WO2021144601A1

WO2021144601A1 - Dual output actuator

Info

Publication number: WO2021144601A1
Application number: PCT/IB2020/000087
Authority: WO
Inventors: Tianxiao Xu
Original assignee: Inteva Products France Sas
Priority date: 2020-01-14
Filing date: 2020-01-14
Publication date: 2021-07-22

Abstract

A dual output actuator (26) for use with an active grill shutter system (14), the dual output actuator (26) having: a housing (28) with a first lever (30) rotatably mounted to the housing (28) for movement about a first side (32) of the housing (28); and a second lever (34) rotatably mounted to the housing (28), the first lever (30) and the second lever (34) being independently rotatable with respect to each other, the actuator (26) being configured to partially or fully move the first lever (30) between a first position and a second position without a corresponding simultaneous movement of the second lever (34) and the actuator (26) is configured to partially or fully move the second lever (34) between a first position and a second position without a corresponding simultaneous movement of the first lever (30).

Description

DUAL OUTPUT ACTUATOR

BACKGROUND

[0001] Exemplary embodiments of the present disclosure pertain to dual output actuators and more particularly, a dual output actuator for an active grill shutter system of a vehicle.

[0002] Active grill shutter systems are located at the front end or nose of a vehicle and can transition between an open position and a closed position. When the shutters are in the open position, they allow air to flow therethrough into the radiator and into the engine compartment, which allows for cooling of the engine and/or the radiator, as well as cooling several radiators/exchangers for air conditioning, air intake of turbo or compressor-charged engines, oil circuit coolers etc. When the shutters are in the closed position the air is blocked and rerouted around the vehicle, which reduces aerodynamic drag and fuel consumption. Also and in cold weather operating conditions this will reduce the warm-up time of the vehicle engine. As such and in some operating conditions and when this cooling air is not required, it is desirable to have the shutters closed. Alternatively and as mentioned above, other operating conditions may require the shutters to be open.

[0003] However, current active grille shutter system employ a synchronous movement for each of the vanes or shutters in the system. As such, current active grille shutter system cannot open or close vanes according to different areas (e.g., upper and lower areas). Also and in some conditions having all of the vanes or shutters of the system closed may not be an optimal solution for reducing aerodynamics drag. Due to the different working conditions of the different radiators, it is desirable to enable a selected control of different areas of the shutters, so that they can be actuated independently. In order to minimize complexity, weight and cost, it is not desirable to reproduce active grill shutter systems in parallel Accordingly, there is a desire to provide an improved actuator for an active grill shutter system of a vehicle enabling independent control of different active grill shutters. BRIEF DESCRIPTION

[0004] Disclosed is a dual output actuator for use with an active grill shutter system, the dual output actuator having: a housing with a first lever rotatably mounted to the housing for movement about a first side of the housing; and a second lever rotatably mounted to the housing, the first lever and the second lever being independently rotatable with respect to each other, the actuator being configured to partially or fully move the first lever between a first position and a second position without a corresponding simultaneous movement of the second lever and the actuator is configured to partially or fully move the second lever between a first position and a second position without a corresponding simultaneous movement of the first lever.

[0005] In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the first lever and the second lever are rotatably mounted to opposite sides of the housing for movement about a same axis.

[0006] In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the first lever is operably coupled to a first or upper portion of the active grill shutter system such that movement of the first lever will partially or fully open and close a plurality of vanes or shutters of the first or upper portion as the first lever partially or fully moves between the first position and the second position and the second lever is operably coupled to a second or lower portion of the active grill shutter system such that movement of the second lever will partially or fully open and close a plurality of vanes or shutters of the second or lower portion as the second lever partially or fully moves between the first position and the second position.

[0007] In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the first lever and the second lever are operably coupled to a gear rotatably mounted to the housing.

[0008] In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the first lever has an integral first output that is configured to engage a first protrusion of the gear and the second lever has an integral second output that is configured to engage a second protrusion, wherein the first protrusion and the second protrusion are located on opposite sides of the gear and the first protrusion and the second protrusion are placed in offsetting locations with respect to each other.

[0009] In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the gear has a first raised portion and a second raised portion, the first raised portion and the second raised portion are located on opposite sides of the gear.

[0010] In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the first raised portion has a curved surface that engages a complimentary curved surface of the first output of the first lever as the gear rotates with respect to the housing and the first raised portion has a reduced area that is configured to allow for rotational movement of arm portions and of the first lever as the first protrusion is slidably received within a gap defined by arm portions and of the first lever.

[0011] In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the second raised portion has a curved surface that engages a complimentary curved surface of the second output of the second lever as the gear rotates with respect to the housing and the second raised portion has a reduced area that is configured to allow for rotational movement of arm portions and of the second lever as the second protrusion is slidably received within a gap defined by arm portions and of the second lever.

[0012] In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the first lever and the second lever are rotatably mounted to the first side of the housing for movement about different axes.

[0013] In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the first lever is operably coupled to a first or upper portion of the active grill shutter system such that movement of the first lever will open and close a plurality of vanes or shutters of the first or upper portion as the first lever moves between the first position and the second position and the second lever is operably coupled to a second or lower portion of the active grill shutter system such that movement of the second lever will open and close a plurality of vanes or shutters of the second or lower portion as the second lever moves between the first position and the second position.

[0014] In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the first lever is operably coupled to a first gear and the second lever is operably coupled to a second gear.

[0015] In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the first lever has an integral first output that is configured to engage a first protrusion of the first gear and the second lever has an integral second output that is configured to engage a second protrusion of the second gear, wherein the first protrusion and the second protrusion are placed in offsetting locations with respect to each other.

[0016] In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the first gear has a first raised portion and the second gear has a second raised portion, the first raised portion having a pair of curved surfaces that engage complimentary curved surfaces of the first output of the first lever as gear rotates with respect to the housing and the first raised portion has a reduced areas that are configured to allow for rotational movement of arm portions and of the first lever as the first protrusion is slidably received within a gap defined by arm portions and of the first lever and the second raised portion of the second gear has a pair of curved surfaces that engage complimentary curved surfaces of the second output of the second lever as the second gear rotates with respect to the housing, the second raised portion having reduced areas that are configured to allow for rotational movement of arm portions and of the second lever as the second protrusion is slidably received within a gap defined by arm portions and of the second lever. [0017] In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the first gear is configured to meshingly engage the second gear.

[0018] In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the first gear is configured to meshingly engage the second gear.

[0019] In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the first lever and the second lever are rotatably mounted to opposite sides of the housing for movement about different axes and.

[0020] In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the first lever is operably coupled to a first gear rotatably mounted to the housing of the dual output actuator and the second lever is operably coupled to a second gear. [0021] In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the first gear is configured to meshingly engage the second gear.

[0022] Also disclosed is a method for operating a dual output actuator of an active grill shutter system, the method including the steps of: rotatably mounting a first lever to a housing of the dual output actuator for movement about a first side of the housing; rotatably mounting a second lever to the housing, wherein the first lever and the second lever are independently rotatable with respect to each other; moving the first lever between a first position and a second position without a corresponding movement of the second lever; and moving the second lever between a first position and a second position without a corresponding movement of the first lever.

[0023] In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the first lever and the second lever are rotatably mounted to opposite sides of the housing for movement about a same axis. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] The following descriptions should not be considered limiting in any way. With reference to the accompanying drawings, like elements are numbered alike:

[0025] FIG. 1 is a partial schematic view of a forward portion of a vehicle with an active grill shutter system;

[0026] FIGS. 2A-2E are views illustrating various positions of an active grill shutter system in accordance with the present disclosure;

[0027] FIG. 3 is a perspective view of a dual output actuator completed for use with an active grill shutter system in accordance with an embodiment of the present disclosure;

[0028] FIG. 4A is a side view of the dual output actuator of FIG. 3 in a first operational position or an initial position;

[0029] FIG. 4B is an opposite side view of the dual output actuator of FIG. 4A in the first operational position or the initial position; [0030] FIG. 5 A is a side view of the dual output actuator of FIG. 3 in a second operational position;

[0031] FIG. 5B is an opposite side view of the dual output actuator of FIG. 5 A in the second operational position;

[0032] FIG. 6A is a side view of the dual output actuator of FIG. 3 in a third operational position;

[0033] FIG. 6B is an opposite side view of the dual output actuator of FIG. 5 A in the third operational position;

[0034] FIG. 7 is an end view of the dual output actuator of FIG. 3; [0035] FIG. 8 is a perspective view of a dual output actuator completed for use with an active grill shutter system in accordance another embodiment of the present disclosure;

[0036] FIG. 9 is a side view of the dual output actuator of FIG. 8 in a first operational position or initial position;

[0037] FIG. 10 is a side view of the dual output actuator of FIG. 8 in a second operational position;

[0038] FIG. 11 is a side view of the dual output actuator of FIG. 8 in a third operational position; [0039] FIG. 12 is a side view of the dual output actuator of FIG. 8 in a fourth operational position;

[0040] FIG. 13 is a side view of the dual output actuator of FIG. 8 in the first operational position or initial position after several sequential operations;

[0041] FIG. 14 is an end view of the dual output actuator of FIG. 8; and [0042] FIG. 15 is an end view of a dual output actuator completed for use with an active grill shutter system in accordance another embodiment of the present disclosure.

DETAILED DESCRIPTION

[0043] A detailed description of one or more embodiments of the disclosed apparatus and method are presented herein by way of exemplification and not limitation with reference to the Figures.

[0044] Referring now to FIG. 1 a partial schematic view of a forward portion 10 of a vehicle 12 with an active grill shutter system 14 is illustrated. Active grill shutter systems are located at a front end or nose 16 of the vehicle 12 and can transition between an open position and a closed position. [0045] When the shutters or vanes of the active grill shutter system 14 are in the open position, they allow air to flow through the system into the radiator and into the engine compartment, which allows for cooling of the engine and/or the radiator. Alternatively and when the shutters or vanes are in the closed position the air is blocked and rerouted around the vehicle, which reduces aerodynamic drag and fuel consumption. Also and in cold weather operating conditions this will reduce the warm up time of the vehicle’s engine.

[0046] Referring now to FIGS. 2A-2E various positions of an active grill shutter system 14 in accordance with the present disclosure are illustrated. In FIG. 2A a plurality of vanes or shutters 18 of the active grill shutter system 14 are illustrated in the closed position, which may also be referred to a first or initial operational position of the active grill shutter system 14. In addition, the plurality of vanes or shutters 18 of the active grill shutter system 14 includes a first or upper portion 20, which comprises some of the plurality of vanes or shutters 18 and a second or lower portion 22, which comprises the remaining plurality of vanes or shutters 18 that are not in the first or upper portion 20. As used herein upper portion 20 may refer to a plurality of vanes or shutters 18 of the active grill shutter system 14 that are located in higher position than the remaining plurality of vanes or shutters 18 of the active grill shutter system 14 of the vehicle. Airflow blocked by the active grill shutter system 14 is illustrated by arrows 24.

[0047] As contemplated herein, the plurality of vanes or shutters 18 of the first or upper portion 20 are configured to move simultaneously through actuation of a first single lever operably coupled to the plurality of vanes or shutters 18 of the first or upper portion 20 by for example linkage and the plurality of vanes or shutters 18 of the second or lower portion 22, which comprise the remaining plurality of vanes or shutters 18 that are not in the first or upper portion 20, are configured to move simultaneously through actuation of a second single lever operably coupled to the plurality of vanes or shutters 18 of the second or lower portion 22 by for example linkage.

[0048] In FIG. 2B the plurality of vanes or shutters 18 of the first or upper portion 20 of the active grill shutter system 14 are illustrated in the open position and the plurality of vanes or shutters 18 of the second or lower portion 22 are illustrated in the closed position, which may also be referred to a second operational position of the active grill shutter system 14. Here airflow illustrated by arrows 24 is allowed to pass through the vanes or shutters 18 of the first or upper portion 20 of the active grill shutter system 14 while the plurality of vanes or shutters 18 of the second or lower portion 22 block airflow.

[0049] In FIG. 2C the plurality of vanes or shutters 18 of the first or upper portion 20 of the active grill shutter system 14 are illustrated in the open position and the plurality of vanes or shutters 18 of the second or lower portion 22 are illustrated in the open position, which may also be referred to a third operational position of the active grill shutter system 14. Here airflow illustrated by arrows 24 is allowed to pass through the vanes or shutters 18 of the first or upper portion 20 of the active grill shutter system 14 and the plurality of vanes or shutters 18 of the second or lower portion 22 of the active grill shutter system 14. [0050] In FIG. 2D the plurality of vanes or shutters 18 of the first or upper portion 20 of the active grill shutter system 14 are illustrated in the closed position and the plurality of vanes or shutters 18 of the second or lower portion 22 are illustrated in the open position, which may also be referred to a fourth operational position of the active grill shutter system 14. Here airflow illustrated by arrows 24 is blocked by the vanes or shutters 18 of the first or upper portion 20 of the active grill shutter system 14 and airflow is allowed to pass through the plurality of vanes or shutters 18 of the second or lower portion 22 of the active grill shutter system 14.

[0051] FIG. 2E illustrates the plurality of vanes or shutters 18 of the first or upper portion 20 of the active grill shutter system 14 and the plurality of vanes or shutters 18 of the second or lower portion 22 in the closed position after movement from the fourth operational position, which is similar to the position illustrated in FIG. 2A.

[0052] Referring now to FIGS. 3-6B, a dual output actuator 26 completed for use with the active grill shutter system 14 is illustrated. The dual output actuator 26 has a housing 28 with a first lever 30 rotatably mounted to the housing 28 for movement about a first side 32 of the housing 28 and a second lever 34 rotatably mounted to a second side 36 of the housing 28. The second side 36 being opposite to the first side 32. In this embodiment, the first lever 30 and the second lever 34 are independently rotatable with respect to each other and the first lever 30 and the second lever 34 are rotatably mounted to the housing 28 for movement about the same axis 38. See at least FIG. 7.

[0053] In one non-limiting embodiment, the first lever 30 is operably coupled to the first or upper portion 20 of the active grill shutter system 14 such that movement of the first lever 30 will open and close the plurality of vanes or shutters 18 of the first or upper portion 20 as the first lever 30 moves about axis 38. The second lever 34 is operably coupled to the second or lower portion 22 of the active grill shutter system 14 such that movement of the second lever 34 will open and close the plurality of vanes or shutters 18 of the second or lower portion 20 as the second lever 34 moves about axis 38.

[0054] For example, the plurality of vanes or shutters 18 of the first or upper portion 20 are configured to move simultaneously through actuation of the first lever 30, which is a single lever operably coupled to the plurality of vanes or shutters 18 of the first or upper portion 20 by for example linkage and the plurality of vanes or shutters 18 of the second or lower portion 22, which comprise the remaining plurality of vanes or shutters 18 that are not in the first or upper portion 20, are configured to move simultaneously through actuation of the second lever 34, which is a single lever operably coupled to the plurality of vanes or shutters 18 of the second or lower portion 22 by for example linkage. [0055] In order to move the first lever 30 and the second lever 34 about axis 38, a gear 40 is rotatably mounted to the housing 28 of the dual output actuator 26. Gear 40 is operably coupled to a motor (not shown) in order to provide the desired rotation of gear 40. For example, the motor may be configured to drive a worm that meshingly engages gear teeth of the gear 40. In one embodiment, only a single motor is employed to provide the desired rotation of gear 40. By using a single motor the dual output actuator 26 is able to have a compact profile and reduces costs and associated weight.

[0056] The first lever 30 has an integral first output 42 that is configured to engage a first protrusion 44 of gear 40. As illustrated, the first lever 30 and the first output 42 are formed as a single piece such that rotation of the first output 42 causes rotation of the first lever 30. The second lever 34 has an integral second output 46 that is configured to engage a second protrusion 48 of gear 40. As illustrated, the second lever 34 and the second output 46 are formed as a single piece such that rotation of the second output 46 causes rotation of the second lever 34. Similar to the first lever 30 and the second lever 34, the first output 42 and the second output 46 are configured to rotate independently with respect to each other. As illustrated, the first protrusion 44 and the second protrusion 48 are located on opposite sides of the gear 40 and are placed in offsetting locations with respect to each other in order to provide the desired movements of the first lever 30 and the second lever 34 as well as the first or upper portion 20 and the second or lower portion 22 of the active grill shutter system 14, which are operably coupled to the first lever 30 and the second lever 34.

[0057] The offsetting locations of the first protrusion 44 and the second protrusion 48 may be defined as offsetting angular rotational angles as defined from the first operational position illustrated in at least FIGS. 4A and 4B, or in other words the degrees of rotation required from the first operational position until the protrusions 44 and 48 engage the levers 30 and 34 in order to provide the desired movement of levers 30 and 34. These offsetting locations may be configured so that there is no simultaneous movement of levers 30 and 34 or they may be varied so that there is only no simultaneous movement of levers 30 and 34 for only a portion of the travel of levers 30 and 34. In other words, one embodiment contemplates some simultaneous movement of levers 30 and 34 only after a portion of non-simultaneous movement of levers 30 and 34 are absolutely no simultaneous movement of levers 30 and 34.

[0058] For example and in one non- limiting configuration, second lever 34 may not be pivotally moved until the first lever 30 has completed its pivotal movement and vice versa or alternatively and in another non- limiting configuration the second lever 34 may not be pivotally moved until the first lever 30 has completed a portion of its pivotal movement and vice versa. This will provide variations in the operational configurations provided to the active grill shutter system 14 by the dual output actuator 26. For example and in one configuration, all of the vanes or shutters 18 of the first or upper portion 20 or all of the vanes or shutters 18 second or lower portion 22 must completely move in their operational range before movement of all of the vanes or shutters 18 of the first or upper portion 20 or all of the vanes or shutters 18 second or lower portion 22.

[0059] Alternatively and in one non-limiting embodiment, there may be simultaneous movement of the vanes or shutters 18 of the first or upper portion 20 or all of the vanes or shutters 18 second or lower portion 22 but only after there is at least some portion of movement of the all of the vanes or shutters 18 of the first or upper portion 20 or at least some portion of movement of all of the vanes or shutters 18 second or lower portion 22 when there is no simultaneous movement of the other. The variations in the corresponding movements of the vanes or shutters 18 of the first or upper portion 20 and the second or lower portion 22 may be determined by variations in the offsetting locations or rotational angles of protrusions 40 and 48 with respect to each other.

[0060] As such, the sequence of movement between the first lever 30 and the second lever 34 can by adjusted by varying the dephasing angle between the first lever 30 and the second lever 34, which is achieved or defined by the locations of protrusions 40 and 48 with respect to each other.

[0061] Gear 40 also has a first raised portion 50 and a second raised portion 52. The first raised portion 50 and the second raised portion 52 are located on opposite sides of the gear 40.

[0062] The first raised portion 50 has a curved surface 54 that engages a complimentary curved surface 56 of the first output 42 of the first lever 30 as gear 40 rotates with respect to the housing 28. In addition, the first raised portion 50 has a reduced area 58 that is configured to allow for rotational movement of arm portions 60 and 62 of the first lever 30 as the first protrusion 44 is slidably received within a gap 64 defined by arm portions 60 and 62 of the first lever 30. This slidable movement of the first protrusion 44 in gap 64 allows for the desired rotational movement of the first lever 30 as the gear 40 rotates.

[0063] The second raised portion 52 has a curved surface 68 that engages a complimentary curved surface 70 of the second output 46 of the second lever 34 as gear 40 rotates with respect to the housing 28. In addition, the second raised portion 52 has a reduced area 72 that is configured to allow for rotational movement of arm portions 74 and 76 of the second lever 34 as the second protrusion 48 is slidably received within a gap 78 defined by arm portions 74 and 76 of the second lever 34. This slidable movement of the second protrusion 48 in gap 78 allows for the desired rotational movement of the second lever 34 as the gear 40 rotates.

[0064] FIG. 4A illustrates the first side 32 of the dual output actuator 26 when it is in the first operational position and FIG. 4B illustrates the second side 36 of the dual output actuator 26 when it is in the first operational position.

[0065] FIG. 5A illustrates the first side 32 of the dual output actuator 26 when it is in the second operational position and FIG. 5B illustrates the second side 36 of the dual output actuator 26 when it is in the second operational position. In this position, the gear 40 has rotated 90 degrees in the direction of arrows 80 and protrusion 44 has slidably engaged arms 60 and 62 as it slides within slot 64 causing first lever 30 to rotate while the second lever 34 remains in the same position as FIG. 4B. Since the first lever 30 is operably coupled to the plurality of vanes or shutters 18 of the first or upper portion 20 of the active grill shutter system 14, the active grill shutter system 14 will be in the configuration illustrated in FIG. 2B. Thus, the dual output actuator 26 of the active grill shutter system 14 allows for some of the plurality of vanes or shutters 18 to be opened while others are closed.

[0066] FIG. 6A illustrates the first side 32 of the dual output actuator 26 when it is in a third operational position after a second sequential operation in the directions of arrow 80 and FIG. 6B illustrates the second side 36 of the dual output actuator 26 when it is in the third operational position after this second sequential operation in the direction of arrow 80. In this position the gear 40 has rotated 180 degrees in the direction of arrows 80 from the position illustrated in FIGS. 3, 4 A and 4B and protrusion 48 has slidably engaged arms 74 and 76 as it slides within slot 78 causing the second lever 34 to rotate while the first lever 30 remains in the same position as FIG. 5A. Since the first lever 30 is operably coupled to the plurality of vanes or shutters 18 of the first or upper portion 20 of the active grill shutter system 14 and the second lever 34 is operably coupled to the plurality of vanes or shutters 18 of the second or lower portion 22, the active grill shutter system 14 will be in the configuration illustrated in FIG. 2C. Thus, the dual output actuator 26 of the active grill shutter system 14 allows for all of the plurality of vanes or shutters 18 to be opened when it is in this position.

[0067] Initial movement of the first lever 30 from the position illustrated in FIG. 4A and the second lever 34 from the position illustrated in FIG. 4B is provided by a large torque which is provided by a large gear reduction ratio of the actuator 26 when the protrusions 44 and 48 start engaging the beginning of the gaps 64, 78 which are located at the distal ends of arms 60 and 62 and arms 74 and 76 respectively, which are at the furthermost distance from the rotational axis of levers 30 and 34. The greater the distance at which the actuator torque is initially transmitted to the levers 30 and 34 with respect to the rotational axis of the first lever 130 and the second lever 134 increases the gear reduction ratio and thus the amount of torque initially applied to the levers 30 and 34. This large gear reduction ratio and/or torque is useful in order to break ice in a winter condition (e.g. when the vanes or shutters that are frozen shut due to the formation of ice on the active grill shutter system 14). Thereafter and as the protrusions 44 and 48 slide within their respective gaps 64 and 78 through rotation of gear 40 and levers 30 and 34, the gear reduction ratio and applied torque varies due to the variation of the distance of protrusions 44 and 48 within gaps 64 and 78 and with respect to the rotational axis of levers 30 and 34.

[0068] In order to achieve the configurations illustrated in FIGS. 2D and 2E rotation of the gear 40 in a direction opposite to arrows 80 for 90 degrees from the position in FIGS. 6A and 6B or 90 degrees from the position in FIGS. 3, 4A and 4B will cause the first lever 30 to return to the position illustrated in FIGS. 3, 4A and 4B due to protrusion 44 sliding within gap 64 which causes rotation of the first lever 30 so that the plurality of vanes or shutters 18 of the first or upper portion 20 of the active grill shutter system 14 are in the closed position. This rotation in the direction opposite to arrows 80 may be achieved by operating the motor operably coupled to gear 40 in an opposite direction. The plurality of vanes or shutters 18 of the second or lower portion 22 of the active grill shutter system 14 will remain in the open position since the second lever 34 does not move as the gear 40 rotates in the direction of opposite to arrows 80 for 90 degrees from the position in FIGS. 6 A and 6B or 90 degrees from the position in FIGS. 3, 4A and 4B. In other words, protrusion 48 does not slide within gap 78 during this rotational movement of gear 40. This configuration is also illustrated in FIG. 2D.

[0069] Continued rotation of the gear 40 in a direction opposite to arrows 80 from the position corresponding to the configuration illustrated in FIG. 2D for an additional 90 degrees or back to the position illustrated in FIGS. 3, 4A and 4B will cause the second lever 34 to return to the position illustrated in FIGS. 3, 4A and 4B since protrusion 48 slidably engages gap 78 so that the plurality of vanes or shutters 18 of the second or lower portion 22 of the active grill shutter system 14 are moved into the closed position. The plurality of vanes or shutters 18 of the first or upper portion 20 of the active grill shutter system 14 remain in the closed position since protrusion 44 does not slidably engage gap 64 and the first lever 30 does not move as the gear 40 rotates in a direction opposite to arrows 80 for 90 degrees from the position corresponding to FIG. 2D or back to the position illustrated in FIGS. 3, 4A and 4B.

[0070] FIG. 7 is an end view of the dual output actuator of FIG. 3, which illustrates that first lever 30 and the second lever 34 are rotationally secured to the housing 28 for movement about the same axis 38.

[0071] FIG. 8 is a perspective view of a dual output actuator 126 completed for use with an active grill shutter system 14 in accordance another embodiment of the present disclosure. The dual output actuator 126 has a housing 128 with a first lever 130 rotatably mounted to the housing 128 for movement about a first side 132 of the housing 128 and a second lever 134 rotatably mounted to the first side 132 of the housing 128. In this embodiment, the first lever 130 and the second lever 134 are independently rotatable with respect to each other and the first lever 130 and the second lever 134 are rotatably mounted to the housing 128 for movement about different axes 138 and 139. See at least FIG. 14.

[0072] In one non- limiting embodiment, the first lever 130 is operably coupled to the first or upper portion 20 of the active grill shutter system 14 such that movement of the first lever 130 will open and close the plurality of vanes or shutters 18 of the first or upper portion 20 as the first lever 130 moves about axis 138. The second lever 134 is operably coupled to the second or lower portion 22 of the active grill shutter system 14 such that movement of the second lever 134 will open and close the plurality of vanes or shutters 18 of the second or lower portion 20 as the second lever 134 moves about axis 139.

[0073] For example, the plurality of vanes or shutters 18 of the first or upper portion 20 are configured to move simultaneously through actuation of the first lever 130, which is a single lever operably coupled to the plurality of vanes or shutters 18 of the first or upper portion 20 by for example linkage and the plurality of vanes or shutters 18 of the second or lower portion 22, which comprise the remaining plurality of vanes or shutters 18 that are not in the first or upper portion 20, are configured to move simultaneously through actuation of the second lever 134, which is a single lever operably coupled to the plurality of vanes or shutters 18 of the second or lower portion 22 by for example linkage.

[0074] In order to move the first lever 130 and the second lever 134 about axes 138 and 139, a first gear 140 and a second gear 141 are rotatably mounted to the housing 28 of the dual output actuator 26. First gear 140 is operably coupled to a motor (not shown) in order to provide the desired rotation of first gear 140 and second gear 141. For example, the motor may be configured to drive a worm that meshingly engages gear teeth of the first gear 140 and the first gear 140 meshingly engages the second gear 141 such that rotation of the first gear 140 will also cause rotation of the second gear 141. In one embodiment, only a single motor is employed to provide the desired rotation of gears 140 and 141. By using a single motor the dual output actuator 126 is able to have a compact profile and reduces costs and associated weight. [0075] The first lever 130 has an integral first output 142 that is configured to engage a first protrusion 144 of first gear 140. As illustrated, the first lever 130 and the first output 142 are formed as a single piece such that rotation of the first output 142 causes rotation of the first lever 130. The second lever 134 has an integral second output 146 that is configured to engage a second protrusion 148 of the second gear 141. As illustrated, the second lever 134 and the second output 146 are formed as a single piece such that rotation of the second output 146 causes rotation of the second lever 134. Similar to the first lever 130 and the second lever 134, the first output 142 and the second output 146 are configured to rotate independently with respect to each other. As illustrated, the first protrusion 144 is located on the first gear 140 and the second protrusion 148 is located on the second gear 141, the first protrusion and the second protrusion are located in offsetting locations with respect to each other in order to provide the desired movements of the first lever 130 and the second lever 134 as well as the first or upper portion 20 and the second or lower portion 22 of the active grill shutter system 14, which are operably coupled to the first lever 130 and the second lever 134. First gear 140 also has a first raised portion 150 and second gear 141 has a second raised portion 152.

[0076] As mentioned above and with regard to the embodiment depicted in at least FIGS. 3-6B, pivotal movement of the first lever 130 and the second lever 134 will depend on the locations of protrusions 144 and 148 and their locations can be varied such that second lever 134 may not be pivotally moved until the first lever 130 has completed its pivotal movement and vice versa or alternatively and in another non limiting configuration the second lever 134 may not be pivotally moved until the first lever 130 has completed a portion of its pivotal movement and vice versa. This will provide variations in the operational configurations provided to the active grill shutter system 14 by the dual output actuator 26. For example and in one configuration, all of the vanes or shutters 18 of the first or upper portion 20 or all of the vanes or shutters 18 second or lower portion 22 must completely move in their operational range before movement of all of the vanes or shutters 18 of the first or upper portion 20 or all of the vanes or shutters 18 second or lower portion 22. [0077] Alternatively and in one non-limiting embodiment, there may be simultaneous movement of the vanes or shutters 18 of the first or upper portion 20 or all of the vanes or shutters 18 second or lower portion 22 but only after there is at least some portion of movement of the all of the vanes or shutters 18 of the first or upper portion 20 or at least some portion of movement of all of the vanes or shutters 18 second or lower portion 22 when there is no simultaneous movement of the other. The variations in the corresponding movements of the vanes or shutters 18 of the first or upper portion 20 and the second or lower portion 22 may be determined by variations in the offsetting locations or rotational angles of protrusions 140 and 148 with respect to each other and the first lever 130 and the second lever 134.

[0078] As such, the sequence of movement between the first lever 130 and the second lever 134 can by adjusted by varying the dephasing angle between the first lever 130 and the second lever 134, which is achieved or defined by the locations of protrusions 140 and 148 with respect to each other.

[0079] The first raised portion 150 has a pair of curved surfaces 154 that engage some of a plurality of complimentary curved surfaces 156 of the first output 142 of the first lever 130 as gear 140 rotates with respect to the housing 128. In addition, the first raised portion 150 has a reduced areas 158 that are configured to allow for rotational movement of arm portions 160 and 162 of the first lever 130 as the first protrusion 144 is slidably received within a gap 164 defined by arm portions 160 and 162 of the first lever 130. This slidable movement of the first protrusion 144 in gap 164 allows for the desired rotational movement of the first lever 130 as the gear 140 rotates.

[0080] The second raised portion 152 of the second gear 141 has a pair of curved surfaces 168 that engage some of a plurality of complimentary curved surfaces 170 of the second output 146 of the second lever 134 as gear 141 rotates with respect to the housing 128. In addition, the second raised portion 152 has reduced areas 172 that are configured to allow for rotational movement of arm portions 174 and 176 of the second lever 134 as the second protrusion 148 is slidably received within a gap 178 defined by arm portions 174 and 176 of the second lever 134. This slidable movement of the second protrusion 148 in gap 178 allows for the desired rotational movement of the second lever 134 as the gear 141 rotates.

[0081] It is also understood that the complimentary curved surfaces 156 of the first output 142 of the first lever 130 will engage some of the complimentary curved surfaces 170 of the second output 146 as gear 140 rotates with respect to the housing 128. In addition, is also understood that the complimentary curved surfaces 168 of the second output 146 of the second lever 134 will engage some of the complimentary curved surfaces 156 of the first output 142 as gear 141 rotates with respect to the housing 128. FIG. 9 illustrates a first side 132 of the dual output actuator 126 when it is in the first operational position, which corresponds to the positions of the plurality of vanes or shutters 18 of the first or upper portion 20 and the second or lower portion 22 of the active grill shutter system 14 illustrated in FIG. 2A.

[0082] FIG. 10 illustrates the first side 132 of the dual output actuator 126 when it is in the second operational position. In this position, the gears 140 and 141 have rotated 90 degrees in the direction of arrows 80 and protrusion 144 has slidably engaged arms 160 and 162 as it slides within slot 164 causing first lever 130 to rotate while the second lever 134 remains in the same position as FIG. 9. Since the first lever 130 is operably coupled to the plurality of vanes or shutters 18 of the first or upper portion 20 of the active grill shutter system 14, the active grill shutter system 14 will be in the configuration illustrated in FIG. 2B. Thus, the dual output actuator 126 of the active grill shutter system 14 allows for some of the plurality of vanes or shutters 18 to be opened while others are closed.

[0083] FIG. 11 illustrates the first side 132 of the dual output actuator 126 when it is in a third operational position. In this position, the gears 140 and 141 have rotated 180 degrees in the direction of arrows 80 from the position illustrated in FIGS. 8 and 9 and protrusion 148 has slidably engaged arms 174 and 176 as it slides within slot 178 causing the second lever 134 to rotate while the first lever 130 remains in the same position as FIG. 10. Since the first lever 130 is operably coupled to the plurality of vanes or shutters 18 of the first or upper portion 20 of the active grill shutter system 14 and the second lever 34 is operably coupled to the plurality of vanes or shutters 18 of the second or lower portion 22, the active grill shutter system 14 will be in the configuration illustrated in FIG. 2C. Thus, the dual output actuator 126 of the active grill shutter system 14 allows for all of the plurality of vanes or shutters 18 to be opened when it is in this position.

[0084] Initial movement of the first lever 130 from the position illustrated in FIGS. 8 and 9 and movement of the second lever 134 from the position illustrated in FIGS. 8 and 9 is provided by a large torque which is provided by a large gear reduction ratio of the actuator 126 when the protrusions 144 and 148 start engaging the beginning of the gaps 164 and 178, which are located at the distal ends of arms 160 and 162 and 174 and 176, which are at the furthermost distance from the rotational axis of levers 130 and 134. The greater the distance at which the actuator torque is initially transmitted to the levers 130 and 134 with respect to the rotational axis of levers 130 and 134 increases the gear reduction ratio and thus the amount of torque initially applied to the levers 130 and 134. This large gear reduction ratio and/or torque is useful in order to break ice in a winter condition (e.g. when the vanes or shutters that are frozen shut due to the formation of ice on the active grill shutter system 14). Thereafter and as the protrusions 144 and 148 slide within their respective gaps 164 and 178 through rotation of gears 140, 141 and levers 130 and 134, the gear reduction ratio and applied torque varies due to the variation of the distance of protrusions 144 and 148 within gaps 164 and 178 and with respect to the rotational axis of levers 130 and 134.

[0085] FIG. 12 illustrates a fourth operational position of actuator 126 wherein the gears 140 and 141 have rotated in the direction of arrows 80 for an additional 90 degrees from the position in FIG. 11 or 270 degrees from the position in FIGS. 8 and 9. This will cause the first lever 130 to return to the position illustrated in FIGS. 8 and 9 due to the first protrusion 144 sliding within gap 164 which causes rotation of the first lever 130 so that the plurality of vanes or shutters 18 of the first or upper portion 20 of the active grill shutter system 14 are in the closed position. The plurality of vanes or shutters 18 of the second or lower portion 22 of the active grill shutter system 14 remain in the open position since the second lever 34 does not move as the gear 141 rotates in the direction of arrows 80 for an additional 90 degrees from the position in FIG. 11 or 270 degrees from the position in FIGS. 8 and 9. In other words, protrusion 148 does not slide within gap 178 during this rotational movement of gear 141. This configuration is also illustrated in FIG. 2D.

[0086] FIG. 13 illustrates continued rotation of the gears 140 and 141 in the direction of arrows 80 from the position corresponding to the configuration illustrated in FIG. 2D and FIG. 12 for an additional 90 degrees or 360 degrees from the position illustrated in FIGS. 8 and 9, which will cause the second lever 134 to return to the position illustrated in FIGS. 8 and 9 since protrusion 148 slidably engages gap 178 so that the plurality of vanes or shutters 18 of the second or lower portion 22 of the active grill shutter system 14 are moved into the closed position. The plurality of vanes or shutters 18 of the first or upper portion 20 of the active grill shutter system 14 remain in the closed position since protrusion 144 does not slidably engage gap 164 and the first lever 130 does not move as the gears 140 and 141 rotate in the direction of arrows 80 for an additional 90 degrees from the position corresponding to FIG. 2D and FIG. 12 or 360 degrees from the position in FIGS. 8 and 9. [0087] FIG. 14 is an end view of the dual output actuator of FIGS. 8-13, which illustrates that first lever 130 and the second lever 134 are rotationally secured to the housing 128 for movement about the different axes 138 and 139.

[0088] FIG. 15 is an end view of a dual output actuator 226 completed for use with an active grill shutter system 14 in accordance yet another embodiment of the present disclosure.

[0089] In this embodiment, a first lever 230 is rotatably mounted to a first side 232 of a housing 228 of the dual output actuator 226 and a second lever 234 is rotatably mounted to a second side 236 of a housing 228 of the dual output actuator 226. In this embodiment, the first lever 230 and the second lever 234 are independently rotatable with respect to each other and the first lever 230 and the second lever 234 are rotatably mounted to the housing 228 for movement about different axes 238 and 239.

[0090] In one non-limiting embodiment, the first lever 230 is operably coupled to the first or upper portion 20 of the active grill shutter system 14 such that movement of the first lever 230 will open and close the plurality of vanes or shutters 18 of the first or upper portion 20 as the first lever 230 moves about axis 238. The second lever 234 is operably coupled to the second or lower portion 22 of the active grill shutter system 14 such that movement of the second lever 234 will open and close the plurality of vanes or shutters 18 of the second or lower portion 20 as the second lever 30 moves about axis 239.

[0091] In order to move the first lever 230 and the second lever 234 about axes 238 and 239 gears 240 and 241 are rotatably mounted to the housing 228 of the dual output actuator 226. Gears 240 and 241 are operably coupled to a motor (not shown) in order to provide the desired rotation of gears 240 and 241. For example, the motor may be configured to drive a worm that meshingly engages gear teeth of the gears 240 and 241. In one embodiment, only a single motor is employed to provide the desired rotation of gears 240 and 241. By using a single motor the dual output actuator 226 is able to have a compact profile and reduces costs and associated weight.

[0092] Accordingly, various embodiments of the present disclosure provide a dual output actuator capable of providing multi sequential operations including following features: providing four sequential independent movements on a dual output actuator with only one motor; keeping the vanes or shutters 18 of the active grill shutter system 14 in an controlled position mechanically; providing a larger torque at an initial operation of the active grill shutter system 14, which may be necessary to break ice in a winter condition (e.g. vanes or shutters that are frozen shut); provide this mechanical solution inside of the actuator housing; provide precise and independent operation and angle range for each output: for example, a first quarter angular range to open a 1st output, a second quarter angular range to open another or 2^nd output, a third quarter angular range to close the 1st output, and a fourth angular range to close the 2nd output; providing a choice to open upper or lower vanes at first independently according to the requirement to increase a radiator's efficiency or reduce aerodynamic resistance to the vehicle.

[0093] The term “about” is intended to include the degree of error associated with measurement of the particular quantity based upon the equipment available at the time of filing the application. For example, “about” can include a range of ± 8% or 5%, or 2% of a given value.

[0094] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the present disclosure. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, element components, and/or groups thereof.

[0095] While the present disclosure has been described with reference to an exemplary embodiment or embodiments, it will be understood by those skilled 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 disclosure. In addition, 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 disclosure not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this present disclosure, but that the present disclosure will include all embodiments falling within the scope of the claims.

Claims

What is claimed is:

1. A dual output actuator (26) for use with an active grill shutter system (14), comprising: a housing (28) with a first lever (30) rotatably mounted to the housing (28) for movement about a first side (32) of the housing (28); and a second lever (34) rotatably mounted to the housing (28), the first lever (30) and the second lever (34) being independently rotatable with respect to each other, the actuator (26) being configured to partially or fully move the first lever (30) between a first position and a second position without a corresponding simultaneous movement of the second lever (34) and the actuator (26) is configured to partially or fully move the second lever (34) between a first position and a second position without a corresponding simultaneous movement of the first lever (30).

2. The dual output actuator (26) as in claim 1, wherein the first lever (30) and the second lever (34) are rotatably mounted to opposite sides of the housing (28) for movement about a same axis (38).

3. The dual output actuator (26) as in claim 1, wherein the first lever (30) is operably coupled to a first or upper portion (20) of the active grill shutter system (14) such that movement of the first lever (30) will partially or fully open and close a plurality of vanes or shutters (18) of the first or upper portion (20) as the first lever (30) partially or fully moves between the first position and the second position and the second lever (34) is operably coupled to a second or lower portion (22) of the active grill shutter system (14) such that movement of the second lever (34) will partially or fully open and close a plurality of vanes or shutters (18) of the second or lower portion (22) as the second lever (30) partially or fully moves between the first position and the second position.

4. The dual output actuator (26) as in claim 1, wherein the first lever (30) and the second lever (34) are operably coupled to a gear (40) rotatably mounted to the housing (28).

5. The dual output actuator (26) as in claim 4, wherein the first lever (30) has an integral first output (42) that is configured to engage a first protrusion (44) of the gear (40) and the second lever (34) has an integral second output (46) that is configured to engage a second protrusion (48), wherein the first protrusion (44) and the second protrusion (48) are located on opposite sides of the gear (40) and the first protrusion (44) and the second protrusion (48) are placed in offsetting locations with respect to each other.

6. The dual output actuator (26) as in claim 5, wherein the gear (40) has a first raised portion (50) and a second raised portion (52), the first raised portion (50) and the second raised portion (52) are located on opposite sides of the gear (40).

7. The dual output actuator (26) as in claim 6, wherein the first raised portion (50) has a curved surface (54) that engages a complimentary curved surface (56) of the first output (42) of the first lever (30) as the gear (40) rotates with respect to the housing (28) and the first raised portion (50) has a reduced area (58) that is configured to allow for rotational movement of arm portions (60) and (62) of the first lever (30) as the first protrusion (44) is slidably received within a gap (64) defined by arm portions (60) and (62) of the first lever (30).

8. The dual output actuator (26) as in claim 7, wherein the second raised portion (52) has a curved surface (68) that engages a complimentary curved surface (70) of the second output (46) of the second lever (34) as the gear (40) rotates with respect to the housing (28) and the second raised portion (52) has a reduced area (72) that is configured to allow for rotational movement of arm portions (74) and (76) of the second lever (34) as the second protrusion (48) is slidably received within a gap (78) defined by arm portions (74) and (76) of the second lever (34).

9. The dual output actuator (26) as in claim 1, wherein the first lever (130) and the second lever (134) are rotatably mounted to the first side (132) of the housing (128) for movement about different axes (138, 139).

10. The dual output actuator (26) as in claim 9, wherein the first lever (130) is operably coupled to a first or upper portion (20) of the active grill shutter system (14) such that movement of the first lever (130) will open and close a plurality of vanes or shutters (18) of the first or upper portion (20) as the first lever (130) moves between the first position and the second position and the second lever (134) is operably coupled to a second or lower portion (22) of the active grill shutter system (14) such that movement of the second lever (134) will open and close a plurality of vanes or shutters (18) of the second or lower portion (22) as the second lever (130) moves between the first position and the second position.

11. The dual output actuator (26) as in claim 10, wherein the first lever (130) is operably coupled to a first gear (140) and the second lever (134) is operably coupled to a second gear (141).

12. The dual output actuator (26) as in claim 11 , wherein the first lever (130) has an integral first output (142) that is configured to engage a first protrusion (144) of the first gear (140) and the second lever (134) has an integral second output (146) that is configured to engage a second protrusion (148) of the second gear (141), wherein the first protrusion (144) and the second protrusion (148) are placed in offsetting locations with respect to each other.

13. The dual output actuator (26) as in claim 12, wherein the first gear (140) has a first raised portion (150) and the second gear (141) has a second raised portion (152), the first raised portion (150) having a pair of curved surfaces (154) that engage complimentary curved surfaces (156) of the first output (142) of the first lever (130) as gear (140) rotates with respect to the housing (128) and the first raised portion (150) has a reduced areas (158) that are configured to allow for rotational movement of arm portions (160) and (162) of the first lever (130) as the first protrusion (144) is slidably received within a gap (164) defined by arm portions (160) and (162) of the first lever (130) and the second raised portion (152) of the second gear (141) has a pair of curved surfaces (168) that engage complimentary curved surfaces (170) of the second output (146) of the second lever (134) as the second gear (141) rotates with respect to the housing (128), the second raised portion (152) having reduced areas (172) that are configured to allow for rotational movement of arm portions (174) and (176) of the second lever (134) as the second protrusion (148) is slidably received within a gap (178) defined by arm portions (174) and (176) of the second lever (134).

14. The dual output actuator (26) as in claim 13, wherein the first gear (140) is configured to meshingly engage the second gear (141).

15. The dual output actuator (26) as in claim 11, wherein the first gear (140) is configured to meshingly engage the second gear (141).

16. The dual output actuator (26) as in claim 1, wherein the first lever (30) and the second lever (34) are rotatably mounted to opposite sides of the housing (28) for movement about different axes (238) and (239).

17. The dual output actuator (26) as in claim 16, wherein the first lever (230) is operably coupled to a first gear (240) rotatably mounted to the housing (228) of the dual output actuator (226) and the second lever (234) is operably coupled to a second gear (241).

18. The dual output actuator (26) as in claim 17, wherein the first gear (240) is configured to meshingly engage the second gear (241).

19. A method for operating a dual output actuator (26) of an active grill shutter system (14), comprising: rotatably mounting a first lever (30) to a housing (28) of the dual output actuator (26) for movement about a first side (32) of the housing (28); rotatably mounting a second lever (34) to the housing (28), wherein the first lever (30) and the second lever (34) are independently rotatable with respect to each other; moving the first lever (30) between a first position and a second position without a corresponding movement of the second lever (34); and moving the second lever (34) between a first position and a second position without a corresponding movement of the first lever (30).

20. The dual output actuator (26) as in claim 1, wherein the first lever (30) and the second lever (34) are rotatably mounted to opposite sides of the housing (28) for movement about a same axis (38).