outward and rotationally locks with stator 102 and rotor 104 . In particular, ramps 116 and 128 are frictionally and compressively locked and outer portion 108 A is frictionally and compressively locked in groove 140 .

As is known in the art, torsional forces T 1 and T 2 are transmitted from camshaft 202 , in directions CD 1 and CD 2 , respectively, to rotor 104 during operation of phaser 100 . The torsional force forces are due to interaction of cam lobes (not shown) on camshaft 202 with various components of a valve train (not shown) of which camshaft 202 is a part. Torsional forces T 1 and T 2 are transmitted in a repeating cycle. Rotor 104 continues to rotate in direction CD 1 in the current example (stator 104 rotating in direction CD 1 ); however, torsional force T 1 causes a relative rotation of rotor 104 in direction CD 1 with respect to the stator and torsional force T 2 causes a relative rotation of rotor 104 in direction CD 2 with respect to the stator. Transmission of torsional force T 1 is associated with the first phase in drive mode and transmission of torsional force T 2 is associated with the second phase in drive mode in the present example.

To explain the drive mode, we start with phaser 100 operating in the second phase. That is, stator 102 , wedge plate 108 , and rotor 104 are non-rotatably connected. To initiate the transition from the second phase to the first phase, torsional force T 1 is transmitted to rotor 104 , causing rotor 104 to rotate in direction CD 1 with respect to stator 102 and wedge plate 108 . Since distance 124 decreases in direction CD 2 and distance 136 increases in direction CD 1 , as rotor 104 is urged in direction CD 1 , ramps 128 slide down ramps 116 and the frictional and compressive engagement of stator 102 , wedge plate 108 , and rotor 104 decreases. At the same time, the rotation of rotor 104 in direction CD 1 causes ramps 126 to slide up ramps 114 in direction CD 2 and stator 102 , wedge plate 106 , and rotor 104 begin to engage. The configuration of rotor 104 and wedge plates 106 and 108 is determined such that as the non-rotatable connection of stator 102 , wedge plate 108 , and rotor 104 is terminating, the non-rotatable connection of stator 102 , wedge plate 106 , and rotor 104 is being established, providing a smooth and continuous transfer of rotation from the stator to rotor 104 .

To initiate the transition from the first phase to the second phase, torsional force T 2 is transmitted to rotor 104 , causing rotor 104 to rotate in direction CD 2 with respect to stator 102 and wedge plate 106 . Since distance 120 decreases in direction CD 1 and distance 132 increases in direction CD 2 , as rotor 104 rotates in direction CD 2 , ramps 126 slide down ramps 114 and the frictional and compressive engagement of stator 102 , wedge plate 106 , and rotor 104 decreases. At the same time, the rotation of rotor 104 in direction CD 2 causes ramps 128 to slide up ramps 116 in direction CD 1 and stator 102 , wedge plate 108 , and rotor 104 engage. The configuration of rotor 104 and wedge plates 106 and 108 is determined such that as the non-rotatable connection of rotor 104 , plate 106 , and stator 102 is terminating, the non-rotatable connection of stator 102 , wedge plate 108 , and rotor 104 is being established, providing a smooth and continuous transfer of rotation from the stator to rotor 104 .

The following describes the phase advance mode. In the course of cycling between the first and second phases of the drive mode, rotor 104 rotates distances 162 A and 168 A, with respect to the stator, in directions CD 1 and CD 2 , respectively, due to torsional forces T 1 and T 2 , respectively. The configuration, noted above, of rotor 104 and wedge plates 106 and 108 results in distances 162 A and 168 A being nominal or negligible; however, for purposes of illustration, distances 162 A and 168 A have been exaggerated in FIG. 2A . The following is an example of initiating and executing the phase advance mode. Assume phaser 100 is in the second phase and receives torsional force T 1 to initiate the first phase. The non-rotational connection of stator 102 , wedge plate 108 , and rotor 104 begins to loosen as described above. However, before ramps 126 can slide up ramps 114 , or before ramps 126 slide up ramps 114 far enough to non-rotatably engage stator 102 , wedge plate 106 , and rotor 104 , pin 144 is displaced in direction AD 1 to non-rotatably connect rotor 104 and wedge plate 106 . Thus, as torsional force T 1 displaces rotor 104 in direction CD 1 , ramps 114 and 126 do not engage as required for the first phase and rotor 104 is free to rotate distance 162 B, in direction CD 1 , beyond distance 162 A. As torsional force T 2 is received by rotor 104 , the second phase of the drive mode is executed as normal.

Thus, for each cycle of the first and second drive mode phases and torsional force forces T 1 and T 2 , while wedge plate 106 is non-rotatably connected to rotor 104 , the relative position of rotor 104 with respect to stator 102 shifts in direction CD 1 by distance 162 B. This process is repeatable via successive cycles of the first and second drive mode phases and torsional force forces T 1 and T 2 to attain the desired shift of rotor 104 . To terminate the shifting of rotor 104 in direction CD 1 , pin 144 is displaced, after transmission of torsional force T 2 and prior to transmission of torsional force T 1 , in direction AD 2 to enable rotation of wedge plate 106 with respect to rotor 104 . Rotor 104 still oscillates due to torsional force forces T 1 and T 2 , but within the frame of reference of the oscillations, the rotational position of rotor 104 with respect to stator 102 has been shifted.

Each distance 162 B in direction CD 1 is a result of phaser 100 implementing a full cycle of the first and second phases of the drive mode, or stated otherwise, receipt of a full cycle of torsional force forces T 1 and T 2 . To shift rotor 104 in direction CD 1 by an amount less than distance 162 B, pin 144 is displaced in direction AD 2 to disengage from wedge plate 106 before the transition from the first phase to the second phase. That is, rotation of wedge plate 106 is enabled during the first phase so that ramps 114 and 126 engage and rotationally lock after rotor 104 has displaced distance 162 A, but prior to rotor 104 displacing distance 162 B.

The following is an example of initiating and executing the phase retard mode. Assume stator 102 is rotating in direction CD 1 . Assume phaser 100 is in the first phase and receives torsional force T 2 to initiate the second phase. The non-rotational connection of stator 102 , wedge plate 106 , and rotor 104 begins to loosen as described above. However, before ramps 128 can slide up ramps 116 , or before ramps 128 slide up ramps 116 far enough to non-rotatably engage stator 102 , wedge plate 108 , and rotor 104 , pin 154 is displaced in direction AD 2 to non-rotatably connect rotor 104 and wedge plate 108 . Thus, as torsional force T 2 displaces rotor 104 in direction CD 2 , ramps 116 and 128 do not engage as required for the second phase and rotor 104 is free to rotate distance 168 B in direction CD 2 , beyond distance 168 A. As torsional force T 1 is received by rotor 104 , the first phase of the drive mode is executed as normal.

Thus, for each cycle of the first and second drive mode phases and torsional force forces T 1 and T 2 , while wedge plate 108 is non-rotatably connected to rotor 104 , the relative position of rotor 104 with respect to stator 102 shifts in direction CD 2 by distance 168 B. This process is repeatable via successive cycles of the first and second drive mode phases and torsional force forces T 1 and T 2 to attain the desired shift of rotor 104 . To terminate the shifting of rotor 104 in direction CD 2 , pin 154 is displaced, after transmission of torsional force T 1 and prior to transmission of torsional force T 2 , in direction AD 1 to enable rotation of wedge plate 108 with respect to rotor 104 . Rotor 104 still oscillates due to torsional force forces T 1 and T 2 , but within the frame of reference of the oscillations, the rotational position of rotor 104 with respect to stator 102 has been shifted.

Each distance 168 B is a result of phaser 100 implementing a full cycle of the first and second phases of the drive mode, or stated otherwise, receipt of a full cycle of torsional forces T 1 and T 2 . To shift rotor 104 in direction CD 2 by an amount less than distance 168 B, pin 154 is displaced in direction AD 1 to disengage from wedge plate 108 before the transition from the second phase to the first phase. That is, rotation of wedge plate 108 is enabled during the second phase so that ramps 116 and 128 engage and rotationally lock after rotor 104 has displaced distance 168 A, but prior to rotor 104 displacing distance 168 B.

FIG. 10 is a front view of stator 102 for camshaft phaser 100 in FIGS. 2A and 2B . In an example embodiment, stator 102 includes at least one radially inwardly projecting protrusion 174 and rotor 104 includes at least one radially outwardly projecting protrusions 176 . Protrusion(s) 176 are configured to contact protrusion(s) 174 to limit a degree to which the rotational position of rotor 104 can be shifted with respect to stator 102 .

It will be appreciated that various of the above-disclosed and other features and functions, or alternatives thereof, may be desirably combined into many other different systems or applications. Various presently unforeseen or unanticipated alternatives, modifications, variations, or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims.