DUAL -ROTOR ASSEMBLY FOR TRANSMITTING FORCE TO A SHAFT
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of United States Patent Application No.
13/370,834, filed February 10, 2012, which is hereby incorporated by reference as though fully
set forth herein.
TECHNICAL FIELD
[0002] The present disclosure relates to force transmitting assemblies and more
particularly to an annular force transmitting assembly that transmits force via rotors to restrict
rotation of a shaft when employed as a brake or to transmit rotation when employed as a clutch.
BACKGROUND
[0003] The terms "assembly" and "force transmitting assembly" as used in this disclosure
refers to an assembly, such as a split powerhead disc brake, that can function as a brake or a
clutch. While the assembly described herein is particularly suited for use as a brake assembly and
will be discussed in detail in the braking context, those of ordinary skill in the art will understand
that the assembly is equally capable of functioning as a clutch. For simplicity, the term
"assembly" will primarily be used, but the term "assembly," "force transmitting assembly,"
"brake assembly," "split powerhead disc brake," and "clutch assembly" are all interchangeable in
the description below.
[0004] Known assemblies have been connected with a shaft to control power
transmission. These known assemblies have been used in various applications, such as draglines,
power shovels, conveyors, shears, power presses, and other machines. When machines have
different operating characteristics, the force-transmitting capability of the assembly should be
adjusted to correspond to the operating characteristics of the machine in which the assembly will
be used. Some machines require transmission of relatively large forces to rotate a shaft or retain a
shaft against rotation.
[0005] To accommodate these large forces, the assembly may apply factional forces to
two rotors instead of one. This dual rotor structure allows the same amount of torque to be
provided in a smaller package. However, it is difficult for one spring set to apply uniform
pressure on both rotors.
[0006] There is a desire for a multiple rotor assembly that overcomes uneven friction pad
wear and maintains uniform pressure on both rotors with no manual intervention.
SUMMARY
[0007] An assembly for transmitting force to a shaft according to one aspect of the
present teachings includes a mounting flange having a central opening to receive the shaft and
first and second rotors mounted on the shaft and rotatable with the shaft. The first and second
rotors each have at least one planar surface. The assembly also includes first front and rear
reaction plates disposed on opposite sides of the first rotor, and second front and rear reaction
plates disposed on opposite sides of the second rotor. The reaction plates each have at least one
friction surface that is engageable with the rotors. The assembly also includes a piston and a
cylinder coupled to the piston to form a fluid pressure chamber. The piston moves in a first
direction when pressurized fluid enters the fluid pressure chamber and the piston moves in a
second direction when pressurized fluid exits the fluid pressure chamber. The assembly further
includes a spring housing operatively coupled to the piston.
[0008] The spring housing itself has a spring plate, a plurality of first spring sets
supported in the spring plate and operatively coupled to the first front and rear reaction plates,
and a plurality of second spring sets supported in the spring plate and operatively coupled to the
second front and rear reaction plates.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] Figure 1 is a perspective view of an assembly according to one aspect of the
system;
[0010] Figure 2 is a section view of the assembly taken along line 2-2' in Figure 1;
[0011] Figure 3 is a plan view of the section view shown in Figure 2;
[0012] Figure 4 is a schematic view of the assembly of Figure 1;
[0013] Figure 5 is a perspective view of a spring housing used in one aspect of the
assembly;
[0014] Figure 6 is a section view of the spring housing taken along line 6-6' in Figure 5;
[0015] Figure 7 is an exploded view of the spring housing of Figure 5; and
[0016] Figure 8 is a partial cutaway view of the assembly of Figure 1.
DETAILED DESCRIPTION
[0017] Figures 1 through 4 and Figure 8 show an assembly 10 that is operable between a
first engaged position, or braking mode, and a second disengaged position, or non-braking mode.
When the assembly 10 is in the engaged position (i.e., when fluid pressure is released within the
assembly 10), the assembly 10 applies frictional force to retain a driven shaft against rotation.
When the brake assembly 10 is in the disengaged position (i.e., when fluid pressure is applied the
assembly 10), the assembly 10 allows the shaft to rotate freely.
[0018] The assembly 10 includes a mounting flange 12 that allows the assembly 10 to be
connected to a customer interface (not shown), such as the frame of a motor or a machine. The
assembly 10 also includes first and second rotors 14a, 14b that are designed to be fixed to a
driven shaft (not shown) so that they are rotatable therewith. The first rotor 14a is disposed
between first front and rear reaction plates 16a, 18a and the second rotor 14b is disposed between
second front and rear reaction plates 16b, 18b. The front and rear reaction plates 16a, 16b, 18a,
18b each have friction surfaces 20 (e.g., friction pads) facing their respective rotors 14a, 14b for
applying a clamping load on the rotors 14a, 14b.
[0019] The rotors 14a, 14b may have a generally cylindrical disc-shape and may each
have a central hub 22 with a bore 24 to hold the rotor 14a, 14b on the shaft. The hub 22 itself
may either be formed as an integral part of its corresponding rotor 14a, 14b or may be formed as
a separate piece and attached to the rotor 14a, 14b with fasteners. In one aspect of the assembly
10, the hub 22 may have a straight bore 24 to be received on a correspondingly straight shaft as
shown in the Figures, or the hub 22 may have a tapered bore 24 to fit on a tapered shaft. The
rotor 14a, 14b may be held in place with a threaded fastener (not shown) on the end of the shaft.
Alternatively, the rotor 14a, 14b may be held in place by the hub 22 via a keyless locking bushing
on a straight or tapered shaft. Each rotor 14a, 14b has a planar surface 26 on each side to act as a
working surface area for frictional engagement with the friction surfaces 20 of the reaction plates
16a, 16b, 18a, 18b.
[0020] The friction surfaces 20 themselves can include any appropriate friction material
in any desired configuration. For example, the friction surfaces 20 may be formed as a single
annular surface or as a plurality of friction pads. The surface or pads may be replaceable, if
desired. Those of ordinary skill in the art will understand that the friction surfaces 20 can have
any composition or configuration without departing from the scope of this disclosure.
[0021] The assembly 10 may also include a cylinder 38 coupled to the piston 32 so that
the piston 32 can slide relative to the cylinder 38. The piston 32 is disposed within the cylinder
38 to form a fluid chamber 4 1 that can receive a pressurized fluid (e.g., pressurized air or
hydraulic fluid). Under pressurized conditions, the piston 32 moves in the direction shown in
arrow A in Figures 2 and 3. The piston 32 and cylinder 38 can float over a small guide tube 43.
The small guide tube 43 is connected to the spring housing 36.
[0022] The mounting flange 12 and a powerhead assembly 28 (described in greater detail
below) can be coupled together with clamp tubes 37 and aligned with guide tubes 40. The
cylinder 38 and the stopper plate 34 can be coupled together with spacer tubes 39, as shown in
Figure 8, and aligned with guide tubes 40. This connection allows the stopper plate 34 and the
cylinder 38 to move together as a single sliding part.
[0023] The guide tubes 40 themselves may be disposed between the mounting flange 12,
stopper plate 34, spring housing 36, stopper plate 34, and cylinder 38 via any known means, such
as via coupling forces between their corresponding components. For example, as can be seen in
Figure 3, guide tubes 40 may be clamped between the mounting flange 12 and the powerhead
assembly 28. Note that the assembly 10 may be considered to have a "floating" structure as
described in commonly-assigned U.S. Published Application 2010/0018831, the disclosure of
which is incorporated herein by reference. More particularly, the reaction plates 16a, 18a, 16b,
18b may float and move axially during the engagement and disengagement operations as the
piston 32 and the cylinder 38 move axially. The guide tubes 40 guide the movement of the
reaction plates 16a, 18a, 16b, 18b. In one aspect of the teachings, the front reaction plates 16a,
16b react to movement of the stopper plate 34 and the rear reaction plates 18a, 18b react to
movement of the piston 32.
[0024] Figures 5 through 7 show the powerhead assembly 28 in greater detail. The
powerhead assembly 28 includes the spring housing 36 that supports a plurality of first spring
sets 42a and a plurality of second spring sets 42b. Although the illustrated example shows eight
spring sets, four of each type 42a, 42b, any number of spring sets may be included in the spring
housing 36. The first spring sets 42a are associated with the first rotor 14a and the second spring
sets 42b are associated with the second rotor 14b. Each spring set 42a, 42b includes a plurality of
springs 44 disposed in between two spring retainers 46. The springs 44 and spring retainers 46
move freely in the axial direction within spring bores 48 in the spring housing 36. As shown in
Figure 3, pressure plates 30a, 30b are disposed on opposite sides of the powerhead assembly 28
and can be connected to the spring retainer 46 via a bolted connection or any other appropriate
connection means. The pressure plates 30a, 30b may be formed as wedge-shaped segments, with
each segment corresponding to a spring set in a spring housing 36 of the powerhead assembly 28.
The front pressure plates 30a may contact the piston 32, while the rear pressure plates 30b may
contact the stopper plate 34.
[0025] The first and second spring sets 42a, 42b can be disposed in an alternating manner
in the spring housing 36 so that the first and second spring sets 42a, 42b distribute force evenly
on the on the reaction plates 16a, 18a, 16b, 18b and consequently the rotors 14a, 14b. As shown
in Figure 7, each front and rear pressure plate 30a, 30b is associated with a particular spring set
42a, 42b so that the pressure plates 30a, 30b can move independently from each other. In one
aspect of the assembly 10, each pressure plate 30a, 30b may have a one or more holes 51 to
accommodate a fastener (e.g., a bolt) connecting the pressure plate 30a, 30b to its corresponding
spring retainer 46. Alternatively, the pressure plate 30a, 30b and spring retainer 46 may be
formed together as an integral piece through any appropriate process, such as casting.
[0026] Since the first and second spring sets 42a, 42b move independently from each
other, they can compensate for uneven wear in the friction surfaces 20 by expanding to different
degrees. For example, if the friction surfaces 20 in the reaction plates 16a, 18a for the first rotor
14a are more worn than the friction surfaces 20 in the reaction plates 16b, 18b for the second
rotor 14b, the first spring sets 42a will expand more than the second spring sets 42b to
compensate for the greater wear and ensure that spring force is applied generally evenly to both
the first and second rotors 14a, 14b. Similarly, using the first rotor 14a as an example, if the
friction surface 20 on the front reaction plate 16a is more worn than the friction surface 20 on the
rear reaction plate 18a, the first spring sets 42a will expand and shift axially within the spring
housing 36 until they hit the friction surface 20 of the first rotor 14a. Thus, both reaction plates
16a, 18a apply force onto the rotor 14a. Thus, the spring sets 42a, 42b automatically compensate
for friction surface 20 wear differences without requiring manual intervention. Also, since the
front reaction plates 16a, 16b are functionally connected to stopper plate 34 and the rear reaction
plates 18a, 18b are functionally connected to the piston 32, pressurization of the fluid chamber 4 1
results in release of the assembly 10 even when the springs 44 expand to different lengths.
[0027] Force transmitting clamp tubes 50 connect the pressure plates 30a, 30b to the
reaction plates 16a, 16b, 18a, 18b. As shown in Figures 2 and 4, the force transmitting clamp
tubes 50 have different lengths so that the pressure plates 30a, 30b can be connected with their
associated reaction plates 16a, 16b, 18a, 18b. Moreover, each pressure plate 30a, 30b is
associated with either a first spring set 42a (and the first rotor 14a) or a second spring set 42b
(and the second rotor 14b). In one aspect of the assembly 10, pressure plates 30a, 30b are
connected to the reaction plates 16a, 18a for their corresponding rotor 14a and pressure plates
30a, 30b are connected to the reaction plates 16b, 18b for their corresponding rotor 14b. This
configuration generates brake torque on the first and second rotors 14a, 14b when the spring sets
42a, 42b expand. As noted above, since the spring sets 42a, 42b are evenly spaced around the
spring housing 36 in an alternating manner, pressure is uniformly distributed on each rotor 14a,
14b. Also, as noted above, since there are separate, independently-acting spring sets 42a, 42b for
each rotor 14a, 14b, the pressure distribution will be equal between both rotors 14a, 14b.
[0028] The operation of the assembly 10 will now be described in greater detail. When
pressure is increased in the fluid chamber 4 1 (e.g., during a brake release operation), the piston
32 moves toward the mounting flange 12 in the direction shown by arrow A in Figures 2 and 3,
and the cylinder 38 moves away from the mounting flange 12 in the direction shown by arrow B.
Because the stopper plate 34 is connected to the cylinder 38 via the spacer tubes 39, the stopper
plate 34 will also move away from the mounting flange 12 (in the direction of arrow B). The
stopper plate 34 and the piston 32 move toward each other and compress the springs 44, causing
the reaction plates 16a, 18a, 16b, 18b to release the rotors 14a, 14b. The assembly 10 is in the
disengaged position at this point.
[0029] To engage the rotors 14a, 14b, fluid is evacuated from the fluid chamber 41,
releasing the fluid pressure. The springs 44 expand, pressing the front and rear pressure plates
30a, 30b outward against the piston 32 and the stopper plate 34, respectively. This in turn causes
the reaction plates 16a, 18a, 16b, 18b to clamp on their respective rotors 14a, 14b. At this point,
the assembly 10 is in the engaged condition.
[0030] Over time, the friction surfaces 20 wear down and the springs 44 compensate by
expanding more. However, if one of the friction pads 20 corresponding to a given rotor 14a, 14b
wears more than the others, the spring set 42a, 42b corresponding to that rotor 14a, 14b will
expand an additional distance equal to the amount of extra wear during braking. As a result, both
rotors 14a, 14b will continue to receive force from the friction pads 20. Conversely, during
release, the rotor 14a, 14b with the reaction plate 16a, 18a, 16b, 18b having the additional wear
will be released before the other rotor 14a, 14b.
[0031] One or more sensors 51may be mounted on the assembly 10 to measure the
amount of wear in the friction surfaces 20. In one aspect, the sensors 51 may be mounted on the
powerhead assembly 28 to monitor the distance between the spring housing 36 and each of the
front and rear pressure plates 30a, 30b. These distances correspond to the amount of wear in the
friction surfaces 20, and the information can be used to check for wear without manual
intervention. Alternatively, the sensors 5 1 maybe mounted to the reaction plates 16a, 18a, 16b,
18b as shown in Figure 8 to monitor the amount of wear in the friction plates 20 more directly.
This data can be sent to a user interface to detect whether the friction surfaces 20 need
maintenance and/or replacement.
[0032] As a result, an assembly having the above structure ensures that the reaction plates
and friction pads apply uniform and equal pressure to both rotors. The assembly described above
can automatically compensate for uneven friction pad wear, both between the two pairs as well as
between a single pair associated with a given rotor to keep pressure application consistent. The
assembly also ensures that all spring sets are disengaged when needed despite their unequal
expansion during compensation.
[0033] It will be appreciated that the above teachings are merely exemplary in nature and
is not intended to limit the present teachings, their application or uses. While specific examples
have been described in the specification and illustrated in the drawings, it will be understood by
those of ordinary skill in the art that various changes may be made and equivalents may be
substituted for elements thereof without departing from the scope of the present teachings as
defined in the claims. Furthermore, the mixing and matching of features, elements and/or
functions between various examples is expressly contemplated herein so that one of ordinary
skill in the art would appreciate from this disclosure that features, elements and/or functions of
one example may be incorporated into another example as appropriate, unless described
otherwise, above. Moreover, many modifications may be made to adapt a particular situation or
material to the teachings of the present disclosure without departing from the essential scope
thereof. Therefore, it is intended that the present teachings not be limited to the particular
examples illustrated by the drawings and described in the specification as the best mode presently
contemplated for carrying out the teachings of the present disclosure, but that the scope of the
present disclosure will include any embodiments falling within the foregoing description and the
appended claims.

CLAIMS
WHAT IS CLAIMED IS:
1. An assembly for transmitting force to a shaft, comprising:
a mounting flange having a central opening to receive the shaft;
first and second rotors mounted on the shaft and rotatable with the shaft, the first
and second rotors each having at least one planar surface;
first front and rear reaction plates disposed on opposite sides of the first rotor;
second front and rear reaction plates disposed on opposite sides of the second
rotor, wherein the first and second front and rear reaction plates each have at least one friction
surface that is engageable with said at least one planar surface on the first and second rotors;
a piston;
a cylinder coupled to the piston to form a fluid pressure chamber, wherein the
piston moves in a first direction when pressurized fluid enters the fluid pressure chamber and the
piston moves in a second direction when pressurized fluid exits the fluid pressure chamber; and
a powerhead assembly operatively coupled to the piston, the powerhead assembly
having
a spring housing,
a plurality of first spring sets supported in the spring housing and
operatively coupled to the first front and rear reaction plates, and
a plurality of second spring sets supported in the spring housing and
operatively coupled to the second front and rear reaction plates.
2. The assembly of claim 1, wherein each of the first and second spring sets
comprise:
a plurality of springs; and
first and second spring retainers on opposite ends of the plurality of springs,
wherein the first and second spring retainers retain the plurality of springs in the spring housing.
3. The assembly of claim 1, wherein the spring housing is annular and has a plurality
of bores that accommodate the plurality of first and second spring sets.
4. The assembly of claim 1, wherein the first and second spring sets are arranged in
an alternating manner in the spring plate.
5. The assembly of claim 1, further comprising:
at least one front pressure plate;
at least one rear pressure plate, wherein at least one of said plurality of first and
second spring sets are disposed between said front and rear pressure plates, and wherein the front
pressure plate is operatively coupled to the piston; and
a stopper plate that is operatively coupled to the cylinder, wherein when
pressurized fluid enters the f uid chamber, the piston and the stopper plate move toward each
other to push the front and rear pressure plates toward each other against a spring force in the
first and second spring sets.
6. The assembly of claim 5, further comprising a plurality of spacer tubes connecting
the stopper plate to the cylinder.
7. The assembly of claim 5, further comprising a plurality of clamp tubes that couple
the front pressure plate to the first and second rear reaction plates and the rear pressure plate to
the first and second front reaction plates.
8. The assembly of claim 1, further comprising at least one sensor for measuring
wear on said at least one friction surface.
9. An assembly for transmitting force to a shaft, comprising:
a mounting flange having a central opening to receive the shaft;
first and second rotors mounted on the shaft and rotatable with the shaft, the first
and second rotors each having at least one planar surface;
first front and rear reaction plates disposed on opposite sides of the first rotor;
second front and rear reaction plates disposed on opposite sides of the second
rotor, wherein the first and second front and rear reaction plates each have at least one friction
surface that is engageable with said at least one planar surface on the first and second rotors;
a piston;
a cylinder coupled to the piston to form a fluid pressure chamber;
a stopper plate that is operatively coupled to the cylinder;
a plurality of front pressure plates operatively coupled to the piston;
a plurality of rear pressure plates operatively coupled to the stopper plate, wherein
at least one of said plurality of first and second spring sets are disposed between said front and
rear pressure plates;
a powerhead assembly disposed between the front and rear pressure plates, the
powerhead assembly having
an annular spring housing having plurality of bores,
a plurality of first spring sets operatively coupled to the first front and rear
reaction plates, and
a plurality of second spring sets operatively coupled to the second front
and rear reaction plates, wherein the first and second spring sets are disposed in the
plurality of bores in the spring housing, and
at least two clamp tubes connecting the powerhead assembly to the
mounting flange.
10. The assembly of claim 9, wherein each of the first and second spring sets
comprise:
a plurality of springs; and
first and second spring retainers on opposite ends of each of the plurality of
springs, wherein the first and second spring retainers retain the plurality of springs in the spring
plate.
11. The assembly of claim 10, wherein the first and second spring sets are arranged in
an alternating manner in the spring plate.
12. The assembly of claim 10, wherein the front pressure plates are attached to the
first spring retainers and the rear pressure plates are attached to the second spring retainers.
13. The assembly of claim 12, wherein the front pressure plates are integrated with the
first spring retainers and the rear pressure plates are integrated with the second spring retainers.
14. The assembly of claim 9, further comprising a plurality of spacer tubes connecting
the stopper plate to the cylinder.
15. The assembly of claim 9, further comprising a plurality of clamp tubes that couple
the front pressure plate to the first and second rear reaction plates and the rear pressure plate to
the first and second front reaction plates.
16. The assembly of claim 15, further comprising a plurality of clamp tubes
connecting the stopper plate to the cylinder,
wherein when pressurized fluid enters the fluid chamber, the piston and the
stopper plate move toward each other to push the front and rear pressure plates toward each other
against a spring force in the first and second spring sets to cause the first front and rear reaction
plates to disengage from the first rotor and the second front and rear reaction plates to disengage
from the second rotor,
and wherein when pressurized fluid exits the fluid chamber, the spring force in the
first and second spring sets push the piston and the stopper plate away from each other to cause
the first front and rear reaction plates to engage the first rotor.
17. The assembly of claim 9, further comprising at least one sensor for measuring
wear on said at least one friction surface.
18. A powerhead assembly for use in a force transmitting assembly having first and
second rotors, the spring housing comprising:
an annular spring housing having plurality of bores;
a plurality of first spring sets associated with the first rotor; and
a plurality of second spring associated with the second rotor, wherein the first and
second spring sets are disposed in the plurality of bores in the spring housing.
19. The spring housing of claim 18, wherein each of the first and second spring sets
comprise:
a plurality of springs; and
first and second spring retainers on opposite ends of each of the plurality of
springs, wherein the first and second spring retainers retain the plurality of springs in the spring
plate.
20. The spring housing of claim 18, wherein the first and second spring sets are
arranged in an alternating manner in the spring housing.