Actuator assembly having at least one driven gear coupled to a housing

Patent metadata

Field	Value
Publication number	US-9879596-B1
Application number	US-201715492051-A
Country	US
Kind code	B1
Filing date	Apr 20, 2017
Priority date	Apr 20, 2017
Publication date	Jan 30, 2018
Grant date	Jan 30, 2018

Abstract

An actuator assembly moves an output shaft. The actuator assembly includes a housing having at least first, second, and third sections at least partially defining first and second cavities, with the third section between the first and second sections. A motor assembly has a rotatable drive shaft and is coupled to the third section. The motor assembly is at least partially disposed in the first cavity and the drive shaft is at least partially disposed in the second cavity. At least one drive gear is within the second cavity and is fixed to the drive shaft. At least one driven gear is within the second cavity and is coupled with the output shaft. The at least one driven gear is coupled to the third section of the housing and is rotatably coupled with the at least one drive gear to transmit rotation from the drive shaft to the output shaft.

First claim

What is claimed is:

1. An actuator assembly comprising:
a housing having at least a first section, a second section, and a third section each having an internal surface, with said third section positioned between said first and second sections such that said internal surfaces of said first and third sections at least partially define a first cavity and said internal surfaces of said second and third sections at least partially define a second cavity;
a motor assembly having a drive shaft rotatable about a shaft axis and capable of transmitting rotational force with said drive shaft, with said motor assembly at least partially disposed in said first cavity and said drive shaft extending through said third section of said housing such that said drive shaft is at least partially disposed in said second cavity, and with said motor assembly coupled to said third section of said housing;
at least one drive gear disposed within said second cavity of said housing, with said at least one drive gear fixed to and rotatable with said drive shaft of said motor assembly; and
at least one driven gear disposed within said second cavity of said housing and configured to be rotatably coupled with an output shaft that is moveable between a plurality of positions, with said at least one driven gear directly coupled to said third section of said housing, and with said at least one driven gear rotatably coupled with said at least one drive gear such that said at least one driven gear is capable of transmitting rotation from said drive shaft of said motor assembly to the output shaft for moving the output shaft between the plurality of positions.

2. The actuator assembly as set forth in claim 1 , wherein said at least one driven gear is coupled to said second section of said housing.

3. The actuator assembly as set forth in claim 2 , wherein said internal surfaces of both of said second and third sections of said housing define a gear retention feature to facilitate coupling of said at least one driven gear with said second and third sections of said housing.

4. The actuator assembly as set forth in claim 3 , wherein said at least one driven gear defines a hole extending therethrough, with said hole corresponding with said gear retention feature to facilitate coupling of said at least one driven gear with said housing.

5. The actuator assembly as set forth in claim 4 , wherein each of said second and third sections of said housing individually define a pocket which collectively define said gear retention feature.

6. The actuator assembly as set forth in claim 5 , further comprising a gear pin extending between a first end and a second end through said hole of said at least one driven gear, with said first end disposed in said pocket defined by said third section of said housing and said second end disposed in said pocket defined by said second section of said housing to facilitate rotatable coupling of said at least one driven gear with said second and third sections of said housing.

7. The actuator assembly as set forth in claim 6 , wherein each of said pockets has a cylindrical configuration, with said pockets opening toward one another to receive said gear pin and operably couple said gear pin to said housing.

8. The actuator assembly as set forth in claim 1 , wherein said third section has a flange at least partially defining an exterior of said housing and a body extending from said flange and enveloped by said flange and said first and second sections such that said body is entirely disposed within said housing.

9. The actuator assembly as set forth in claim 8 , wherein said at least one driven gear is coupled to said body of said third section of said housing.

10. The actuator assembly as set forth in claim 9 , wherein said flange extends from said body in opposing directions such that said flange and said body of said third section define a portion of said first cavity and a portion of said second cavity.

11. The actuator assembly as set forth in claim 1 , wherein said third section of said housing is enveloped by said first and second sections of said housing such that said third section is entirely disposed within said housing.

12. The actuator assembly as set forth in claim 1 , wherein said at least one driven gear includes an output gear configured to be coupled with the output shaft, and at least one intermediate gear engageable with each of said at least one drive gear and said output gear to transmit rotation from said at least one drive gear to said output gear.

13. The actuator assembly as set forth in claim 12 , wherein said at least one intermediate gear has a first gear section and a second gear section spaced from and fixed to said first gear section, with said first gear section being engageable with said at least one drive gear and said second gear section being engageable with said output gear.

14. The actuator assembly as set forth in claim 1 , wherein said motor assembly includes a primary circuit board configured to control electrical distribution within said motor assembly, with said primary circuit board disposed within said first cavity and coupled to said third section of said housing.

15. The actuator assembly as set forth in claim 14 , wherein said primary circuit board is fixed to said housing.

16. The actuator assembly as set forth in claim 15 , wherein said third section has at least one stud extending into said first cavity, with said primary circuit board defining a recess for receiving said stud such that said stud and said recess position said primary circuit board within said first cavity and fix said primary circuit board to said third section.

17. The actuator assembly as set forth in claim 14 , wherein said motor assembly includes a single sensor group operatively coupled to said primary circuit board and a single magnet group spaced from said single sensor group and fixed to said drive shaft, with said single sensor group detecting the position of said single sensor group and said drive shaft to control rotation of said drive shaft.

18. The actuator assembly as set forth in claim 17 , wherein said motor assembly includes a secondary circuit board fixed to and electrically coupled with said primary circuit board, with said single sensor group positioned on said secondary circuit board.

19. The actuator assembly as set forth in claim 18 , wherein said secondary circuit board is positioned between said primary circuit board and said single magnet group to locate said single sensor group in proximity with said single magnet group.

20. The actuator assembly as set forth in claim 19 , wherein said secondary circuit board and said single sensor group at least partially encircles said drive shaft.

21. The actuator assembly as set forth in claim 1 , wherein said third section of said housing is comprised of a metallic material, with said coupling of said motor assembly with said third section providing a heat sink for said motor assembly through said third section.

22. An actuated turbocharger system for use with an engine of a vehicle, said actuated turbocharger system comprising:
a turbocharger for pressurizing air into the engine;
a pressure control mechanism coupled to said turbocharger and movable between a plurality of states for regulating the pressure of the air produced by said turbocharger; an output shaft coupled to said pressure control mechanism and movable between a plurality of positions corresponding with the plurality of states of said pressure control mechanism

Assignees

• Borgwarner Inc

Inventors

• Bogen Martin P
• Keefover Robert D
• Sharpe James C
• Wightman Brian C

Classifications

• H02K11/33

  Drive circuits, e.g. power electronics (H02K11/38 takes precedence) · CPC title

• F16H2057/02034

  Gearboxes combined or connected with electric machines · CPC title

• F16H19/001

  for conveying reciprocating or limited rotary motion · CPC title

• F16H37/12

  Gearings comprising primarily toothed or friction gearing, links or levers, and cams, or members of at least two of these types (gearings with cranks, eccentrics, or like members fixed to one rotary member and guided along tracks on the other F16H21/14; crank or eccentric gearings with cams or additional guides, or with members having rolling contact F16H21/28, F16H21/30) · CPC title

• F16H57/02

  Gearboxes; Mounting gearing therein · CPC title