Rotational coupling device with integrated rotor and brake disc

1. A rotational coupling device, comprising:

a hub configured for coupling to a shaft for rotation with said shaft about an axis of rotation;

a rotor supported on said hub and configured for rotation relative to said hub about said axis of rotation, said rotor including

a first member defining a radially extending wall having a first rotor coupling surface and an axially extending, radially inner rotor pole; and,

a second member coupled to said first member for rotation therewith, but axially movable relative to said first member, said second member defining an axially extending, radially outer rotor pole, a second rotor coupling surface and a first braking surface;

an armature supported on said hub for rotation therewith and disposed on a first side of said radially extending wall of said rotor;

a field shell disposed about said hub on a second side of said radially extending wall of said rotor opposite from said armature, said field shell housing a conductor therein and defining radially spaced inner and outer field shell poles aligned with said inner and outer rotor poles, respectively, energization of said conductor establishing an electromagnetic circuit among said field shell, said rotor and said armature to urge said armature in a first axial direction towards said radially extending wall of said rotor and couple said rotor to said hub for rotation therewith; and,

a first brake plate defining a second braking surface aligned with said first braking surface of said second member of said rotor

wherein said second member of said rotor is configured such that, upon energization of said conductor, said second member of said rotor is urged towards said first member of said rotor and said second rotor coupling surface is urged into engagement with said first rotor coupling surface and, upon deenergization of said conductor, said second member of said rotor is urged towards said first brake plate, said first braking surface is urged into engagement with said second braking surface and said second rotor coupling surface is urged to disengage from said first rotor coupling surface to create a fluid flow opening between said first and second members of said rotor.

2. The rotational coupling device of claim 1 , further comprising a first permanent magnet coupled to said first brake plate, said first permanent magnet establishing a magnetic circuit including said first brake plate and said second member of said rotor.

3. The rotational coupling device of claim 2 , further comprising a second permanent magnet coupled to said first brake plate, said second permanent magnet having the same polarity relative to said first permanent magnet.

4. The rotational coupling device of claim 3 , wherein said first brake plate defines a slot disposed circumferentially between said first and second permanent magnets.

5. The rotational coupling device of claim 1 , further comprising means for urging said second member of said rotor towards said first brake plate and said first and second braking surfaces into engagement.

6. The rotational coupling device of claim 1 , wherein said second member of said rotor defines a radially extending flange extending from said outer rotor pole and defining said first braking surface.

7. The rotational coupling device of claim 6 , wherein said flange extends radially outwardly from said outer rotor pole.

8. The rotational coupling device of claim 1 , wherein said second member of said rotor is a unitary body.

9. The rotational coupling device of claim 1 , further comprising a leaf spring coupled at one end to said first member of said rotor and at a second end to said second member of said rotor.

10. The rotational coupling device of claim 1 , further comprising a second brake plate defining a third braking surface aligned with said first braking surface of said second member of said rotor.

11. The rotational coupling device of claim 10 , wherein a circumferential center of said first brake plate and a circumferential center of said second brake plate are circumferentially spaced less than one hundred and eighty degrees apart.

12. The rotational coupling device of claim 1 , further comprising:

a first clutch plate disposed axially between said radially extending wall of said rotor and said armature, said first clutch plate coupled to said hub for rotation therewith, but axially movable relative to said hub; and,

a second clutch plate disposed axially between said radially extending wall of said rotor and said armature, said second clutch plate coupled to said rotor for rotation therewith, but axially movable relative to said rotor;

wherein said first and second clutch plates are configured for movement in said first axial direction towards said radially extending wall of said rotor upon energization of said conductor and into frictional engagement with one another to couple said rotor to said hub for rotation therewith and are configured for movement in a second axial direction opposite said first axial direction upon subsequent deenergization of said conductor, at least one of said hub and said rotor defining a first shoulder configured to limit movement of a corresponding one of said first and second clutch plates in said second axial direction.

13. The rotational coupling device of claim 12 , wherein another one of said hub and said rotor defines a second shoulder configured to limit movement of another one of said first and second clutch plates in said second axial direction.

14. The rotational coupling device of claim 1 , further comprising:

a first clutch plate disposed axially between said radially extending wall of said rotor and said armature, said first clutch plate coupled to said hub for rotation therewith, but axially movable relative to said hub; and,

a second clutch plate disposed axially between said radially extending wall of said rotor and said armature, said second clutch plate coupled to said rotor for rotation therewith, but axially movable relative to said rotor;

wherein said first and second clutch plates are configured for movement in said first axial direction towards said radially extending wall of said rotor upon energization of said conductor and into frictional engagement with one another to couple said rotor to said hub for rotation therewith and are configured for movement in a second axial direction opposite said first axial direction upon subsequent deenergization of said conductor, at least one of said hub and said rotor including first means for limiting movement of a corresponding one of said first and second clutch plates in said second axial direction.

15. The rotational coupling device of claim 1 , wherein said rotor defines a chamber on said first side of said radially extending wall surrounding said hub, said chamber defining a sump containing a fluid, and further comprising:

a first clutch plate disposed axially between said radially extending wall of said rotor and said armature, said first clutch plate coupled to said hub for rotation therewith, but axially movable relative to said hub;

a second clutch plate disposed axially between said radially extending wall of said rotor and said armature, said second clutch plate coupled to said rotor for rotation therewith, but axially movable relative to said rotor; and,

a first tube having a first end submerged in said fluid and extending through a first aperture in said armature wherein rotation of said armature draws fluid through said first tube and onto said first and second clutch plates.

16. The rotational coupling device of claim 1 , wherein said rotor defines a chamber on said first side of said radially extending wall surrounding said hub, said chamber defining a sump containing a fluid and said field shell and said conductor are isolated from said fluid.

17. The rotational coupling device of claim 16 , wherein said radially extending wall of said rotor includes an aperture extending axially therethrough between a radially innermost surface of said rotor and a radially outermost surface of said rotor and further comprising a sealing plate configured to prevent fluid from flowing through said aperture, said sealing plate having a higher magnetic reluctance than said radially extending wall of said rotor.

18. The rotational coupling device of claim 1 , further comprising a spring biasing said armature in said first axial direction, said spring configured to counteract an opposing force biasing said armature in a second axial direction opposite said first axial direction.

19. The rotational coupling device of claim 1 , further comprising:

a first clutch plate disposed axially between said radially extending wall of said rotor and said armature, said first clutch plate coupled to said hub for rotation therewith, but axially movable relative to said hub; and,

a second clutch plate disposed axially between said radially extending wall of said rotor and said armature, said second clutch plate coupled to said rotor for rotation therewith, but axially movable relative to said rotor; and,

a fluid slinger disposed about said hub on an opposite side of said first and second clutch plates from said armature wherein said hub includes a vent bore extending from a radially outer surface of said hub to a radially inner surface of said hub, said vent bore disposed on an opposite side of said fluid slinger from said first and second clutch plates.

20. The rotational coupling device of claim 1 , wherein said field shell includes:

a first member defining axially extending, radially inner and outer field shell poles; and,

a second member disposed within said first member radially between said radially inner and outer field shell poles and configured to receive said conductor

wherein said inner field shell pole of said first member is configured to prevent movement of said second member of said field shell in a second axial direction opposite said first axial direction.