This application claims priority from Italian Patent Application No. 102017000053604 filed on May 17, 2017, the disclosure of which is incorporated by reference.
The present invention relates to an accessory drive for an internal combustion engine of a motor vehicle.
In motor vehicles, a reversible electric machine is increasingly frequently used in place of the conventional alternator; said electric machine can operate as a generator but also as an electric motor at the start-up or as a booster motor.
The accessory drive generally comprises a pulley connected to the drive shaft and a pulley connected to the rotor of the electric machine and can comprise one or more pulleys for driving other accessories, for example the conditioning system compressor. The accessory drive further comprises a belt for transmission of the movement between the above-mentioned pulleys and a tensioner adapted to ensure a correct minimum tension level of the belt and avoid slipping between the same and the pulleys.
In conventional accessory drives, in which the electric machine is an alternator driven by the engine, the tensioner acts on the slack branch of the belt, i.e. the branch positioned downstream of the engine and upstream of the alternator with reference to the direction of movement of the belt.
The use of a reversible electric machine means that the branch of the belt that is tensioned in the operating conditions in which the electric machine is driven by the engine becomes the slack branch when the torque is delivered by the electric machine.
Various solutions have therefore been developed, which enable both branches of the belt to be tensioned.
One solution consists for example in using a tensioner with two arms hinged in a common pin and bearing respective pulleys. The arms are subject to the elastic force of a spring which moves them in proximity to each other so as to maintain the pulleys into contact with respective branches of the belt. An example of this solution is described for example in EP 1581753-A. The common axis of the two arms can be inside or outside the path of the belt.
Another solution consists in mounting the tensioner on the electric machine. According to this solution, the tensioner comprises an annular element rotating about the axis of the electric machine and bearing a pulley, and an arm articulated or sliding in respect to the annular element and bearing the other pulley; a spring is interposed between the annular element and the arm so as to push the pulleys into contact with the belt.
One problem connected with the known solutions is the following.
Both the belt and the layout of the drive are subject to production and assembly tolerances. Therefore there can be marked differences in installation tension (nominal tension), and consequently very variable tensioner installation positions.
Consider for example the following limit conditions:
1) the belt length is at the upper limit of its tolerance field, and development of the belt revolution, depending on the centre distances between the pulleys axis on which it is fitted, is at the lower limit of its tolerance field; and
2) the belt length is at the lower limit of its tolerance field and the development of the belt revolution is at the upper limit of its tolerance field.
It is evident that condition 1 will result in an installation tension (nominal) much lower than condition 2.
The belt tension cannot drop below a threshold value (or end-of-life value) below which, the correct operation of the drive is not ensured and slipping and noise can occur.
In the known drives, therefore, taking account of the above-mentioned tolerances and the natural elongation of the belt during its life, the design value of the nominal tension is oversized to ensure that the tension is maintained above the minimum value for the entire predicted life of the belt also in the worst case (condition 1 described above).
It follows that the known drives operate at a higher tension level than functionally necessary, which determines undesired losses and a consequent increase in consumption.
Furthermore, the drive components, and in particular the tensioner, must be sized for a higher tension than necessary, and are therefore heavier.
The object of the present invention is to solve the problems connected with the known drives and highlighted above.
The above-mentioned object is achieved by a drive according to claim 1.
According to a preferred embodiment of the invention, the tensioner comprises a support element adapted to be fixed on or in proximity to the electric machine, an intermediate element carried by the support element and rotating with respect thereto about a first fixed axis and a rigid tensioning element rotating with respect to the intermediate element about a second axis parallel to the first axis and distinct therefrom. A first and a second tensioning pulley are carried by the tensioning element and are rotating with respect thereto about respective axes distinct from said first and second axis and arranged in use in a fixed relative position, and the at least one spring acts between the support element and the intermediate element to push the tensioning pulleys into contact with said respective branches of the belt.
With this embodiment, the reactivity of the tensioner is maximized.
According to another preferred embodiment of the invention, the tensioner comprises two arms hinged about a common axis and provided with respective tensioning pulleys, the spring being interposed between the arms and acting in the direction of pushing the tensioning pulleys into contact with respective branches of the belt.
The present invention is also relative to an installation method according to claim 12.
For a better understanding of the present invention, some embodiments are described below, by way of non-limiting examples and with reference to the accompanying drawings, in which:
The drive 1 comprises a first pulley 2 rotationally coupled to a drive shaft 3 of an internal combustion engine 4 of the vehicle, a second pulley 5 rotationally coupled to a rotor of a reversible electric machine 6 and a third pulley 7 for driving a compressor (not illustrated) of a conditioning system of the vehicle.
The drive 1 further comprises a belt 9, expediently of the poly-V type, which cooperates with the first, second and third pulley 2, 5, 7 for transmission of the movement between the same.
The drive 1 lastly comprises a tensioner 10 mounted on or in proximity to the electric machine 6 and comprising (
A construction example of the tensioner 10 is described below, using the same reference numbers for the parts already described with reference to the preceding figures. The description of particular accessories such as bushings, bearings or other axial or radial support elements, used in order to reduce the friction and/or wear between the parts in relative movement, or to produce controlled damping between parts in relative movement, is omitted for the sake of brevity. Said details are illustrated, in particular in the exploded views, and their function will be evident to a person skilled in the art.
The support element 11 of the tensioner 10, expediently made of pressed sheet metal, is substantially disc-shaped with a flat bottom wall 19 and an outer perimeter edge 20 folded axially towards the electric machine 6 (
The intermediate element 12 of the tensioner 10 is substantially disc-shaped having axis B with an eccentric hole 25 rotatingly engaged by the pin 24.
The tensioner element 13 comprises an annular hub portion 30 rotating around the intermediate element 12 (and therefore the axis B) and a pair of arms 31, 32 radially extending in directions diverging from the hub portion 30.
Expediently, the tensioner element 13 consists of a pair of half-shells 13a, 13b (
According to the present invention, one of the two tensioning pulleys (15) is mounted in an adjustable manner on the respective arm 32, so as to allow variation of the centre distance between the pulleys axes to adjust the installation tension of the belt and compensate for the manufacturing tolerances of the belt itself and the drive layout.
For the above purpose, the tensioning pulley 15 is mounted by means of a bearing 34 on a sleeve 39 which is telescopically coupled to an intermediate bushing 33 (
The intermediate bushing 33 comprises a discoidal end flange, on the opposite side of the bearing 34, from which an eccentric peg 36 extends axially (
The arm 32 further comprises a curved slot 44 having centre of curvature on the axis C. A screw 42 is arranged passing through the slot 44 (without transversal play) and through the intermediate bushing 33, and is screwed into the sleeve 39.
The flange 35 of the intermediate bushing 33 is lastly provided with a prismatic, for example hexagonal, seat 45 for a wrench (not illustrated), arranged diametrically opposite the peg 36 with respect to the axis of the intermediate bushing 33.
Since the two half-shells 13A, 13B are identical to each other, also the arm 31 has the hole 37 and the slot 44, although not necessary for the purposes of adjustment of the position of the tensioner pulley 14. Therefore, the tensioner pulley 14 is mounted on a support 49 engaging the slot 44 in a fixed manner.
The spring 16, acting between the support element 11 and the intermediate element 12 so as to exert on the latter a thrust maintaining the pulleys 14 and 15 against the belt 9, is a helical spring with two coils, housed in the support element 11 and provided with end curls 40, 41 cooperating respectively with a seat 46 on the edge 20 of the support element 10 and a seat 47 obtained in an axial protrusion 48 of the intermediate element 12.
Operation of the tensioner 10, already partly evident from the preceding description, is as follows.
At installation, the screw 42 for blocking the intermediate bushing 33 is loosened, therefore the tensioner pulley 15 can be arranged in the most favourable position for installation of the belt 9. After the belt 9 has been installed on the pulleys 2, 5, 7, with the respective branches 9a, 9b arranged with their back into contact with the tensioner pulleys 14, 15, the tensioner pulley 15 can be moved, by means of a spanner in the seat 45 on the intermediate bushing 33 and rotating it about the axis C, to a position such as to bring the belt 9 to the nominal tension under the thrust of the spring 16. The screw 42 is then tightened, fixing the intermediate bushing 33 to the tensioner element 13.
During operation, the tensioner element 13 is arranged in a position of equilibrium to the rotation about the axis B under the action of the forces exchanged between the branches 9a, 9b of the belt 9 and the respective tensioner pulleys 14, 15. The tensioned branch of the belt 9 can be the branch 9a or the branch 9b according to the operating mode of the electric machine 6 (as a generator driven by the internal combustion engine 4 or as motor).
When the electric machine passes from one operating mode to the other, the tensioner element 13 rotates rigidly with respect to the intermediate element 12 about the axis B and is arranged in a new position of equilibrium, rotated with respect to the preceding position towards the new tensioned branch; also the intermediate element 12 finds a new position of equilibrium by rotating with respect to its axis A.
Since the tensioner element 13 is rigid and there is no elasticity interposed between the tensioner pulleys 14 and 15, the tensioner 10 is very reactive and promptly compensates for the instantaneous tension variations of the belt.
The length variations of the belt 9 during the working life thereof are compensated by rotation of the intermediate element 12 with respect to the support element 11 about the axis A (in anticlockwise direction with reference to
The drive 50 comprises a first pulley 2 rotationally coupled to a drive shaft 3 of the engine 4, a second pulley 5 rotationally coupled to a rotor of a reversible electric machine 6 (
The drive 50 further comprises a belt 9, preferably of the poly-V type, which cooperates with the first, the second and the third pulley 2, 5, 51 for transmission of the movement between the same.
Lastly, the drive 50 comprises a tensioner 52 with two arms (
The tensioner 52 (
Expediently, the hub portions 59, 60 of the arms 53, 54 of the tensioner 52 comprise respective radial appendages 64, 65 which, in an installation position, are aligned with each other and with a corresponding appendage 68 (optional) of the base 57 (
The pin 71 is adapted to be fixed to the engine by means of a screw 73 arranged passing through the hole 67.
The pin 71 has, on one axial face opposite the engine, a pair of holes 74 (illustrated schematically in
Operation of the drive 50 is as follows.
The tensioner 52 is mounted on the engine in the installation position, with the blocking peg 67 inserted.
The screw 73 is loosened and the pin 71 of the third pulley 51 can be rotated so that the pulley 51 is retracted as far as possible with respect to the path of the belt 9 (
Once the belt 9 has been fitted, the pin 71 can be rotated acting on the holes 74 by means of the wrench so as to bring the belt 9 to the desired nominal tension, after which the pin 71 is blocked on the engine 4 by tightening the screw 73.
The nominal tension can be chosen so that the forces transmitted from the branches of the belt 9a, 9b to the arms 53, 54 of the tensioner 52 balance the elastic force transmitted to the arms by the spring 62. It is therefore possible to identify when this tension value has been reached without measurements due to the fact that the peg 67 can be extracted without effort, since it is no longer subject to the elastic force of the spring 62.
Alternatively, the nominal tension can be higher than the equilibrium tension which allows the peg 66 to slide out. In this case, after the peg 67 has been extracted, the tension can be further increased until reaching a relative position between the arms 53, 54 defined by a visual indicator.
In
The tensioner 52 works like a twin-arm tensioner of known type, and each time tensions the slack branch 9a or 9b of the belt, according to the operating mode of the electric machine. However, since the drive 50 operates at a predetermined nominal tension compensating the tolerances of the belt and the layout, said tension can be lowered with respect to the values used in the conventional drives.
The drive 75 is similar to the drive 50 described, with the difference that the tension adjustment function is not performed by the third pulley 7 (which has a fixed axis), but by one of the tensioning pulleys as in drive 1.
In particular, the drive 75 comprises a twin-arm tensioner 76 in which the tensioning pulley 56 is mounted in an adjustable manner on the arm 54. Otherwise, the tensioner 76 is identical to the tensioner 52 described.
The tensioning pulley 56 is mounted on the arm 54 analogously to what is described for the pulley 15 in the drive 1, or on a sleeve 39 (
The intermediate bushing 33 comprises a discoidal end flange 35, on the opposite side of the bearing 34, from which an eccentric peg 36 axially extends (
The arm 32 further comprises a curved slot 44 having centre of curvature on the axis C (
The operation of the drive 75, already partly evident from the previous description, is as follows.
The tensioner 76 is mounted on the engine in the installation position with the blocking peg 66 inserted.
The screw 52 is loosened and the intermediate bushing 33 is rotated around the axis C so that the pulley 56 is as retracted as possible with respect to the path of the belt 9 (
Once the belt 9 has been fitted, the intermediate bushing 33 can be rotated by acting on the seat 45 of the peg 36 with the wrench so as to bring the belt 9 to the desired nominal tension, after which the screw 52 is tightened thus blocking the axis of the tensioning pulley 56 with respect to the arm 54.
The nominal tension is determined without measurements, as described for the drive 50, detecting the position in which the locking peg 66 can be extracted without effort, or a predetermined relative position between the arms 53, 54.
Lastly it is clear that modifications and variations that do not depart from the protective scope defined by the claims can be made to the drives 1, 50 and 75 described.
In particular, in place of the tensioners described, tensioners of any type can be used on the condition, obviously, that they are provided with two tensioning pulleys adapted to cooperate with the respective branches of the belt. For example, the tensioning pulleys can be carried by one single common arm, or by two Y-shaped arms, or by an element rotating around the axis of the electric machine and by an arm hinged on the element rotating or sliding circumferentially with respect thereto. The tensioner can furthermore be of a linear type, i.e. with the tensioning pulleys constrained to perform a relative movement along a line. Lastly, two independent single-arm tensioners each acting on a respective branch of the belt can be used.
Whatever the embodiment of the tensioner, the adjustable position pulley can consist of one of the tensioning pulleys carried by the tensioner itself or by an idler pulley of the drive distinct from the tensioner.
Number | Date | Country | Kind |
---|---|---|---|
102017000053604 | May 2017 | IT | national |
Filing Document | Filing Date | Country | Kind |
---|---|---|---|
PCT/IB2018/053478 | 5/17/2018 | WO | 00 |