Viscous clutch with return bore through rotor

Abstract

A viscous clutch (20) includes a housing assembly (28), a rotor assembly (26), a reservoir (38) to hold a supply of a shear fluid, a working chamber (40) operatively positioned between the housing assembly and the rotor assembly, and a fluid return bore (26-1B) that optionally extends radially through at least an outer diameter portion of the rotor assembly to the working chamber. Selective introduction of the shear fluid to the working chamber facilitates selective torque transmission between the housing assembly and the rotor assembly. The fluid return bore can form at least a portion of a fluid return path (50) from the working chamber to the reservoir.

The invention claimed is: 
     
       1. A viscous clutch comprising:
 a rotationally fixed journal bracket having a shaft portion;  
 a housing assembly; 
 a rotor assembly that includes a disk and a bearing hub connected to the disk for co-rotation therewith, wherein the bearing hub extends beyond the housing assembly in a direction away from the journal bracket to provide a mounting location for an output member, and wherein the rotor assembly is rotatably supported on the shaft portion; 
 a reservoir to hold a supply of a shear fluid, the reservoir carried by the housing assembly; 
 a reservoir cover defining a portion of a boundary of the reservoir; 
 a working chamber operatively positioned between the housing assembly and the rotor assembly, wherein selective introduction of the shear fluid to the working chamber facilitates selective torque transmission between the housing assembly and the rotor assembly; 
 an electromagnetically actuated valve assembly configured to controllably translate a first valve element that controls flow of the shear fluid between the reservoir and the working chamber; 
 an electromagnetic coil assembly located rearward of the housing assembly, wherein energization of the coil assembly controls translation of the first valve element, wherein the reservoir is located in between the electromagnetic coil assembly and the mounting location for the output member on the bearing hub, and wherein the valve assembly extends from a location adjacent to the electromagnetic coil assembly into the reservoir;  
 an outlet bore in the reservoir cover to allow the shear fluid out of the reservoir to the working chamber along a fluid delivery path; and 
 a fluid return bore that extends radially through at least an outer diameter portion of the disk of the rotor assembly to the working chamber, the fluid return bore forming at least a portion of a fluid return path from the working chamber to the reservoir. 
 
     
     
       2. The viscous clutch of  claim 1  and further comprising:
 an electromagnetically actuated valve assembly configured to controllably translate a first valve element that controls flow of the shear fluid between the reservoir and the working chamber. 
 
     
     
       3. The viscous clutch of claim  2  1 and further comprising:
 a second valve element configured to be actuated concurrently with the first valve element to further control flow of the shear fluid between the reservoir and the working chamber, wherein the first and second valve elements are actuated by a common translating armature. 
 
     
     
       4. The viscous clutch of  claim 1 and further comprising:
 an, wherein the electromagnetic coil assembly is positioned adjacent to the housing assembly, and wherein the electromagnetic coil assembly includes first and second windings each having terminals electrically connectable in a configuration selected from the group consisting of series and parallel, for operation at different voltages. 
 
     
     
       5. The viscous clutch of  claim 1 , wherein the rotor assembly comprises:
 a disk, wherein the fluid return bore extends radially through at least a portion of the disk; and   a bearing hub connected to the disk for co-rotation therewith, wherein the bearing hub extends beyond the housing assembly to provide a mounting location for an output member.   
     
     
       6. The viscous clutch of  claim 1  and further comprising:
 a pulley connected to the housing assembly for co-rotation with the housing assembly. 
 
     
     
       7. The viscous clutch of  claim 1  and further comprising:
 a rotationally fixed journal bracket having a shaft portion; 
 a first set of tapered roller bearings for rotationally supporting the housing assembly on the shaft portion of the journal bracket; and 
 a second set of tapered roller bearings for rotationally supporting the rotor assembly on the shaft portion of the journal bracket. 
 
     
     
       8. The viscous clutch of  claim 1 , wherein the housing assembly includes a plurality of cooling fins, and wherein the cooling fins are configured to rotate whenever there is a rotational input to the viscous clutch. 
     
     
       9. The viscous clutch of  claim 1  and further comprising:
 an interchangeable pump bore insert positioned at least partially within the fluid return bore, wherein the inter-changeable pump bore insert includes a bore in fluid communication with the fluid return bore. 
 
     
     
       10. The viscous clutch of  claim 9  and further comprising:
 an access opening in the housing assembly configured to allow access to the interchangeable pump bore insert. 
 
     
     
       11. The viscous clutch of  claim 1  and further comprising:
 a wiper at an outer diameter portion of the rotor assembly and protruding, at least partially, into the working chamber. 
 
     
     
       12. The viscous clutch of  claim 11 , wherein the wiper is removably attached to a the disk of the rotor assembly. 
     
     
       13. The viscous clutch of  claim 1  and further comprising:
 a flow guide that traverses the reservoir cover to deliver the shear fluid from the fluid return bore of the rotor assembly to the reservoir along the fluid return path. 
 
     
     
       14. The viscous clutch of  claim 1  and further comprising:
 a bearing hub connected to the disk for co-rotation therewith, wherein the bearing hub extends beyond the housing assembly to provide a mounting location for an output member; 
 a rotationally fixed journal bracket having a shaft portion, wherein the bearing hub extends beyond the housing assembly in a direction away from the journal bracket; 
 a first bearing set for rotationally supporting the housing assembly on the shaft portion of the journal bracket; and 
 a second bearing set for rotationally supporting the rotor assembly on the shaft portion of the journal bracket. 
 
     
     
       15. A method for selective torque transmission, the method comprising:
 delivering a rotational input to a housing assembly that carries a reservoir; 
 rotating the housing assembly on a rotationally fixed mounting shaft with a first bearing set, wherein the first bearing set is located radially inward from the reservoir;  
 selectively delivering a shear fluid to a working chamber along a fluid delivery path extending from the reservoir to the working chamber, wherein the fluid delivery path extends through an outlet bore along a boundary of the reservoir; 
 transmitting torque to a rotor assembly as a function of volume of the shear fluid selectively delivered to the working chamber; 
 rotating the rotor assembly on the rotationally fixed mounting shaft with a second bearing set; and 
 returning the shear fluid from the working chamber to the reservoir along a fluid return path that extends through a substantially radial bore through a disk of the rotor assembly. 
 
     
     
       16. The method of  claim 15  and further comprising:
 providing a first interchangeable pump bore insert to provide pumping at a first rate when returning the shear fluid from the working chamber to the reservoir. 
 
     
     
       17. The method of  claim 16  and further comprising:
 replacing the first interchangeable pump bore insert having a bore of a first size with a second interchangeable pump bore insert having a bore of a second size that is different from the first size. 
 
     
     
       18. The method of  claim 15  and further comprising:
 securing a removably attached wiper to an outer diameter portion of the disk adjacent to the substantially radial bore such that the wiper protrudes into the working chamber. 
 
     
     
       19. A viscous clutch comprising:
 a housing assembly;   a rotor assembly;   a reservoir to hold a supply of a shear fluid;   a working chamber operatively positioned between the housing assembly and the rotor assembly, wherein selective introduction of the shear fluid to the working chamber facilitates selective torque transmission between the housing assembly and the rotor assembly;   a fluid return bore that extends radially through at least an outer diameter portion of the rotor assembly to the working chamber, the fluid return bore forming at least a portion of a fluid return path from the working chamber to the reservoir;   an interchangeable pump bore insert positioned at least partially within the fluid return bore, wherein the inter-changeable pump bore insert includes a bore in fluid communication with the fluid return bore; and an access opening in the housing assembly configured to allow access to the interchangeable pump bore insert.   
     
     
       20. A viscous clutch comprising:
 a housing assembly;   a rotor assembly including a disk;   a reservoir to hold a supply of a shear fluid;   a working chamber operatively positioned between the housing assembly and the rotor assembly, wherein selective introduction of the shear fluid to the working chamber facilitates selective torque transmission between the housing assembly and the rotor assembly;   a fluid return bore that extends radially through at least an outer diameter portion of the rotor assembly to the working chamber, the fluid return bore forming at least a portion of a fluid return path from the working chamber to the reservoir; and   a wiper at an outer diameter portion of the rotor assembly and protruding, at least partially, into the working chamber, wherein the wiper is removably attached to the disk of the rotor assembly.   
     
     
       21. A viscous clutch comprising:
 a rotationally fixed shaft;   an input assembly rotationally mounted on the shaft;   an output assembly rotationally mounted on the shaft, wherein the output assembly includes a disk and a bearing hub connected to the disk for co-rotation therewith, wherein the bearing hub extends beyond a front of the input assembly to provide a forward-facing mounting surface;   a reservoir to hold a supply of a shear fluid, the reservoir carried by the input assembly;   a reservoir cover attached to the input assembly, the reservoir cover defining a portion of a boundary of the reservoir;   a working chamber operatively positioned between the input assembly and the disk of the output assembly;   an outlet bore in the reservoir cover to allow the shear fluid out of the reservoir to the working chamber along a fluid delivery path;   an additional outlet bore in the reservoir cover to further allow the shear fluid out of the reservoir to the working chamber along the fluid delivery path;   an electromagnetically actuated valve assembly including:
 a first valve element that controls flow of the shear fluid between the reservoir and the working chamber through the outlet bore; 
 a second valve element that further controls flow of the shear fluid between the reservoir and the working chamber through the additional outlet bore; 
 a first axially-extending rod that passes through a first rod opening in the input assembly and that engages the first valve element; 
 a second axially-extending rod that passes through a second rod opening in the input assembly and that engages the second valve element; and 
 a translating armature located rearward of the disk and secured to both the first and second axially-extending rods, such that the first and second valve elements are actuatable concurrently in response to magnetic flux applied to the translating armature; and 
   a fluid return bore that extends radially through at least an outer diameter portion of the disk of the output assembly to the working chamber, the fluid return bore forming at least a portion of a fluid return path from the working chamber to the reservoir.