WO2015153585A1

WO2015153585A1 - Rotary knob assembly with selectable cable angle output

Info

Publication number: WO2015153585A1
Application number: PCT/US2015/023552
Authority: WO
Inventors: Mark S. SIMON
Original assignee: Kelsey-Hayes Company
Priority date: 2014-04-04
Filing date: 2015-03-31
Publication date: 2015-10-08
Also published as: CN106163859A; BR112016022457A2

Abstract

A rotary knob assembly includes a carrier and a pinion shaft mounted to the carrier to rotate about a first axis. A lever arm is mounted to the carrier to rotate about a second axis different from the first axis. The pinion shaft includes a pinion gear that rotates with rotation of the pinion shaft and the lever arm includes a lever arm gear that meshes with the pinion gear so that rotation of the pinion shaft causes movement of the lever arm along a lever arm plane. The carrier is mountable to a base plate at a selected rotatabie orientation about the first axis so as to control an angle of the lever arm plane.

Description

ROTARY KNOB ASSEMBLY

WITH SELECTABLE CABLE AHGL OUTPUT

Related Applications

This application claims priority to U.S. Provisional Application No. 61/975,065, filed April 4, 2014, the entirety of which is incorporated herein by reference.

Field of the 1 r enion

The present invention is directed to a rotary knob assembly and is particularly directed to a rotary knob assembly for controlling movement of a cable in which the rotary knob has a selectable cable angle output.

Background

A rotary knob assembly for controlling an end use device is known in the art. In vehicle heating, ventilating, and air conditioning ("HVAC") systems, rotary knobs are often used to control the position of vent doors of the HVAC system where the vent doors are located under the vehicle dashboard and not otherwise directly accessible to the vehicle operator. For example, one rotary knob could be used to control a vent door that directs the air flow from the HVAC system to either the floor area, the mid- cabin region, or the windshield area of the vehicle. The rotary knob assembly is connected to the door to be controlled through a push-pull cable arrangement known as a Bowden cable. The rotary knob assembly has a lever arm connected to the cable. Rotary motion of the knob results in substantially linear motion of the lever arm which results in pushing and pulling of the cable. When the knob is rotated in one direction, the cable, through the lever arm, pushes on a door located in the HVAC air flow path so as to cause the door to pivot in a first direction thereby directing the air flow in a first area. When the knob is rotated in the other direction, the cable, through the lever arm, pulls the door so as to pivot the door in the other direction and thereby changing the direction of air flow. Depending on the entry angle of the cable into the housing that houses the rotary knob assembly, a specific associated knob assembly design is required so as to have the plane of the lever arm movement in the same plane of the cable movement. Otherwise, the cable could bind. Therefore, the fact that several different vehicle platforms would have several different cable entry angles into the rotary knob assembly housing requires a commensurate number of different rotary knob assembly configurations.

Summary of the Invention

The present invention provides a rotary knob assembly for

controlling cable movement that is adaptable for variable cable angle outputs so that one rotary knob assembly design can be used on several different vehicle platforms having different cable entry angles into the housing of the rotary knob assemDsy.

In accordance with one example embodiment of the present

Invention, a rotary knob assembly includes a carrier and a pinion shaft mounted to the carrier to rotate about a first axis. A lever arm is mounted to the carrier to rotate about a second axis different from the first axis. The pinion shaft includes a pinion gear that rotates with rotation of the pinion shaft and the lever arm includes a lever arm gear that meshes with the pinion gear so that rotation of the pinion shaft causes movement of the lever arm along a lever arm plane. The carrier is mountable to a base plate at a selected rotatable orientation about the first axis so as to control an angle of the lever arm plane,

In accordance with another example embodiment of the present invention, a rotary knob assembly is provided comprising an L-shaped carrier having a gear drive mounting portion and a mounting plate portion. A stub shaft extends from the gear drive mounting portion of the L-shaped carrier and is substantially parallel to the mounting plate port of the L- shaped carrier. A pinion shaft is mounted though the mounting plate portion of the L-shaped carrier and in a bearing opening of the stub shaft so as to rotate about a first axis. A lever arm assembly is rotatably mounted to the stub shaft so as to rotate about a second axis substantially

perpendicular to the first axis. The pinion shaft includes a pinion gear that rotates with rotation of said pinion shaft and the lever arm assembly includes a lever arm gear that meshes with the pinion gear so that rotation of the pinion shaft causes movement of the lever arm along a lever arm plane. The mounting plate portion of the L-shaped carrier is mountable to a base plate at a selected rotatable orientation about the first axis so as to control an angle of the lever arm plane,

In accordance with yet another example embodiment of the present invention a rotary knob assembly is provided for use with a vehicle HVAC system. The rotary knob assembly comprises an L-shaped carrier having a gear drive mounting portion and a mounting plate portion. A stub shaft extends from the gear drive mounting portion of the L-shaped carrier and is substantially parallel to the mounting plate port of the L-shaped carrier. A pinion shaft is mounted though the mounting plate portion of the L-shaped carrier and in a bearing opening of the stub shaft so as to rotate about a first axis. A lever arm assembly is rotatabiy mounted to the stub shaft so as to rotate about a second axis substantially perpendicular to the first axis. The pinion shaft includes a pinion gear that rotates with rotation of the pinion shaft and the lever arm assembly includes a lever arm gear that meshes with the pinion gear so that rotation of the pinion shaft causes movement of the lever arm along a lever arm plane. The mounting plate portion of the L-shaped carrier is mountable to a base plate at a selected rotatable orientation about the first axis so as to control an angle of the lever arm plane. A cable is secured to the end of the lever arm so that movement of the lever arm in one direction results in cable movement in the one direction and movement of the lever arm in a second direction results in cable movement in the second direction. The cable is connected to a vent door of said vehicle HVAC system. A haptic feedback device is operative!y mounted between the L-shaped carrier and the pinion shaft and provides Incremental grab and release feel to a user as the pinion shaft is rotated about the first axis.

Brief Description of the Drawings

The foregoing and other features and advantages of the present invention will become apparent to those skilled in the art to which the present invention relates upon reading the following description with reference to the accompanying drawings, in which:

Fig. 1 is a top perspective view of an HVAC control box housing having a rotary knob assembly in accordance with one example

embodiment of the present invention;

Fig. 2 is a bottom perspective view of the HVAC control box housing of Fig. 1 ;

Fig. 3 is a back perspective view of the HVAC control box housing of

Fig, 1 ;

Fig. 4 is a top plan view of the HVAC control box housing of Fig. 1 ;

Fig. 5 is a bottom plan view of the HVAC control box housing of Fig.

-I■

' t

Fig. 6 side elevation view of the HVAC control box housing of Fig. 1 ; Figs. 7 and 8 are perspective views showing the rotary knob assembly of Fig. 1 in greater detail;

Fig. 9 is an exploded view of the rotary knob assembly of Figs. 7 and

8; and

Fig. 10 is a perspective view of the back cover of the present invention showing one example of a mounting hole arrangement of the present invention.

Detailed Description

Referring to Figs. 1-10, a rotary knob assembly 20, in accordance with one example embodiment of the present Invention, is shown. By way of example, the rotary knob assembly 20 is described for use in a vehicle HVAC system but could be used for other purposes and/or other systems, The rotary knob assembly 20 is mounted in a control panel housing 28 such as a housing used to control the vehicle HVAC system. The rotary knob assembly 20 includes several movable pads mounted onto a subcarrier 30. The subcarrier 30 is a one piece unit that includes a gear drive mounting portion 32 and a mounting plate portion 34. A stub shaft 36 or sector pivot extends from the gear drive mounting portion 32. The stub -s- shaft 38 can be molded with the subcarrier 30 to form one integral piece or, alternatively, can be a separate shaft attached to the subcarrier 30 by appropriate means.

The rotary knob assembly 20 further includes a rotary pinion shaft 40 received in a through-hole 42 that functions as a bearing for rotation of the pinion shaft 40. The pinion shaft 40 is also mounted in a through-hole 44 of the mounting plate portion 34. The through-hole 44 also functions as a bearing for rotation of the pinion shaft 40. The end of the pinion shaft 40 carries a rotary dial knob 48 fixed to the end of the pinion shaft 40 such as by press fitting or a spline connection. Also, the knob mounting end of the pinion shaft could be multi-sided so that the rotary position of the knob on the pinion shaft 40 can be controlled as is further described below. The pinion shaft 40 Is rotatabie about a first axis. In accordance with one example embodiment of the present invention, the axis of the stub shaft 36 is perpendicular to the axis of the pinion shaft 40.

The subcarrier 30 is secured to a back cover 50 of the housing 26 via screws 52, 54 at any one of a plurality of desired angles in a manner that is described in more detail below. Although two screws are shown, more screws could be used. A decorative cover plate 58 is attached to the back cover 50 of the housing 28. The pinion shaft 40 extends through one opening 58 of the cover 56. Control settings indications 59 surround the opening 58. The knob 48 carries a setting indicator 57, such as a pointing line, to aid the operator in aligning the rotary position of the pinion shaft 40 with a desired control function such as air flow direction to a particular vehicle cabin location. Since the knob 48 needs to be aligned with setting indications 59 surrounding the opening 58, the multi-fiat sided end of the pinion shaft 40 aids in this purpose. Those skilled in the art will appreciate that the length of the pinion shaft 40 and the size of the dial knob 48 are selected so that the dial knob will: cover the opening 58 and align with the setting indicators 59 while still allow the setting indicators 59 to be seen. Knob end stops 64. 65, 68, 88 could also be used to control the depth of the knob on the pinion shaft 40 so as to better align with the setting indicators 59 and to limit the amount of knob rotation.

The pinion shaft 40 includes a detent profile 60 and a bevel gear 62, both integrally formed on the pinion shaft 40. A rotatable [ever arm assembly or sector 70 includes a mounting bore sleeve 72 mounted onto the stub shaft or sector pivot shaft 38. The rotatable lever arm assembly 70 further includes a fever arm 74 extending from the mounting bore sleeve 72 and a sector gear portion 76 aiso extending out from the bore sleeve 72. The rotatable lever arm assembly 70 is dimensioned so that the bevel gear 62 operatively meshes with the gear portion 76. As should be appreciated, when the pinion shaft 40 is rotated (as occurs when the dial 48 is turned or rotated), th rotatable lever arm assembly 70 will pivot about the shaft 36 thereby resulting in movement of the end 80 of the lever arm 74. Although really rotating or pivoting about the stub shaft 36, the movement of the end 80 of the lever arm 74 can be considered to be substantially linear movement.

A Bowden cable 84 is secured to a cable mounting opening 86 at the end 80 of the lever arm 74. An opposite end of the Bowden cable 84 could be connected to an end use device to be controlled such controlling the pivotal position of an air flow vent control door (not shown). When the Bowden cable 84 pushes In one direction, the door is pivoted in a first direction to a first position. When the Bowden cable 84 is pulled In a second direction, the door is pivoted in a second direction to a second position. As mentioned, the motion between the end 80 of the pivot arm 74 and the Bowden cable can be considered substantially linear in a lever arm plane although the lever arm 74 is, in fact, rotating about the center of the stub shaft 36,

The Bowden cable 84 can enter the housing 28 at a particular angle depending on the particular vehicle platform and the specific location of the end use device being controlled, it is desired that the plane of the push- pull linear movement of the Bowden cable be in the same plane as the movement of the lever arm 74. in accordance with the present Invention, the mounting arrangement of the rotary knob assembly 20 allows the entire knob assembly 20 to be rotated about the axis of the pinion shaft 40 prior to attachment of the rotary knob assembly to the back cover 50 of the housing 28 and thereby insure planar alignment of the Bowden cable movement with the planar movement of the Sever arm 74 and thereby prevent any binding of the Bowden cable. It should be appreciated that the entire subcarrier 30 is rotatabie about the axis of the pinion shaft thereby controlling the angle of the planar movement of the lever arm. Once the proper angle of the subcarrier is located, the subcarrier 30 is attached to the back cover 50 with screws 52, 54. The rotary knob assembly 20 of the present invention can be used across several different vehicle platforms even though the Bowden cable enters the control box housing 26 at a different angle since the rotary knob assembly 20 can be rotated prior to attachment to the back cover of the housing so as to align lever arm movement with the Bowden cable movement. The knob 48 can then be placed onto the end of the pinion shaft 40 so as to align with the control indications shown on the front cover of the control housing .

The detent profile 60 is designed to provide haptio feedback. The detent profile 60 is connected to a bail and spring arrangement 90 that is ca ried by the subcarrier 30 or some other type of spring loaded grab and release device. S effect, for each predetermined amount of rotation of the knob 48, the operator will feel, i.e., hapfic feedback, a click and lock affect each incremental amount of dial knob rotation depending on the spacing of the detents.

Referring to Figs. 9 and 10, the rotary knob assembly 20 includes a mounting d isk 91 integrally formed on the mounting plate portion 34 of the subcarrier 30. The mounting disk 91 is received in a commensurate mounting hole 102 of slightly larger diameter In the back cover 50. A retaining disk 92 is located on the other side of the back cover 50 and has a diameter larger than the mounting hole 102 in the back cover and that of the mounting disk 91 , The subcarrier 30 is bolted to the retaining disk 92 with multiple bolts 94 and nuts 96. The bolts 94 and nuts 96 are tightened but still allow the subcarner 30 can be rotated about an axis defined by the center of the hole 102 and the relative to the back cover 50, and in turn, relative to the control panel housing 26, so as to select a cable angle output. The mounting hose 102 functions as a bearing surface for the mounting disk 91 as the subcarner is rotated into a desired angular position.

Once the subcarrier 30 is rotated into the desired angular position, the bolts 52 and 54 are mounted through a pair of plurality of mounting holes 104 in the back cover 50. The nuts associated with bolts 52, 54 are placed on the bolts and tightened thereby locking the subcarrier 30 at the desired relative angle. The number of mounting holes 104 controls the angular increments that the subcarrier 30 can be positioned at in the final assembly. By way of example, if there are thirty-six sets of mounting holes 104 evenly spaced about the center hole 102 would allow an angular mounting arrangement at a desired angular position separated by ten degree increments. Any desired incremental mounting arrangement may be used. Those skilled in the art will also appreciate that the mounting holes 104 could be replaced with crescent shaped openings to allow a significant increase in the amount of incremental angular selection.

Also, Fig. 9 shows an alternative arrangement for the stub shaft 36.

As mentioned, rather than being integrally formed with the subcarrier 30, the stub shaft 36 could be a separate piece connected to the subcarrier 30 via a bolt 98 and nut 00. The end of the stub shaft 38 could also have a keyed flat surface and be received into a commensurate recess opening In the subcarrier 30 to prevent rotation of the stub shaft 36 relative to the subcarrier 30.

From the above description of the invention, those skilled in the art will perceive improvements, changes and modifications. Such

improvements, changes and modifications within the skill of the art are intended to be covered by the appended claims.

Claims

Having described the invention, the following is claimed:

1. A rotary knob assembly comprising:

a carrier;

a pinion shaft mounted to the carrier to rotate about a first axis;

a fever arm mounted to the carrier to rotate about a second axis different from the first axis;

wherein the pinion shaft includes a pinion gear that rotates with rotation of said pinion shaft and wherein said lever arm includes a lever arm gear that meshes with said pinion gear so that rotation of said pinion shaft causes movement of said lever arm along a lever arm plane; and

said carrier being mountable to a base plate at a selected rotatah!e orientation about the first axis so as to control an angle of said lever arm plane.

2. The rotary knob assembly of claim 1 further comprising a cable secured to the end of the lever arm so that movement of the lever arm in one direction results in cable movement in said one direction and movement of said (ever arm in a second direction results in cable movement in the second direction,

3. The rotary knob assembly of claim 2 wherein said cable is connected to an end use device in a vehicle HVAC system.

4. The rotary knob assembly of claim 3 wherein said end use device is a vent door of the vehicle HVAC system.

The rotary knob assembly of claim 1 wherein the pinion gear -IO

CS. The rotary knob assembly of claim 1 wherein said rotary knob assembly further includes a haptic feedback device operative!y mounted between the carrier and the pinion shaft that provides an incremental grab and release feel to a user as the pinion shaft is rotated about the first axis.

7. A rotary knob assembly comprising:

an L-shaped carrier having a gear drive mounting portion and a mounting plate portion;

a stub shaft extending from the gear drive mounting portion of said L-shaped carrier and being substantially parallel to said mounting plate port of said L-shaped carrier;

a pinion shaft mounted though said mounting plate portion of said L-shaped carrier and in a bearing opening of said stub shaft so as to rotate about a first axis;

a lever arm assembly rotatably mounted to said stub shaft so as to rotate about, a second axis substantially perpendicular to the first axis;

wherein the pinion shaft includes a pinion gear that rotates with rotation of said pinion shaft and wherein said lever arm assembly includes a lever arm gear that meshes with said pinion gear so that rotation of said pinion shaft causes movement of said lever arm along a lever arm plane; and

wherein said mounting plate portion of said L-shaped carrier being mountabSe to a base plate at a selected rotatable orientation about the first axis so as to control an angle of said lever arm plane.

8. The rotary knob assembly of claim 7 further comprising a cable secured to the end of the lever arm so that movement of the lever arm in one direction results in cable movement in said one direction and movement of said lever arm in a second direction results in cable

movement in the second direction.

9. The rotary knob assembly of claim 8 wherein said cable is connected to an end use device in a vehicle HVAC system.

10. The rotary knob assembly of claim 9 wherein said end use device is a vent door of the vehicle HVAC system. 1 . The rotary knob assembly of claim 7 wherein the pinion gear is a beveled gear.

12. The rotary knob assembly of claim 7 wherein said rotar knob assembly further includes a haptic feedback device operativeiy mounted between the t-shaped carrier and the pinion shaft that provides

incremental grab and release feel to a user as the pinion shaft is rotated about the first axis.

13. A rotary knob assembly for use with a vehicle HVAC system, said rotary knob assembly comprising:

an L -shaped carrier having a gear drive mounting portion and a mounting plate portion;

a pinion shaft mounted though said mounting plate portion of sasd L-shaped carrier and in a bearing opening of said stub shaft so as to rotate about a first axis;

a lever arm assembly rotatably mounted to said stub shaft so as to rotate about a second axis substantiall perpendicular to the first axis:

wherein the pinion shaft includes a pinion gear that rotates with rotation of said pinion shaft and wherein said lever arm assembly includes a lever arm gear that meshes with said pinion gear so that rotation of said pinion shaft causes movement of said lever arm along a lever arm plane; wherein said mounting plate portion of said L- shaped carrier being mountable to a base plate at a selected rotaiable orientation about the first axis so as to control an angle of said lever arm plane;

a cable secured to the end of the lever arm so that movement of the lever arm^' in one direction results in cable movement in said one direction and movement of said lever arm in a second direction results in cable movement in the second direction and wherein said cable is connected to a vent door of said vehicle HVAC system; and

a haptic feedback device operative^ mounted between the L~ shaped carrier and the pinion shaft that provides incremental grab and release feel to a user as the pinion shaft is rotated about the first axis.