Bi-directional overrunning clutch

Abstract

A bi-directional overrunning clutch is disclosed for controlling torque transmission between a secondary drive shaft and secondary driven shafts. The overrunning clutch includes a pinion input shaft in a differential housing that engages with a clutch housing rotatably disposed within the differential housing. At least one race is located adjacent to the clutch housing and is engaged with an output shaft. A cage is located between the race and the clutch housing. The cage is movable with respect to the clutch housing. A first coil is mounted within the differential housing adjacent to the cage and is adapted to produce an electromagnetic field when energized which causes the cage to drag with respect to the clutch housing. The dragging of the cage with respect to the clutch housing positions rolls within the cage to engage the clutch housing with the race when wheels on a primary drive shaft lose traction. A If desired a second coil is may be mounted within the differential housing adjacent adjacent to the cage. The second coil is adapted to produce an electromagnetic field when energized which advances cage with respect to the clutch housing causing the clutch housing to engage with the races. When the second coil is activated, the output shaft drives the pinion input shaft producing engine braking. An electronic control system is utilized to control the energizing of the coils.

We claim:  
     
       1. An overrunning clutch for controlling torque transmission between a pinion input shaft and at least one output shaft, the clutch comprising 
       a differential housing;  
       a pinion input shaft having an end rotatably disposed within the differential housing;  
       at least one output shaft having an end rotatably disposed within the differential housing;  
       a roller clutch disposed within the differential housing and adapted to control torque transmission between the pinion input shaft and the at least one output shaft, the roller clutch having a first position wherein the roller clutch is positioned to engage the pinion input shaft to the at least one output shaft to permit torque transmission from the pinion input shaft to the at least one output shaft, and a second position wherein the roller clutch engages the pinion input shaft with the at least one output shaft to permit torque transmission from the at least one output shaft to the pinion input shaft; and  
       a first electromagnetic adjustment device mounted within the differential housing, the first electromagnetic device adapted to place the roller clutch in its first position when energized; and  
       a second electromagnetic adjustment device mounted within the differential housing, the second electromagnetic adjustment device adapted to place the roller clutch in its second position when energized .  
     
     
       2. An overrunning clutch according to  claim 1  wherein the roller clutch includes a clutch housing and a roll cage, and wherein the first adjustment device includes a first coil which when energized drags the roll cage with respect to the clutch housing. 
     
     
       3. An overrunning clutch according to  claim 2  wherein the first electromagnetic device further includes a first armature plate for engaging the roll cage, the energizing of the first coil adapted to cause the armature plate to drag the roll cage. 
     
     
       4. An overrunning clutch according to  claim 2  wherein the clutch housing has a plurality of toggle levers pivotally mounted thereon, each toggle lever engaged with the roll cage, the first armature plate adapted to pivot the toggle levers when the first coil is energized to retard the roll cage. 
     
     
       5. An overrunning clutch according to  claim 2  wherein the first armature plate includes tangs which engage with slots formed in the roll cage. 
     
     
       6. An overrunning clutch according to  claim 2 further comprising a second electromagnetic adjustment device mounted within the differential housing, the second electromagnetic adjustment device adapted to place the roller clutch in its second position when energized; and wherein the second adjustment device includes a second coil which when energized advances the roll cage with respect to the clutch housing. 
     
     
       7. An overrunning clutch according to  claim 6  wherein the second electromagnetic device further includes a second armature plate disposed between the coil and the roll cage, the energizing of the second coil adapted to cause the second armature plate to advance the roll cage so that the roller clutch is in its second position. 
     
     
       8. An overrunning clutch according to  claim 7  wherein the clutch housing has a plurality of toggle levers pivotally mounted thereon, each toggle lever engaged with the roll cage, the second armature plate adapted to pivot the toggle levers when the second coil is energized to advance the roll cage. 
     
     
       9. An overrunning clutch according to  claim 8  wherein the third adjustment device includes a third coil which when energized pivots the toggle levers to retard the roll cage, the retarding of the roll cage moving the roller clutch out of its second position. 
     
     
       10. An overrunning clutch according to  claim 1  wherein the overrunning clutch is mounted to a vehicle, the vehicle including a drive shaft and two half shafts, each half shaft having a wheel engaged therewith, the overrunning clutch including two output shafts, each output shaft being rotatably engaged with a half shaft, the pinion input shaft being rotatably engaged with the drive shaft, and an electronic control system for controlling the electromagnetic adjustment devices  device. 
     
     
       11. An overrunning clutch according to  claim 1  further comprising a second electromagnetic adjustment device mounted within the differential housing, the second electromagnetic adjustment device adapted to place the roller clutch in its second position when energized; and a third electromagnetic adjustment device mounted within the differential housing, the third electromagnetic adjustment device adapted to disengage the roller clutch from its second position when the third electromagnetic device is activated. 
     
     
       12. A bi-directional overrunning clutch for controlling torque transmission between a pinion input shaft and at least one output shaft, the clutch comprising 
       a differential housing;  
       a pinion input shaft having an end rotatably disposed within the differential housing, the pinion input shaft adapted to rotate an input gear located within the differential housing;  
       a ring gear disposed within the housing and rotatably engaged with the input gear;  
       a clutch housing attached to the ring gear and rotatably disposed within the differential housing, the clutch housing having a cam surface formed on one side;  
       at least one race disposed adjacent to the cam surface and engaged with an output shaft;  
       a roll cage disposed between the race and the cam surface, the roll cage including a plurality of slots formed in and spaced circumferentially about the roll cage, each slot having a roll located therein, the roll cage movable with respect to the clutch housing and the at least one race;  
       a first armature plate located adjacent to the roll cage; and  
       a first coil mounted within the differential housing adjacent to the first armature plate, the first coil adapted to produce an electromagnetic field when energized which hinders the rotation of the first armature plate causing the roll cage to drag with respect to the clutch housing;  
       a second armature plate located adjacent to the roll cage; and  
       a second coil mounted within the differential housing adjacent to the second armature plate, the second coil adapted to produce an electromagnetic field when energized which hinders the rotation of the second armature plate and causes the roll cage to advance with respect to the clutch housing, the advancement of the roll cage with respect to the clutch housing adapted to cause the clutch housing to drivingly engage with the at least one race .  
     
     
       13. A bi-directional overrunning clutch according to  claim 12  wherein the dragging of the roll cage with respect to the clutch housing positions the rolls so as to permit rotatable engagement between the at least one race and the clutch housing for transmitting torque from the pinion input shaft to the output shaft when the output shaft rotates at a speed substantially equal to the pinion input shaft. 
     
     
       14. A bi-directional overrunning clutch according to  claim 12  further comprising at least one toggle lever pivotally mounted to the clutch housing, the at least one toggle lever engaged with the roll cage such that pivoting of the at least one toggle lever causes the roll cage to move with respect to the clutch housing; and wherein the first armature plate retards the roll cage by urging the at least one toggle lever to pivot. 
     
     
       15. A bi-directional overrunning clutch according to  claim 12  wherein the first armature plate includes tangs which engage with slots formed in the roll cage. 
     
     
       16. A bi-directional overrunning clutch according to  claim 12  wherein the advancement of the roll cage with respect to the clutch housing rotatably engages the at least one race to the clutch housing such that the output shaft is drivingly engaged with the pinion input shaft. 
     
     
       17. A bi-directional overrunning clutch according to  claim 12  further comprising a second armature plate located adjacent to the roll cage; a second coil mounted within the differential housing adjacent to the second armature plate, the second coil adapted to produce an electromagnetic field when energized which hinders the rotation of the second armature plate and causes the roll cage to advance with respect to the clutch housing, the advancement of the roll cage with respect to the clutch housing adapted to cause the clutch housing to drivingly engage with the at least one race; at least one toggle lever pivotally mounted to the clutch housing, the at least one toggle lever engaged with the roll cage such that pivoting of the at least one toggle lever causes the roll cage to move with respect to the clutch housing; and wherein the second armature plate advances the roll cage by urging the at least one toggle lever to pivot. 
     
     
       18. A bi-directional overrunning clutch according to  claim 17  wherein the engagement between the at least one toggle lever and the roll cage is provided by at least one pin formed in the roll cage, the at least one toggle lever having an end adapted to engage the pin in the roll cage. 
     
     
       19. A bi-directional overrunning clutch according to  claim 18  wherein there are three toggle levers spaced substantially equidistant around the clutch housing, each toggle lever includes an inner forked end which mates with a corresponding pin formed on the roll cage, the pin being capable of moving within the forked end of the toggle lever. 
     
     
       20. A bi-directional overrunning clutch according to  claim 12  further comprising a second armature plate located adjacent to the roll cage; a second coil mounted within the differential housing adjacent to the second armature plate, the second coil adapted to produce an electromagnetic field when energized which hinders the rotation of the second armature plate and causes the roll cage to advance with respect to the clutch housing, the advancement of the roll cage with respect to the clutch housing adapted to cause the clutch housing to drivingly engage with the at least one race; a third armature plate located adjacent to the roll cage; and a third coil mounted within the differential housing adjacent to the third armature plate, the third coil adapted to produce an electromagnetic field when energized which hinders the rotation of the third armature plate and causes the roll cage to retard with respect to the clutch housing, the retarding of the roll cage with respect to the clutch housing adapted to disengage the driving engagement between the clutch housing and the at least one race. 
     
     
       21. A bi-directional overrunning clutch according to  claim 20  further comprising at least one toggle lever pivotally mounted to the clutch housing, the at least one toggle lever engaged with the roll cage such that pivoting of the at least one toggle lever causes the roll cage to move with respect to the clutch housing; and wherein the third armature plate retards the roll cage by urging the at least one toggle lever to pivot. 
     
     
       22. A bi-directional overrunning clutch according to  claim 21  wherein there are a plurality of toggle levers pivotally mounted to the clutch housing, each toggle lever having a first end which is engaged with the roll cage and an outer projection formed on an end of the toggle lever on the opposite side of the pivotal attachment from the first end, and wherein the second armature plate has a plurality of tangs formed thereon which project toward the roll cage, the second armature plate positioned within the differential housing so that the tangs are radially aligned with the outer projections on the toggle levers and adapted to contact the outer projections when the second coil is energized, the contact between the tangs and the outer projections adapted to cause the toggle lever to pivot. 
     
     
       23. A vehicle having four wheel drive capability comprising: 
       a transmission;  
       a primary drive shaft rotatably driven by the transmission;  
       two primary half shafts rotatably engaged with the primary drive shaft, each primary half shaft engaged with a corresponding primary wheel;  
       a secondary drive shaft rotatably engaged with the transmission;  
       an overrunning clutch assembly engaged to the secondary drive shaft, the overrunning clutch assembly including:  
       a differential housing;  
       a pinion input shaft rotatably disposed within the differential housing and engaged with the secondary drive shaft;  
       a clutch housing disposed within the differential housing and rotatably connected to the pinion input shaft, the clutch housing having an inner surface;  
       at least one race disposed adjacent to the inner surface of the clutch housing, the at least one race being engaged with an output shaft;  
       a cage disposed between the at least one race and the inner surface of the clutch housing, the cage having a plurality of slots formed in and spaced circumferentially about the cage, each slot having a movable member located therein, the cage being adjustable with respect to the clutch housing and the at least one race;  
       a first armature plate located adjacent to and adapted to engage with the cage;  
       a first coil mounted within the differential housing adjacent to the first armature plate, the first coil adapted to produce an electromagnetic field when energized which hinders the rotation of the first armature plate causing the cage to move to a first position with respect to the clutch housing, the first position of the cage locating the movable members so as to wedge between the inner surface and the at least one race when one of the primary wheels loses traction;  
       a second armature plate located adjacent to the cage;  
       a second coil mounted within the differential housing adjacent to the second armature plate, the second coil adapted to produce an electromagnetic field when energized which hinders the rotation of the second armature plate and causes the cage to move to a second position with respect to the clutch housing, the second position of the cage adapted to wedge the movable members between the inner surface and the at least one race;  and  
       an electronic control system connected to the first and second coils  coil, the electronic control system providing signals for controlling energizing of the first and second coils  coil.  
     
     
       24. A vehicle according to  claim 23  wherein the overrunning clutch further includes a second armature plate located adjacent to the cage; a second coil mounted within the differential housing adjacent to the second armature plate, the second coil adapted to produce an electromagnetic field when energized which hinders the rotation of the second armature plate and causes the cage to move to a second position with respect to the clutch housing, the second position of the cage adapted to wedge the movable members between the inner surface and the at least one race; and a third armature plate located adjacent to the cage; and a third coil mounted within the differential housing adjacent to the third armature plate, the third coil adapted to produce an electromagnetic field when energized which hinders the rotation of the third armature plate and causes the cage to move out of the second position and the movable members to disengage from between the inner surface and the at least one race. 
     
     
       25. A vehicle according to  claim 23  wherein the electronic control system includes a manually actuated button which when activated results in the energizing of the first coil. 
     
     
       26. An overrunning clutch assembly comprising: 
       a differential housing;  
       a pinion input shaft having an end rotatably disposed within the differential housing;  
       a clutch housing disposed within the differential housing and rotatably connected to the pinion input shaft, the clutch housing having an inner surface;  
       at least one race disposed adjacent to the inner surface of the clutch housing, the at least one race being engaged with an output shaft;  
       a cage disposed between the at least one race and the inner surface of the clutch housing, the cage having a plurality of slots formed in and spaced circumferentially about the cage, each slot having a movable member located therein, the cage being adjustable with respect to the clutch housing and the at least one race;  
       a first armature plate located adjacent to and adapted to engage with the cage; and  
       a first coil mounted within the differential housing adjacent the first armature plate, the first coil adapted to produce an electromagnetic field when activated which hinders the rotation of the first armature plate causing the cage to move to a first position with respect to the clutch housing, the first position of the cage locating the movable members so as to be adapted to wedge between the inner surface and the at least one race;  
       a second armature plate located adjacent to the cage; and  
       a second coil mounted within the differential housing adjacent to the second armature plate, the second coil adapted to produce an electromagnetic field when activated which hinders the rotation of the second armature plate and causes the cage to move to a second position with respect to the clutch housing, the second position of the cage adapted to wedge the movable members between the inner surface and the at least one race  when the inner surface is rotating faster than the at least one race.  
     
     
       27. An overrunning clutch according  claim 26  further comprising a second armature plate located adjacent to the cage; a second coil mounted within the differential housing adjacent to the second armature plate, the second coil adapted to produce an electromagnetic field when activated which hinders the rotation of the second armature plate and causes the cage to move to a second position with respect to the clutch housing, the second position of the cage adapted to wedge the movable members between the inner surface and the at least one race.