CROSS REFERENCE TO RELATED APPLICATIONS

[0001 j This application claims the benefit of U.S. provisional application Serial No.

62/743,218, filed October 9, 2018, the disclosure of which is hereby incorporated in its entirety by reference herein.

TECHNICAL FIELD 0002| This invention generally relates to coupling and control assemblies for use in motor vehicles such as hybrid vehicles which have an internal combustion engine and one or more electric motors.

OVERVIEW

[O0O3J As described in ITS. Patent Nos. 9,255,6.14; 9,54.1 ,14.1 ; and 9,678,266, coupling assemblies such as clutches are used in a wide variety· of applications to selectively couple power from a first rotatable driving member, such as a driving disk or plate, to a second, independently rotatable driven member, such as a driven disk or plate. In one known variety of clutches, commonly referred to as“one-way” or“overrunning” clutches, the clutch engages to mechanically couple the driving member to the driven member only when the driving member rotates in a first direction relative to the driven member. Further, the clutch otherwise permits the driving member to freely rotate in the second direction relative to the driven member. Such“freewheeling” of the driving member in the second direction relative to the driven member is also known as the “overrunning” condition. 0004| One type of one-way clutch includes coaxial driving and driven plates having generally planar clutch faces in closely spaced, juxtaposed relationship. A plurality of recesses or pockets is formed in the face of the driving plate at angularly spaced locations about the axis, and a strut or pawl is disposed in each of the pockets. Multiple recesses or notches are formed in the face of the driven plate and are engageable with one or more of the struts when the driving plate is rotating in a first direction. When the driving plate rotates in a second direction opposite the first di ection, the struts disengage the notches, thereby allowing freewheeling motion of the driving plate with respect to the driven plate.

[0005| When the driving plate reverses direction from the second direction to the first direction, the driving plate typically rotates relative to the driven plate until the clutch engages. As the amount of relative rotation increases, the potential for an engagement noise also increases.

[0006J Controllable or selectable one-way clutches (i.e , OWCs) are a departure from traditional one-way clutch designs. Selectable OWCs add a second set of locking members in combination with a slide plate. The additional set of locking members plus the slide plate adds multiple functions to the OWC. Depending on the needs of the design, controllable OWCs are capable of producing a mechanical connection between rotating or stationary shafts in one direction or both directions. Also, depending on the design, OWCs are capable of overrunning in one or both directions, A controllable OWC contains an externally controlled selection or control mechanism. Movement of this selection mechanism can be between two or more positions which correspond to different operating modes.

|0007| U.S. Patent No, 5,927,455 discloses a bi-directional overrunning pawl-type clutch,

U.S. Patent No. 6,244,965 discloses a planar overrunning coupling, and U.S Patent No. 6,290,044 discloses a selectable one-way clutch assembly for use in an automatic transmission U.S. Patent Nos. 7,258,214 and 7,344,010 disclose overrunning coupling assemblies, and U.S. Patent No, 7,484,605 discloses an overrunning radial coupling assembly or clutch, iOOOSJ A properly designed controllable OWC can have near-zero parasitic losses in the

“off” state. It can also be activated by electro-mechanics and does not have either the complexity or parasitic losses of a hydraulic pump or val ves. f 011091 In a powershift transmission, tip-in clunk is one of most difficult challenges due to absence of a torque converter. When the driver tips-in, i.e., depresses the accelerator pedal following a coast condition, gear shift harshness and noise, called clunk, are heard and felt in the passenger compartment due to the mechanical linkage, without a fluid coupling, between the engine and powershift transmission input. Tip-in clunk is especially acute in a parking-lot maneuver in which a vehicle coasting at low speed is then accelerated in order to maneuver into a parking space.

[0010! In order to achieve good shift quality and to eliminate tip-in clunk, a powershift transmission should employ a control strategy that is different from that of a conventional automatic transmission. The control system should address the unique operating characteristics of a powershift transmission and include remedial steps to avoid the objectionable harshness yet not interfere with driver expectations and performance requirements of the powershift transmission. There is a need to eliminate shift harshness and noise associated with tip-in clunk in a powershift transmission

[001 If For purposes of this disclosure, the term“coupling” should be interpreted to include clutches or brakes wherein one of the plates is driveably connected to a torque delivery element of a transmission and the other plate is driveably connected to another torque delivery element or is anchored and held stationary with respect to a transmission housing. The terms“coupling,” “clutch,” and“brake” may be used interchangeably.

[0012| A pocket plate may be provided with angularly disposed recesses or pockets about the axis of the one-wa clutch. The pockets are formed in the planar surface of the pocket plate. Each pocket recei ves a torque transmitting strut, one end of which engages an anchor point in a pocket of the pocket plate. An opposite edge of the strut, which may hereafter be referred to as an active edge, is moveable from a position within the pocket to a position in which the active edge extends outwardly· fro the planar surface of the pocket plate. The stmts may be biase away from the pocket plate by indi vidual springs.

[0013| A notch plate may be formed with a plurality of recesses or notches located approximately on the radius of the pockets of the pocket plate. The notches are formed in the planar surface of the notch plate.

[00141 Another example of an overrunning planar dutch is disclosed in U.S. Patent No.

5,597,057.

[00151 Some U.S. patents related to the present invention include: U.S. Patent Nos

4,056,747; 5,052,534; 5,070,978; 5,449,057; 5,486,758; 5,678,668; 5,806,643; 5,918,715; 5,964,331 ; 5,979,627; 6,065,576; 6,1 16,394; 6, 125,980; 6,129,1 0; 6,186,299; 6, 193,038;

6,386,349; 6,481 ,551 ; 6,505,721 ; 6,571 ,926; 6,814,201 ; 7,153,228; 7,275,628; 8,051 ,959;

8,196,724; and 8,286,772.

[0Q16| Yet still other related U.S. patents include U.S. Patent Nos. 4,200,002; 5,954, 174; and 7,025,188.

[8017J U.S. Patent No. 6,854,577 discloses a sound-dampened, one-way clutch including a plastic/steel pair of struts to dampen engagement clunk. The plastic strut is slightly longer than the steel stmt. This pattern can be doubled to dual engaging. This approach has had some success. However, the dampening function stopped when the plastic parts became exposed to hot oil over a period of time.

[00181 Metal injection molding (MIM) is a metalworking process where finely-powdered metal is mixed with a measured amount of binder material to comprise a‘feedstock’ capable of being handled by plastic processing equipment through a process known as injection mold forming. The molding process allows complex parts to be shaped in a single operation and in high volume. End products are commonly component items used in various industries and applications. The nature of MIM feedstock flow is defined by a science called rheology. Current equipment capability requires processing to stay limited to products that can he molded using typical volumes of 100 grams or less per“shot” into the mold. Rheology does allow this“shot” to be distributed into multiple cavities, thus becoming cost-effective for small, intricate, high -volu e products which would otherwise be quite expensive to produce by alternate or classic methods. The variety of metals capable of implementation within MIM feedstock are referred to as powder metallurgy, and these contain the same alloying constituents found in industry standards for common and exotic metal applications. Subsequent conditioning operations are performed on the molded shape, where the binder material is removed and the metal particles are coalesced into the desired state for the metal alloy.

[0019j Other U.S. patent documents related to at least one aspect of the present invention includes U.S. Patent Nos. 8,813,929; 8,491,440; 8,491,439, 8268,772; 8,272,488; 8, 187, 141 ; 8,079,453; 8,007,396; 7,942,781 ; 7,690,492; 7,661,518; 7,455,157; 7,455,156; 7,451,862; 7,448,481; 7,383,930; 7, 223 J 98; 7,100,756; and 6,290,044; and U.S. published application Nos.

2015/0000442; 2014/0305761; 2013/0277164; 2013/0062151; 2012/0152683; 2012/0149518;

2012/0152687; 2012/0145505; 2011/0233026; 2010/0105515; 2010/0230226; 2009/0233755;

2009/0062058; 2009/0211863, 2008/0100715; 2008/0188388; 2008/0185253; 2006/0124425;

2006/0249345; 2006/0185957; 2006/0021838, 2004/0216975; and 2005/0279602.

[9020J Some other U.S. patent documents related to at least one aspect of the present invention includes U.S. Patent Nos. 9,255,614; 9,541,141; 9,638,266; 8,720,659; 8,418,825; 5,996,758; 4,050,560; 8,061,496; 8,196,724; and U.S. published application Nos. 2014/0190785; 2014/0102844; 2014/0284167; 2012/0021862; 2012/0228076; 2004/0159517; and 2010/0127693.

[09211 As used herein, the term“sensor” is sued to describe a circuit or assembly that includes a sensing element and other components. In particular, as used herein the term“magnetic field sensor” is used to describe a circuit or assembly that include a magnetic field sensing element and electronics coupled to the magnetic field sensing element.

[9922] As used herein, the term“magnetic field sensing element” is used to describe a variety of electronic elements that can sense a magnetic field. The magnetic field sensing elements can be, but are not limited to, Hall effect elements, magnetoresistance elements, or magnetotransistors. As is known, there are different types of Hall effect elements, for example, a planar Hall element, a vertical Hall element, and a circular vertical Hall (CVH) element. As is also known, there are different types of magnetoresi tance elements, for example, a giant magnetoresistance (GMC) element, an anistropic magnetoresistance element (AMR), a tunneling magnetoresistance (TMR) dement, an Indium antimonide (InSb) sensor, and a magnetic tunnel junction (MTJ) f 00231 As is known, som of the above-described magnetic field sensing elements tend to have an axis of maximum sensitivity parallel to a substrate that supports the magnetic field sensing dement, and others of the above-described magnetic field sensing elements tend to have an axis of maximum sensitivity perpendicular to a substrate that supports the magnetic field sensing element.

In particular, planar Hall elements tend to have axes of sensitivity perpendicular to a substrate, while magnetoresistance elements and vertical Hall elements (including circular vertical Flail (CVH) sensing element) tend to have axes of sensitivity paral lel to a substrate.

[0024| Magnetic field sensors are used in a variety of applications, including, but not limited to, an angle sensor that senses an angle of a direction of a magnetic field, a current sensor that senses a magnetic field generated by a current carried by a current-carrying conductor, a magnetic switch that senses the proximity of a ferromagnetic object, a rotation detector that senses passing ferromagnetic articles, for example, magnetic domains of a ring magnet, and a magnetic field sensor that senses a magnetic field density of a magnetic field.

[0025] As well as U.S, Patent No. 9,381 ,799, (i.e.‘799 patent), hybrid vehicles may be powered by more than one power source. For example, a hybrid electric vehicle may be powered by an internal combustion engine and one or more electric motors. During certain vehicle operating conditions, the internal combustion engine may be disabled so that the one or more electric motors may instead power the hybrid vehicle.

[0026] As used herein, the temimoiogy“hybrid vehicle” refers to a vehicle that is powered by a first power source and a second power source that is different: from the first power source. For example, die hybrid vehicle may be powered by an internal combustion engine and an electric motor.

[0027] Therefore, a hybrid vehicle may be a hybrid electric vehicle (HEV), a plug-in hybrid electric vehicle (PHEV), or an extended range electric vehicle (E-REV), and the internal combustion engine may be useful for automotive vehicles including a passenger car or a sport utility vehicle. However, it is to be appreciated that the internal combustion engine may also be useful for non- automotive applications such as marine and recreational vehicle applications.

[002$] The‘799 patent discloses a hybrid vehicle including an engine block, a flywheel, and a grounding clutch coupled to the block. The flywheel is rotatable about an axis and includes a spline. The spline has a first tooth and a second tooth spaced apart from the first tooth to define a gap therebetween. Tire dutch is configured for preventing rotation of the flywheel about the axis and include a locking pin. The pin is transitionable between a locked position in which the pin is disposed within the gap and abuts the first and second teeth such that the flywheel does not rotate, and ati unlocked position in which the pin does not abut the first and second teeth such that the flywheel rotates.

[0029f A problem with the‘799 patent is that locking is provided when the locking pin precisely fits within a gap between teeth and does not adequately deal with a tooth butt condition and does not provide enough operating modes.

SUMMARY OF EXAMPLE EMBODIMENTS OF THE INVENTION

[00301 An object of at least one embodiment of the present invention is to provide a coupling and control assembly having a large number of operating modes to control the rotation of a powertrain component about its axis.

[00311 In carrying out the object and other objects of at least one embodiment of the present invention, a coupling and control assembly for use in a motor vehicle and having multiple operating modes is provided. The assembly includes a first coupling face of an engine powertrain component or part supported by the powertrain component for rotation therewith about an axis. The first coupling lace is oriented to face either axially or radially with respect to the axis. The first coupling face has a first set of locking formations. Each of the locking formations defines a first load bearing surface adapted for abutting engagement with a first load bearing surface of a first locking element. The assembly also includes a coupling member supported on a stationary member of the vehicle. I ^' he coupling member has a second coupling face in close-spaced opposition with the first coupling face. The second coupling face has a pocket which receives the first locking element and defines a second load bearing surface adapted for abutting engagement w ith second load bearing surface of the first locking element. The assembly further includes an electromechanical actuator to move the first locking element across a gap towards the first coupling face to a coupling position in response to the actuator receiving an electrical control signal. The first locking element abuttingly engages one of the locking formations to prevent rotation of the powertrain component in a first direction about the axis in the coupling position.

[0032] The powertrain component may be a flywheel rotatable about the axis and the stationary member may be an engine block. f (B3| The first and second coupling faces may be oriented to face axially in opposite directions along the axis

|0034| The first and second coupling faces may be oriented to face radially in opposite directions with respect: to the axis.

[0035 j The part may comprise an annular ring having the first coupling face.

[0036 j The first locking element may comprise an active strut.

[00371 A surface of the powertrain component may have the first coupling face.

[00381 The assembly may further include a third coupling face having a second set of locking formations and a fourth coupling face in close-space opposition with the third coupling face and having a pocket which receives a second locking element. The second locking element may move across a gap towards the third coupling face to a coupling position to abutting !y engage one of the second set of locking formations to prevent rotation of the powertrain component in a second direction opposite the first direction about the axis.

[00391 The assembly may further include a second electromechanical actuator coupled to the second locking element to actively move the second locking member.

[00401 The second locking element may be a passive locking element which passively moves.

[0041 J Further in carrying out the above object and other objects of at least one embodiment of the present: invention, a coupling and control assembl for use in a hybrid vehicle having an internal combustion engine and one or more electric motors is provided. The assembly includes a first coupling face of a flywheel of the engine or an annular structure supported by the flywheel for rotation therewith about an axis. The first coupling face is oriented to face either axially or radially with respect to the axi s. The first coupling face has a first set of locking formations. Each of the locking formations defines a first load bearing surface adapted for abutting engagement with a first load bearing surface of a first locking element. The assembly further includes a coupling member supported on an engine block of the vehicle. The coupling member has a second coupling face in close-spaced opposition with the first coupling face. The second coupling face haa a pocket which receives the first locking element and defines a second load hearing surface adapted for abutting engagement with a second load bearing surface of the first locking element. An electromechanical actuator moves the first locking element across a gap towards the first coupling face to a coupling position in response to the actuator receiving an electrical control signal. The first locking element abuttingly engages one of the locking formations to prevent rotation of the flywheel in a first direction about the axis in the coupling position to disable the engine so that the one or more electric motors may instead power the hybrid vehicle.

|00421 The first and second coupling faces may be oriented to face axially in opposite directions along the axis,

[O043J The first and second coupling faces may be oriented to face radially in opposite directions with respect to the axis

[0044| The first locking element may comprise an active strut,

[00451 A surface of the flywheel may have the first coupling face,

100461 The assembl may further include a third coupling face having a second set of

Socking formations and a fourth coupling face in close-space opposition with the third coupling l ce and having a pocket which receives a second locking element. The second locking element may move across a gap towards the third coupling face to a coupling position to abuttingl engage one of the second set of locking formations to prevent rotation of the flywheel in a second direction opposite the first direction about the axis to disable the engine so that the one or more electric motors may instead power the hybrid vehicle

[0O47| The assembly may further include a second electromechanical actuator coupled to the second locking element to actively move the second locking member.

{0048J The second locking element may be a passive locking element which passively moves. BRIEF DESCRIPTION OF THE DRAWINGS

[00491 Figure 1 is a perspective, schematic view, partially broken away, illustrating a starter motor being supported on an internal combustion engine block;

[00501 Figure 2 is a schematic view of a coupling and control assembly constructed in accordance with a first embodiment of the present invention and which is to be located on the engine block of Figure 1 in place of the starter motor;

100511 Figures 3a and 3b are perspective, schematic front and back views of the assembly of

Figure 2;

[0052 [ Figure 3c is a view, similar to the view of Figure 2, but without the axis of rotation;

[0053] Figure 4 is a view, similar to the views of Figures 2 and 3c, but of a second embodiment of the invention;

Figure 5 is a view, similar to the view of Figure 4, but of a third embodiment;

[0055f Figures 6a and 6b are perspective, schematic front and back views of a fourth embodiment of the assembly supported on the engine block;

[0056 Figure 6c is a schematic vie of the fourth embodiment;

Figure 7 is a schematic view of a filth embodiment; and

10058f Figure 8 is a schematic view of a sixth embodiment.

DETAILED DESCRIPTION

[00591 As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merel exemplary of the invention that may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basts for teaching one skilled in the art to variously employ the present invention.

[0060J The following table refers to drawings figures 2-8 and summarizes the six embodiments of a coupling and control assembl constructed in accordance with the present invention: Passive-Active Comments

Dual Planar Figures 2, 3a-3c: Passive planar. Active planar Pockets on ring gear

notches on flywheel

Fig. 4: Passive planar, Active radial 90° Pockets and notches

on Ring gear

Dual radial Fig 5: Passive radial. Active radial Parallel tracks on OD of

ring gear

Active- Active

Dual Planar Figs. 6a-6c: Active planar. Active planar side-by-side notches on

ring gear

Dual radial Fig 7: Active radial, Active radial Notches on ring OD,

Double teeter totter struts

[00611 Fig. 8: Active pianar, Active radial 90 ^~ notches on Ring gear

[9062] In general, each of the six embodiment comprises a coupling and control assembly for use in a motor vehicle and having multiple operating modes. Each assembly includes a first coupling face of an engine powertrain component or part supported by the powertrain component for rotation therewith about an axis. The first coupling face is oriented to face either axially or radially with respect to the axis. The first coupling lace has a first set of locking formation. Each of the locking formations defines a first load bearing surface adapted for abutting engagement with a first load bearing surface of a first locking element. Each assembly also includes a coupling member supported on a stationary member of the vehicle. Th coupling member has a second coupling face in close-spaced opposition with the first coupling face. The second coupling face has a pocket which receives the first locking element and defines a second load bearing surface adapted for abutting engagement with a second load bearing surface of the first locking element. Each assembly also includes an electromechanical actuator coupled to the first locking element to move the first locking element across a gap towards the first coupling face to a coupling position in response to the actuator receiving an electrical control signal. The first locking element abuttingly engages one of the locking formations to prevent rotation of the powertrain component in a first direction (i.e. CW) about the axis in the coupling position. 0963f Also, in each of the embodiments, each assembly includes a third coupling face having a second set of locking formations and a fourth coupling face in close-space opposition with the third coupling face and having a pocket which receives a second locking element. The second locking element moving across a gap towards the third coupling face to a coupling position to abuttingly engage one of the second set of locking formations to prevent rotation of the powertrain component i a second directio (i.e, CCW) opposite the first direction about the axis.

|0064J The phrase“active-active” means that both clockwise (CW) and counter-clockwise

(CCW) locking elements or struts are actively controlled by the actuator. The phrase“passive- active” means the CW locking element is actively controlled and the CCW element passively disengages with flywheel speed.

|0065| in general, the coupling and control assembl of at least one embodiment of the present invention is a subsystem or assembly of a hybrid powertrain and it connects/grounds the engine crankshafi/fly wheel to the engine block. The assembly is a modular design consisting of an actuator (i.e. solenoid), a latching mechanism, a position sensor and a five pin USCAR connector. The assembly allows free engine rotation in either direction when disengaged and is able to bidirectionally prevent or lock engine rotation when engaged. The assembly allows forward engine motion (CW) when commanded to transitio to the disengaged state.

[00<¾>! Figure 1 shows a typical position of a starter motor 10 on an engine block 12. A first embodiment of a coupling and control assembly, generally indicated at 14 in Figure 2, will typically occupy this position. A second embodiment of the assembly is generally indicated at 1 14 in Figure 4. A third embodiment is generally indicated at 214 in Figure 5. A fourth embodiment is generally indicated at 314 in Figure 6c A fifth embodiment is generally indicated at 414 in Figure 7. A sixth embodiment is generally indicated at 515 in Figure 8, In other words, the same or similar parts in each embodiment have the same last two numbers.

[0067] In Figures 6A, 6B, and 6C, a pair of side-by-side actuators are shown at 316 and 317

(i e“x2”). Each of the actuators 316 and 317 drive its respective active strut 318 or 319 supported in pockets within a coupling member housing 320 located in the starter motor packing space as shown in Figures 6 A and 6B When the actuators 316 and 317 are energized, they move their respective struts 318 and 319 into notches 322, 332 formed in an annular ring part 324 supported for rotation on a flywheel 326 about the engine/ flywheel axis A of Figure 2,

[0068] in Figure 7, a pair of active stmts 418 and 419 are actively controlled to move by actuators 416 and 417, respectively, to CCW lock and CW lock. 0116 1 In Figure 8, a pair of active stmts 518 and 519 are actively controlled to move by actuators 516 and 517, respectively. 0070| In Figures 3A-3C. an active stmt 18 is actively controlled to move by actuator 16 to

CW lock. Passive strut 30 moves passively to CCW lock.

[0071J In Figure 4, active strut 1 18 is actively controlle to move via actuator 1 16 to CW lock. Passive strut 130 moves passively to CCW lock. Three notches 132 are preferably provided,

[0072] In Figure 5, active strut 218 is actively controlled to move via actuator 216 to CW lock. Passive strut 230 moves passively to CCW lock.

[0073J in each of th above-noted six embodiments, a magnetic field position sensor (not show n) is located in front of each active strut to provide position feedback to a controller (not shown) of the actuator(s). Al so, preferably a spring (not shown) is provided under each of the active and passive stmts to bias its stmt to its disengaged or engaged positions. |00?4J In each of the above-noted six embodiments, the coupling and control assembly is coupled to the engine block and configured for preventing rotation of the flywheel about the axis A when the automatic transmission operates in flic electric inode. The assembly may be coupled to the engine block 12 in any maimer. For example, the assembly ma be bolted to the engine block 12. As such, the assembly may not be rotatable about the axis A, but may rather be fixed to the engine block 12. The assembly may be useful for preventing rotation of the flywheel, while the electric motor provides motive power to the hybrid vehicle. Since the electric motor may drive, he., provide motor power to the hybrid vehicle more efficientl when the interna! combustion engine is disabled or disengaged, e.g., when the flywheel is stationary and does not rotate the hybrid vehicle including the assembly may have excellent efficiency. The assembly may be characterized as a coupling configured for connecting and disconnecting a driving component, he. flywheel of the internal combustion engine and a driven component, Le., the automatic transmission.

|0075| The assembly may be positioned to occupy a space on the engine block 12 vacated by a non-existent starter mechanism (not shown) for the internal combustion engine. That is, since the hybrid vehicle may not include a conventional starter mechanism for the internal combustio engine, the assembly may be disposed in a location dial would be otherwise occupied by the starter mechanism.

|0076J While exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention. Additionally, the features of various implementing embodiments may be combined to form further embodiments of the invention.