Claims:WE CLAIM:
1. A method of assembling a bearing-hub assembly (110) for operating clutches in vehicles, said method comprising the following steps:
a. holding an outer race (100b) with its larger opening facing upside;
b. placing a lock washer (109) concentrically within said outer race (100b);
c. placing steel balls (100c) and cage (100d) sub-assembly concentrically within said outer race (100b) over said lock washer (109);
d. filling grease around the steel balls (100c);
e. fitting a top side rubber seal (100e) on said steel balls (100c) and cage (100d) sub-assembly;
f. induction heating of the sub-assembly;
g. fitting an inner race (100a) inside said inductively heated sub-assembly;
h. fitting a hub with bracket to form hub-bracket set; and
i. inserting said hub inside sub-assembly obtained in step (g) such that external groove (104b) of said hub (104) engages with said lock washer (109) thereby locking said hub 104 inside said bearing assembly 100 to form said actuator (110).
2. The method of assembling a bearing-hub assembly (110) as claimed in claim 1, wherein the dimension of inner diameter (ID) of said inner race 100a is configured to prevent dust entry inside bearing assembly 100 from the inner diameter (ID) side area.
3. The method of assembling a bearing-hub assembly (110) as claimed in claim 1, wherein said outer race (100b) is manufactured by stamping operation.
4. The method of assembling a bearing-hub assembly (110) as claimed in claim 1, wherein the inner diameter (ID) of said outer race (100b) is configured to facilitate self-centring operation of the bearing assembly (100) with respect to hub (104).
5. The method of assembling a bearing-hub assembly (110) as claimed in claim 1, wherein external groove (104b) is provided on the outer circumferential surface of said hub (102), said external groove (104b) configured to co-operate with locking elements of said lock washer (100f) when the hub (104) is inserted into said bearing assembly (100).
6. The method of assembling a bearing-hub assembly (110) as claimed in claim 1, wherein a grease retention groove (104a) defined on the inner circumferential surface of said hub (104) to provide lubrication.
7. The method of assembling a bearing-hub assembly (110) as claimed in claim 1, wherein a resting area for said bearing assembly (100) is defined on said hub (104), said resting area includes a plurality of ribs (111) designed in such a way that the self-centring bearing area is not open from the downside and configured to prevent dust entry, therefrom.
8. A bearing-hub assembly (110) for clutch actuator in vehicles, said bearing-hub assembly (110) comprising:
a. a hub (104);
b. a hub-bracket (106);
c. a bearing assembly (100) comprising:
i. an inner race (100a);
ii. an outer race (100b);
iii. balls (100c) and cage (100d) sub-assembly;
iv. Ga top seal (100e); and
v. a lock washer (100f),
d. a circular groove (112) defined on the bigger face of said inner race (100a) near the inner diameter, said circular groove (112) configured to divert the direction of dust and particles are generated due to clutching action and wear of components.
9. The bearing-hub assembly (110) as claimed in claim 8, wherein a resting area for said bearing assembly (100) is defined on said hub (104), said resting area including a plurality of ribs (111) designed in such a way that the self-centring bearing area is not open from the downside and configured to prevent dust entry, therefrom.
10. The bearing-hub assembly (110) as claimed in claim 8, wherein the dimension of inner diameter (ID) of said inner race (100a) is configured to prevent dust entry inside bearing assembly (100) from the inner diameter (ID) side area.
11. The bearing-hub assembly (110) as claimed in claim 8, wherein said outer race (100b) is manufactured by stamping operation.
12. The bearing-hub assembly (110) as claimed in claim 8, wherein the inner diameter (ID) of said outer race (100b) is configured to facilitate self-centring operation of the bearing assembly (100) with respect to hub (104).

13. The bearing-hub assembly (110) as claimed in claim 8, wherein external groove (104b) is provided on the outer circumferential surface of said hub (102), said external groove (104b) configured to co-operate with locking elements of said lock washer (100f) when the hub (104) is inserted into said bearing assembly (100).

14. The bearing-hub assembly (110) as claimed in claim 8, wherein a grease retention groove (104a) defined on the inner circumferential surface of said hub (104) to provide lubrication.
15. The bearing-hub assembly (110) as claimed in claim 1 or 8, wherein a dust accumulation groove provided on the face of said hub (104).
, Description:FIELD
The present disclosure relates to the field of actuators. More particularly, the present disclosure relates to bearing-hub sub-assemblies for clutch actuator in vehicles and a method of assembling the same.
BACKGROUND
The background information herein below relates to the present disclosure but is not necessarily prior art.
Clutch is an important component in automobiles. Effective control of clutch system is crucial in handling of automobiles. Presently different types of clutches are used auto-industry. This includes mechanically actuated clutch, hydraulically actuate clutch and pneumatically actuated clutch. Pneumatically actuated clutches are finding increased demand due to their light weight and use of air as a pressurized fluid instead of oil.
There is always a challenge for design engineers to keep the cost and weight of the clutch actuation assembly to minimum. Lower weight will improve the dynamic performance of the clutch actuation assembly while lower cost will increase the competitive edge in market. The conventional method used for assembling the bearing-hub assembly available in the market use operations such as crimping which require special tooling and increased time of assembly.
There is, therefore, felt a need of a bearing-hub assembly for clutch actuator and a method of assembling that alleviates the above mentioned drawbacks.
OBJECTS
Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as follows:
An object of the present disclosure is to provide a bearing-hub assembly for clutch actuator and a method of assembling thereof.
Another object of the present disclosure is to provide a bearing-hub assembly for clutch actuator that is lighter in than conventional actuation system.
Yet another object of the present disclosure is to provide a bearing-hub assembly for clutch actuator that has less number of components.
Yet another object of the present disclosure is to provide a bearing-hub assembly for clutch actuator that has improved static and dynamic properties.
Yet another object of the present disclosure is to provide a bearing-hub assembly for clutch actuator that ensures dust protection.
Yet another object of the present disclosure is to provide a bearing-hub assembly for clutch actuator that reduces sliding noise level.
Yet another object of the present disclosure is to provide a method of assembling a bearing-hub assembly that reduces the number of steps involved.
Yet another object of the present disclosure is to provide a method of assembling a bearing-hub assembly that reduces the overall time of manufacturing the sub-assembly.
Yet another object of the present disclosure is to provide a method of assembling a bearing-hub assembly that eliminates the used of special tools such as crimping.
Other objects and advantages of the present disclosure will be more apparent from the following description, which is not intended to limit the scope of the present disclosure.
SUMMARY
The present disclosure envisages a bearing-hub assembly for clutch actuator in vehicles and a method of assembling thereof. The method of assembling a bearing-hub assembly for operating clutches in vehicles, the method comprising the following steps:
• holding an outer race with its larger opening facing upside;
• placing a lock washer concentrically within the outer race;
• placing steel balls and cage sub-assembly concentrically within the outer race over the lock washer;
• filling grease around the steel balls;
• fitting a top side rubber seal on the steel balls and cage sub-assembly;
• induction heating of the sub-assembly;
• fitting an inner race inside the inductively heated sub-assembly;
• fitting a hub with bracket to form hub-bracket set; and
• inserting the hub inside sub-assembly obtained in step (g) such that external groove of the hub engages with the lock washer thereby locking the hub inside the bearing assembly to form the actuator.
In an embodiment, the dimension of inner diameter (ID) of the inner race is configured to prevent dust entry inside bearing assembly from the inner diameter (ID) side area.
In another embodiment, the outer race is manufactured by stamping operation.
In another embodiment, the inner diameter (ID) of the outer race is configured to facilitate self-centring operation of the bearing assembly with respect to hub.
In another embodiment, external groove is provided on the outer circumferential surface of the hub, the external groove configured to co-operate with locking elements of the lock washer when the hub is inserted into the bearing assembly.
In another embodiment, a grease retention groove defined on the inner circumferential surface of the hub to provide lubrication.
In another embodiment, a resting area for the bearing assembly is defined on the hub. The resting area includes a plurality of ribs designed in such a way that the self-centring bearing area is not open from the downside and configured to prevent dust entry, therefrom.
In according to an aspect of the present disclosure, the bearing-hub assembly for clutch actuator in vehicles comprises a hub, a hub-bracket, and a bearing assembly. The bearing assembly comprises an inner race, an outer race, balls and cage sub-assembly, a top seal, a lock washer, and a bottom seal.
In an embodiment, a circular groove is defined on the bigger face of the inner race near the inner diameter, the circular groove is configured to divert the direction of dust and particles are generated due to clutching action and wear of components.
In an embodiment, a resting area for the bearing assembly is defined on the hub. The resting area includes a plurality of ribs designed in such a way that the self-centring bearing area is not open from the downside and configured to prevent dust entry, therefrom.
BRIEF DESCRIPTION OF ACCOMPANYING DRAWING
The bearing-hub assembly for clutch actuator, and a method of assembling thereof, of the present disclosure will now be described with the help of the accompanying drawings, in which:
Figure 1 illustrates a front view of a conventional bearing-hub assembly for a clutch actuator;
Figures 2A & 2B illustrate a conventional method of assembling the conventional bearing-hub assembly of Figure 1;
Figure 3 illustrates a front view of a bearing-hub assembly, in accordance with an embodiment of the present disclosure;
Figure 4 illustrates a method of assembling the bearing-hub assembly of Figure 3, in accordance with an embodiment of the present disclosure;
Figure 5 illustrates a right-hand side view of the bearing-hub assembly of Figure 3;
Figures 6 & 7 illustrates perspective views of the bearing-hub assembly of Figure 3;
Figure 8 illustrates a perspective view of an inner race, in accordance with an embodiment of the present disclosure;
Figure 9 illustrates a perspective view of an outer race, in accordance with an embodiment of the present disclosure; and
Figure 10 illustrates a zoomed-in view of the sealing area of bearing-hub assembly of Figure 3.
LIST OF REFERENCE NUMERALS USED IN DETAILED DESCRIPTION AND DRAWING
50 – Conventional clutch actuator
60 – Bearing assembly
52 – Sleeve
52a, 52b – Crimped ends of sleeve
54 – Hub
56 – Hub-bracket
58 – Cover
60a – Inner race
60b – Outer race
60c – Steel balls
60d – Cage
60e – Top seal
60f – Lock washer
60g – Bottom seal
S1 – Grease filling around steel balls
S2 – Induction heating
S3 – Crimping of sleeve
100 – Bearing assembly
100a – Inner race
100b – Outer race
100c – Steel balls
100d – Cage
100e – Top rubber-seal
100f – Lock washer
104 – Hub
104a – Grease retention groove
104b – external groove
106 – Hub-bracket
111 – Hub-ribs
112 – Circular groove on inner race
P1 – Grease filling around steel balls
P2 – Induction heating
P3 – Final inspection
DETAILED DESCRIPTION
Embodiments, of the present disclosure, will now be described with reference to the accompanying drawing.
Embodiments are provided so as to thoroughly and fully convey the scope of the present disclosure to the person skilled in the art. Numerous details are set forth, relating to specific components, and methods, to provide a complete understanding of embodiments of the present disclosure. It will be apparent to the person skilled in the art that the details provided in the embodiments should not be construed to limit the scope of the present disclosure. In some embodiments, well-known processes, well-known apparatus structures, and well-known techniques are not described in detail.
The terminology used, in the present disclosure, is only for the purpose of explaining a particular embodiment and such terminology shall not be considered to limit the scope of the present disclosure. As used in the present disclosure, the forms “a”, “an”, and “the” may be intended to include the plural forms as well, unless the context clearly suggests otherwise. The terms “comprises”, “comprising”, “including”, and “having”, are open ended transitional phrases and therefore specify the presence of stated features, integers, steps, operations, elements, modules, units and/or components, but do not forbid the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The particular order of steps disclosed in the method and process of the present disclosure is not to be construed as necessarily requiring their performance as described or illustrated. It is also to be understood that additional or alternative steps may be employed.
When an element is referred to as being “mounted on”, “engaged to”, “connected to”, or “coupled to” another element, it may be directly on, engaged, connected or coupled to the other element. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed elements.
The terms first, second, third, etc., should not be construed to limit the scope of the present disclosure as the aforementioned terms may be only used to distinguish one element, component, region, layer or section from another component, region, layer or section. Terms such as first, second, third etc., when used herein do not imply a specific sequence or order unless clearly suggested by the present disclosure.
Terms such as “inner”, “outer”, “beneath”, “below”, “lower”, “above”, “upper”, and the like, may be used in the present disclosure to describe relationships between different elements as depicted from the figures.
The present disclosure envisages a bearing-hub assembly 110 for clutch actuator in vehicles and a method of assembling/manufacturing the same.
Figure 1 shows a conventional bearing-hub assembly 50. The conventional bearing-hub assembly 50 comprises a sleeve 52, a hub 54, a hub-bracket 56, a cover 58, and a conventional bearing assembly 60. The conventional bearing assembly 60 includes an inner race 60a, an outer race 60b, a plurality of steel balls 60c, a steel cage 60d, a top seal 60e, and a bottom seal 60g. A lock washer 60f is used for locking together the hub-bracket 56 and the bearing assembly 60.
Figures 2A & 2B show the conventional method of assembling the bearing-hub assembly 50 of Figure 1.
The conventional method of assembling the bearing-hub assembly 50 involves the following steps:
a. placing the outer race 60b of bearing sub-assembly on a flat surface (such as platform, work table) with its axis perpendicular to the flat surface;
b. fitting the bottom seal 60g at one end of the outer race 60b;
c. adding steel balls 60c and cage 60d sub-assembly inside the outer race 60b and placing the same over the bottom seal 60g;
d. filling grease around the steel balls 60c;
e. fitting the top seal 60e on the other end opposite to that of the bottom seal 60g;
f. induction heating the sub-assembly of step e;
g. fitting the inner race 60a inside the balls 60c and cage 60d sub-assembly;
h. simultaneously fitting the hub 54 with the hub-bracket 56;
i. adding the steel sleeve 52 along the axis of the hub 58;
j. crimping the circumferential edge of the steel sleeve 52’ over the hub 54;
k. putting together the bearing sub-assembly from step g and the hub-sleeve assembly from step j together;
l. adding a lock washer 60f on top side of the outer race 60b; and
m. crimping the circumferential edge of the cover 58 over the edge of the lock washer 60f and the outer race 60b to lock the bearing 60 with the hub-bracket sub-assembly to achieve the conventional bearing-hub assembly 50.
Figure 3 shows the bearing-hub assembly 110 for a clutch actuator in vehicles, in accordance with an embodiment of the present disclosure. The bearing-hub assembly 110 comprises a hub 104, a hub-bracket 106, and a bearing assembly 100. The bearing assembly 100 includes an inner race 100a, an outer race 100b, a plurality of steel balls 100c, a cage 100d, a top seal 100e, and a lock washer 100f.
Figure 4 shows the method of assembling the bearing-hub assembly 110 of Figure 3, in accordance with an embodiment of the present disclosure.
The method of assembling the bearing-hub assembly 110 involves the following steps:
a. holding the outer race 100b of the bearing sub-assembly 100 with its larger opening facing upside;
b. placing a lock washer 100f inside the outer race 100b;
c. adding steel balls 100c and cage 100d sub-assembly above the lock washer 100f;
d. filling grease around the steel balls 100c;
e. fitting the top side rubber seal 100e on the steel ball 100c and cage 100d sub-assembly;
f. induction heating the sub-assembly of step e;
g. fitting the inner race 100a inside the balls 60c and cage 60d sub-assembly;
h. simultaneously fitting the hub 104 with the hub-bracket 106 to form a sub-assembly; and
i. fitting the bearing assembly 100 on hub 104 portion of the hub-bracket 106 sub-assembly such that the lock washer 100f engages with the featured provided on the circumference of the hub 104, such as to achieve the bearing-hub assembly 100 of the present disclosure.
In the bearing-hub assembly 110 of the present disclosure, a separate sleeve that was used in the conventional bearing-hub assembly 50 is eliminated. The hub 104 is shaped in such a manner to perform the function of the sleeve. The hub 104 includes a portion extended along its axis in the form of sleeve. External groove 104b is provided on the outer circumferential surface of the hub 104 to co-operate with locking elements of the lock washer 100f when the hub 104 is inserted into the bearing assembly 100. The engagement between the external groove 104b of the hub 104 and the lock washer 100f prevents the backward movement of the hub 104 with respect to the bearing assembly 100.
Due to the elimination of a separate cover that was earlier used to prevent dust entry in the conventional bearing-hub assembly, there is significant saving of material and number of components that go into the manufacturing of the bearing-hub assembly. Furthermore, two set operations of crimping the sleeve are eliminated resulting in saving of time required for assembling the sub-assembly.
Features of outer race 100b:
For design improvement, by preferring stamping route weight reduction is possible without affecting performance. The inner diameter ID of the bottom face of the outer race 100b is designed to facilitate self-centring operation with respect to the hub 104 in an assembled condition. The outer race 100b is designed in such a way that whole bearing assembly rests on the hub 104. At the time of self-centring action, the outer race 100b slides on the hub 104, wherein the hub 104 is made of plastic. Therefore, the sliding noise is also eliminated. Whereas, in the conventional design of the bearing-hub assembly 50, the outer race 60b slides on the cover 58 made of metal at the time of self-centring operation.
Features of inner race 100a:
? The inner race 100a is designed in such a way that it can fulfil the existing requirements with additional function of dust entry prevention.
? For clutching action and contacts, the outer diameter OD of the inner race is kept as it is in the existing design. So, there is no issue related to fouling in clutch finger.
? The inner diameter ID of the inner race is designed in such a way that it can prevent the dust entry from the inner diameter side area.
? Additionally, a circular groove 112 is provided on the bigger face of the inner race 100a near the inner diameter. The circular groove 112 diverts the direction of the dust and particles, which are generated due to clutching action and wear of components.
? For achieving dimensional specification of existing bearing, inner race 100a is manufactured by forging and optimized for contact with clutch fingers.
Features of Hub 104
? The hub 104 is made from plastic or suitable polymer. The design of the hub 104 is complete modified and optimized for weight reduction and strength requirements.
? The hub 104 has a resting area for the bearing assembly 100. The resting area is includes ribs 111 designed in such a way that the self-centring bearing area must not open from the downside and also to function to prevent dust entry, therefrom.
? The outer diameter of the hub 104 is designed for providing self-centring within limit by depending on corresponding inner diameter of the outer race 100b.
? Additionally a grease retention groove 104a is defined on the inner circumferential surface of the hub 104 to provide lubrication.
? The shape of the metallic bracket 106 is kept unchanged.
The outer race 100b is manufactured by sheet metal works and stamping instead of forging, as done in convention process.
The hub 104 includes a dust accumulation groove defined on the face of the said.
Cage 100d and steel balls 100c sub-assembly includes two extra steel balls to ensure matching of dynamic capacities. The design of the cage 100d remains unchanged.
In existing design of bearing-hub assembly 50, the cover 58 is used to hold bearing assembly and for providing a self-centring action. In the improved design of present bearing-hub assembly 110 the cover 58 is eliminated. Further, the bearing sub-assembly holding and self-centring is facilitated by the lock washer 100f.
In existing design a plastic hub 104 is a separate component. In the design of the actuator 100 of the present disclosure, instead of steel sleeve, a plastic hub 104 is extended along the axis of bearing sub-assembly and makes a single component. Further a groove is provided in the hub 104 to retain the sliding grease.
In existing design the bottom seal 60g is provided for dust entry prevention from the space between the steel-sleeve 52, while in the improved design the inner diameter ID of the inner race 100a is optimised such as to cover some portion of plastic hub 104 for covering any open area.
The advantages of the bearing-hub assembly 110 of the present disclosure are as below:
• Light weight
• Lower cost
• Dust entry prevention
• Self-centring ability
The foregoing description of the embodiments has been provided for purposes of illustration and not intended to limit the scope of the present disclosure. Individual components of a particular embodiment are generally not limited to that particular embodiment, but, are interchangeable. Such variations are not to be regarded as a departure from the present disclosure, and all such modifications are considered to be within the scope of the present disclosure.
TECHNICAL ADVANCES AND ECONOMICAL SIGNIFICANCE
The present disclosure described herein above has several technical advantages including, but not limited to, the realization of a bearing-hub assembly for clutch actuator in vehicles, that:
• is simple in design;
• lighter in weight;
• is easy to assembly;
• requires less time for manufacturing;
• prevents dust entry;
• involves a less number of steps in the method of assembling thereof; and
• has low maintenance.
The foregoing description of the specific embodiments so fully reveals the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.
Throughout this specification the word “comprise”, or variations such as “comprises” or “comprising”, will be understood to imply the inclusion of a stated element, integer or step, or group of elements, integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps.
The use of the expression “at least” or “at least one” suggests the use of one or more elements or ingredients or quantities, as the use may be in the embodiment of the disclosure to achieve one or more of the desired objects or results.
Any discussion of documents, acts, materials, devices, articles or the like that has been included in this specification is solely for the purpose of providing a context for the disclosure. It is not to be taken as an admission that any or all of these matters form a part of the prior art base or were common general knowledge in the field relevant to the disclosure as it existed anywhere before the priority date of this application.
While considerable emphasis has been placed herein on the components and component parts of the preferred embodiments, it will be appreciated that many embodiments can be made and that many changes can be made in the preferred embodiments without departing from the principles of the disclosure. These and other changes in the preferred embodiment as well as other embodiments of the disclosure will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation.