WO2024040452A1

WO2024040452A1 - Actuator with inbuilt automatic synchronization of feedback potentiometer and manually adjustable auxiliary switch switchpoint

Info

Publication number: WO2024040452A1
Application number: PCT/CN2022/114412
Authority: WO
Inventors: Haiming Chen; Jian Zhang; Shuwei JIN; Tao Hu; Yun Zhi LIU; Jason L ABLEITNER
Original assignee: Honeywell International Inc.
Priority date: 2022-08-24
Filing date: 2022-08-24
Publication date: 2024-02-29

Abstract

A modular actuator (10) may include a modular actuator base assembly (12) and a modular control assembly (14). Each of the modular actuator base assembly (12) and the modular control assembly (14) may be selected from a plurality of different modular actuator base assemblies (12), and a plurality of different modular control assemblies (14) in order to provide an appropriate functionality for a particular application. One or more of the modular actuator base assembly (12) and the modular control assembly (14) may be field-replaceable, in order to provide additional functionality to an installed modular actuator. The modular control assembly (14) may be configured to allow for adjusting the auxiliary switch switchpoint, The modular control assembly (14) may be configured to automatically synchronize the feedback potentiometer.

Description

ACTUATOR WITH INBUILT AUTOMATIC SYNCHRONIZATION OF FEEDBACK POTENTIOMETER AND MANUALLY ADJUSTABLE AUXILIARY SWITCH SWITCHPOINT

Technical Field

The present disclosure pertains generally to actuators and more particularly to actuators for use in building automation systems.

Background

Actuators are used in a number of different applications that potentially require significant differences in design, such as motor size, motor torque, gear train reduction gearing, and/or actuator output type (e.g. linear or rotary) . Actuators can also have differences in how a particular actuator is controlled. For example, some actuator controllers are configured to provide additional functionality beyond simply opening or closing a valve or damper. Some actuator controllers simply receive control commands and control the actuator according to the received control commands. Some actuator controllers are configured to receive one or more sensor inputs and control the actuator in accordance with the one or more sensor inputs. Some actuator controllers are configured to provide communications capability with one or more communication networks.

In some cases, an actuator controller may include control features such as a feedback potentiometer and/or an auxiliary switch. When provided, a feedback potentiometer may report the current position of the actuator to the actuator controller. The actuator controller may then control the actuator base at least in part on the current position of the actuator. When provided, an auxiliary switch may switch at a switchpoint along the operating stroke of the actuator. The auxiliary switch may provide a control signal to control one or more auxiliary components, such as a fan, another actuator or other auxiliary component. These are just examples.

Providing actuators that are customized for a particular application can mean needing a large number of different actuator SKU’s that vary by, for example, motor size, motor torque, gear train performance, actuator output type, control features and/or communication capability. As control systems are modernized, this can require actuator replacement when the existing actuator does not have the necessary functionality. One approach for reducing the number of required SKU’s would be to provide a modular actuator design. However, modular actuators may create difficulties, such as difficulties in adjusting an auxiliary switch switchpoint and/or synchronizing a feedback potentiometer with a known position of the actuator. What would be beneficial are improved modular actuators that can be assembled, sometimes in the field, from combinations of modular components. What would be beneficial are improved modular actuators that can be upgraded in the field by simply replacing one or more modules to provide desired or upgraded functionality. What would be beneficial are improved modular actuators that are configured to provide improved control features control such as adjustment of an auxiliary switch switchpoint and/or synchronization of a feedback potentiometer of the modular actuator.

Summary

This disclosure relates generally to actuators and more particularly to actuators for use in building automation systems. An example may be found in an actuator having an actuator output that is movable along an output stroke between a first end stop and an opposing second end stop. The actuator also includes a driver assembly for driving the actuator output along the output stroke. The driver assembly includes an electric motor and one or more gears. A controller is operatively coupled to the driver assembly for controlling the electric motor to drive the actuator output to a desired position along the output stroke. In this example, a feedback potentiometer assembly is configured to provide to the controller a measure that indicates a current position of the actuator output along the output stroke. A feedback clutch assembly is operatively coupled between the feedback potentiometer assembly and the driver assembly, wherein the feedback clutch assembly is configured to slip once the feedback potentiometer assembly engages a feedback potentiometer stop, and continues to slip as the driver assembly continues to drive the actuator output to the first stroke end stop. This self-synchronizes the feedback potentiometer assembly with the actuator output at the first stroke end stop. In this example, the actuator includes an auxiliary switch with a first terminal and a second terminal, an auxiliary switch cam assembly that is configured to switch the auxiliary switch when the current position of the actuator output reaches a desired auxiliary switch position along the output stroke of the actuator output, and an auxiliary switch clutch assembly that is operatively coupled between the auxiliary switch cam assembly and the driver assembly. The auxiliary switch clutch assembly is configured to slip when the auxiliary switch cam assembly is manually moved by a user to set the desired auxiliary switch position of the auxiliary switch cam assembly along the output stroke of the actuator output.

Another example may be found in a modular actuator that includes a modular actuator base assembly and a modular control assembly that is field-attachable to the modular actuator base assembly. The modular actuator base assembly includes a modular actuator base housing and an electric motor that is operatively coupled to a gear train, wherein the gear train includes two or more reduction gears for driving an actuator output. In this example, the electric motor and the gear train are carried by the modular actuator base housing. The modular control assembly includes a control assembly housing and an auxiliary switch with a first terminal and a second terminal. A user adjustable auxiliary switch cam is configured to be operatively coupled to the gear train once the modular control assembly has been field-attached to the modular actuator base assembly. The user adjustable auxiliary switch cam is configured to switch the auxiliary switch when a current position of the actuator output reaches a desired auxiliary switch position. An auxiliary switch clutch assembly is operatively coupled between the user adjustable auxiliary switch cam and the gear train once the modular control assembly has been field-attached to the modular actuator base assembly, wherein the auxiliary switch clutch assembly is configured to slip when the user adjustable auxiliary switch cam is manually moved by a user to set the desired auxiliary switch position of the user adjustable auxiliary switch cam. A feedback potentiometer assembly is configured to be operatively coupled to the gear train once the modular control assembly has been field-attached to the modular actuator base assembly, the feedback potentiometer assembly configured to provide a measure that indicates the current position of the actuator output. A feedback clutch assembly is operatively coupled between the feedback potentiometer assembly and the gear train once the modular control assembly has been field-attached to the modular actuator base assembly, wherein the feedback clutch assembly is configured to slip once the feedback potentiometer assembly engages a feedback potentiometer stop, and continues to slip as the modular actuator base assembly continues to drive the actuator output to an end stop position, which self-synchronizes the feedback potentiometer assembly with the actuator output at the end stop position. A controller is carried by the control assembly housing and is operably coupled with the feedback potentiometer assembly in order to inform the controller of the current position of the gear train (and thus the output position of the actuator) . The controller is configured to control the electric motor of the modular actuator base assembly, and thus control the actuator output through the gear train in accordance with the informed current position of the gear train.

Another example may be found in a modular control assembly that is field-attachable to a modular actuator base assembly. The modular actuator base assembly includes a modular actuator base housing, an electric motor operatively coupled to a gear train that includes two or more reduction gears for driving an actuator output of the modular actuator base assembly. The modular control assembly includes a control assembly housing and an auxiliary switch with a first terminal and a second terminal. A user adjustable auxiliary switch cam assembly is configured to be operatively coupled to the gear train once the modular control assembly has been field-attached to the modular actuator base assembly. The user adjustable auxiliary switch cam assembly is configured to switch the auxiliary switch when a current position of the actuator output reaches a desired auxiliary switch position, wherein the desired auxiliary switch position is adjustable by a user. A feedback potentiometer assembly is configured to be operatively coupled to the gear train once the modular control assembly has been field-attached to the modular actuator base assembly. The feedback potentiometer assembly is configured to provide a measure that indicates the current position of the actuator output, and is further configured to self-synchronize the feedback potentiometer assembly with the actuator output. A controller is carried by the control assembly housing and operably coupled with the feedback potentiometer assembly in order to inform the controller of the current position of the gear train. The controller is configured to control the electric motor of the modular actuator base assembly, and thus control the actuator output through the gear train in accordance with the informed current position of the gear train.

The preceding summary is provided to facilitate an understanding of some of the features of the present disclosure and is not intended to be a full description. A full appreciation of the disclosure can be gained by taking the entire specification, claims, drawings, and abstract as a whole.

Brief Description of the Drawings

The disclosure may be more completely understood in consideration of the following description of various illustrative embodiments of the disclosure in connection with the accompanying drawings, in which:

Figure 1 is a schematic block diagram of an illustrative modular actuator;

Figure 2 is a schematic block diagram of an illustrative modular actuator base assembly forming part of the illustrative modular actuator of Figure 1

Figure 3 is a schematic block diagram of an illustrative modular control assembly forming part of the illustrative modular actuator of Figure 1;

Figure 4 is a schematic block diagram of a plurality of illustrative modular actuator base assemblies and a plurality of illustrative modular control assemblies that may be combined in a variety of different combinations in forming the illustrative modular actuator of Figure 1;

Figure 5 is a perspective view of an illustrative modular actuator;

Figures 6 through 12 are perspective views of various portions of the illustrative modular actuator of Figure 5;

Figure 13 is a perspective view of an illustrative modular actuator; and

Figures 14 through 18 are perspective views of various portions of the illustrative modular actuator of Figure 5.

While the disclosure is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit aspects of the disclosure to the particular illustrative embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the disclosure.

Description

The following description should be read with reference to the drawings wherein like reference numerals indicate like elements. The drawings, which are not necessarily to scale, are not intended to limit the scope of the disclosure. In some of the figures, elements not believed necessary to an understanding of relationships among illustrated components may have been omitted for clarity.

All numbers are herein assumed to be modified by the term “about” , unless the content clearly dictates otherwise. The recitation of numerical ranges by endpoints includes all numbers subsumed within that range (e.g., 1 to 5 includes 1, 1.5, 2, 2.75, 3, 3.80, 4, and 5) .

As used in this specification and the appended claims, the singular forms “a” , “an” , and “the” include the plural referents unless the content clearly dictates otherwise. As used in this specification and the appended claims, the term “or” is generally employed in its sense including “and/or” unless the content clearly dictates otherwise.

It is noted that references in the specification to "an embodiment" , "some embodiments" , "other embodiments" , etc., indicate that the embodiment described may include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with an embodiment, it is contemplated that the feature, structure, or characteristic may be applied to other embodiments whether or not explicitly described unless clearly stated to the contrary.

Figure 1 is a schematic block diagram of an illustrative modular actuator 10. The illustrative modular actuator 10 may be considered as representing an actuator that may be used to open or close a damper in a Heating, Ventilating and Air Conditioning (HVAC) system, for example. The illustrative modular actuator 10 may be considered as representing an actuator that may be used to open or close a water valve, for example. The illustrative modular actuator 10 may be considered as representing an actuator that may be used to control one or more components of an industrial process. In some cases, the modular actuator 10 may represent a rotary actuator. The modular actuator 10 may represent a linear actuator. These are just examples.

The illustrative modular actuator 10 includes several components that may each be chosen from multiple options for that component. The illustrative modular actuator 10 includes a modular actuator base assembly 12 that in some cases may be selected from two, three, four, or more different modular actuator base assemblies 12. The illustrative modular actuator 10 further includes a modular control assembly 14 that in some cases may be selected from two, three, four or more different modular control assemblies 14. Further details regarding the modular actuator base assembly 12 and the modular control assembly 14 are shown in Figures 2 and 3, respectively.

Figure 2 is a schematic block diagram of the illustrative modular actuator base assembly 12. The illustrative modular actuator base assembly 12 includes an electric motor 16 that is operably coupled to a gear train 18. The gear train 18 includes two or more reduction gears 20 that are configured to provide a decreased speed but increased torque relative to the speed and torque that is generated by the electric motor 16 itself. In some cases, the gear train 18 may include only one gear, for example. The gear train 18 is configured to drive an actuator output 22. A modular actuator base housing 24 houses the electric motor 16 and the gear train 18. The actuator output 22 may be at least partially exposed by the modular actuator base housing 24 such that the actuator output 22 may be able to engage and drive another component (e.g. damper or valve shaft) . The modular actuator base assembly 12 may, as shown, include one or more circuit elements 26 that may be used to store information that describes one or more features or aspects of the modular actuator base assembly 12 that may be accessed by another component of the modular actuator 10 in order to provide the other component with the information. In some cases, the one or more circuit elements 26 may include one or more resistors. The one or more circuit elements 26 may include one or more non-volatile memories. The component information may include, for example, maximum motor current allowed, maximum torque, maximum range of motion, maximum operating speed, type of output (rotary, linear) , type and number of sensor outputs (e.g. end stop detection, position detection, power draw, diagnostic information, etc. ) , type (s) of communication protocols, type (s) of commands that can be received executed, type (s) of control algorithms that can be executed, type (s) of feedback provided, as well as any other suitable component information.

In some cases, the modular actuator base assembly 12 may be available in multiple sizes, such as a small size, a medium size and a large size. This is merely illustrative, as the modular actuator base assembly 12 may have only one size or two sizes, or may have four, five, six or more different sizes. Each of the sizes may have a particular electric motor 16, with unique power properties such as maximum torque, maximum operating speed or varying power consumption. The electric motor 16 within a large size modular actuator base assembly 12 may be larger, or have more available torque, than the corresponding electric motor 16 within a medium size modular actuator base assembly 12. The electric motor 16 within a medium size modular actuator base assembly 12 may be larger, or have more available torque, than the corresponding electric motor 16 within a small size modular actuator base assembly 12.

Similarly, the gear train 18 may be different within each of the small modular actuator base assembly 12, the medium modular actuator base assembly 12 and the large modular actuator base assembly 12. The gear train 18 within each of the small modular actuator base assembly 12, the medium modular actuator base assembly 12 and the large modular actuator base assembly 12 may have different gearing, with differing reduction gears 20. The gear train 18 within some of the small modular actuator base assembly 12, the medium modular actuator base assembly 12 and the large modular actuator base assembly 12 may have differing numbers of gears, for example. It will be appreciated that for a particular gear reduction between an input to the gear train 18 and an output of the gear train 18 (such as the actuator output 22) may be accomplished by any of a variety of different combinations of gears, gear sizes, number of teeth on each gear, and so on.

Figure 3 is a schematic block diagram of the illustrative modular control assembly 14. The illustrative modular control assembly 14 includes a controller 28 that is operably coupled with an I/O port 30. The I/O port 30 may be used, for example, to receive configuration or settings information from the one or more circuit elements 26 within the modular actuator base assembly 12, when present. In some cases, resistance varies with torque, and the modular control assembly 14 may be configured to determine the torque of the modular actuator base assembly 12 by sampling a resistance value. In addition, or alternatively, the I/O port 30 may be used to receive operational commands from a system employing the modular actuator 10, such as a Building Management System (BMS) for example. The I/O port 30 may operate in accordance with any desired wired or wireless communication protocol. For example, the I/O port 30 may utilize Bluetooth wireless communication. This is just an example. The I/O port 30 may also be used to connect to a controller (when present) and/or one or more sensors (when present) of the modular actuator base assembly 12 to monitor and/or control the operation of the modular actuator base assembly 12.

The illustrative modular control assembly 14 has a control assembly housing 32 that houses the controller 28 and the I/O port 30, although in some cases the I/O port 30 may be physically accessible from exterior to the control assembly housing 32. The control assembly housing 32 may be removably mountable to the modular actuator base housing 24 in the field, meaning subsequent to manufacture of the modular actuator 10. For example, the control assembly housing 32 may be removably mountable to the modular actuator base housing 24 using screws, clips, snaps, clasps, clamps, pins and/or any other suitable reversable attachment mechanism that can be removed/released in the field with minimal tools (e.g. screw driver, socket, etc. ) without causing damage to the control assembly housing 32 or the modular actuator base housing 24. In some cases, the same attachment mechanism (e.g. screws, clips, snaps, clasps, clamps, pins) may be re-used to removably mount a different control assembly housing to the modular actuator base housing 24 when desired.

The controller 28 may be configured to control operation of the electric motor 16 of the modular actuator base assembly 12, and thus the controller 28 may be configured to control the actuator output 22 of the modular actuator 12 through the gear train 18.

In some cases, the modular control assembly 14 may be available having a variety of different functionalities. For example, one model of the modular control assembly 14 may be programmed with a first communication protocol while another model of the modular control assembly 14 may be programmed with a second communication protocol that is different from the first communication protocol. An operator may wish to replace an installed modular control assembly 14 that is programmed with the first communication protocol with a replacement modular control assembly 14 that is programmed with the second communication protocol if the system in which the modular actuator 10 is installed is upgrading its communication protocol. This means that the installed modular actuator 10 does not need to be replaced in its entirety, but merely needs a different modular control assembly 14 to be installed.

In some cases, a different modular control assembly 14 may be configured to implement a different control algorithm, and there may be a desire to be able to implement a different control algorithm. As another example, a different modular control assembly 14 may be configured to receive one or more inputs (e.g. sensor inputs and/or control inputs) that a currently installed modular control assembly 14 is not configured to receive. By replacing the currently installed modular control assembly 14 with the different modular control assembly 14 that is configured to receive the one or more additional inputs, the different modular control assembly 14 is able to control operation of the modular actuator 10 using the one or more new additional inputs.

In some cases, the modular control assembly 14 includes additional components that allow the modular control assembly 14 to be able to operate the modular actuator base assembly 12 to which the modular control assembly 14 is ultimately attached to. The modular control assembly 14 includes an auxiliary switch 34 having a number of terminals 36, individually labeled as 36a, 36b and 36c. While a total of three terminals 36 are shown, in some cases the auxiliary switch 34 may have four or more terminals 36, or perhaps only two terminals 36. The illustrative modular control assembly 14 includes a user adjustable auxiliary switch cam 38 that is configured to be operatively coupled to the gear train 18 once the modular control assembly 14 has been field-attached to the modular actuator base assembly 12, the user-adjustable auxiliary switch cam 38 being configured to switch the auxiliary switch when a current position of the actuator output 22 reaches a desired auxiliary switch position. In some cases, the user-adjustable auxiliary switch cam 38 may include a knob (not shown) that the user may use in order to actuate the user-adjustable auxiliary switch cam 38.

The illustrative modular control assembly 14 includes an auxiliary switch clutch assembly 40 that is operatively coupled between the user adjustable auxiliary switch cam 38 and the gear train 18 once the modular control assembly 14 has been field-attached to the modular actuator base assembly 12. The auxiliary switch clutch assembly 40 is configured to slip when the user adjustable auxiliary switch cam is manually moved by a user to set the desired auxiliary switch position of the user adjustable auxiliary switch cam. In some cases, the auxiliary switch clutch assembly 40 may include an interference connection that is overcome when the user adjustable auxiliary switch cam 38 is manually moved by the user to set the desired auxiliary switch position of the user adjustable auxiliary switch cam 38.

The illustrative modular control assembly 14 includes a feedback potentiometer assembly 42 that is configured to be operatively coupled to the gear train once the modular control assembly has been field-attached to the modular actuator base assembly, the feedback potentiometer assembly configured to provide a measure that indicates the current position of the actuator output. A feedback clutch assembly 44 is operatively coupled between the feedback potentiometer assembly 42 and the gear train 18 once the modular control assembly 14 has been field-attached to the modular actuator base assembly 12. The feedback clutch assembly 44 is configured to slip once the feedback potentiometer assembly 42 engages a feedback potentiometer stop (discussed with respect to Figure 5) , and continues to slip as the modular actuator base assembly 12 continues to drive the actuator output 22 to an end stop position, which self-synchronizes the feedback potentiometer assembly 42 with the actuator output 22 at the end stop position (discussed with respect to Figure 5) . In some cases, the feedback clutch assembly 44 may include an interference connection that is overcome when the feedback potentiometer assembly 42 engages the feedback potentiometer stop (discussed subsequently) , and while the modular actuator base assembly 12 continues to drive the actuator output 22 to the end stop position. In some cases, the end stop position may be a full open position or a full closed position of the actuator output 22 of the modular actuator 10.

The controller 28 is carried by the control assembly housing 32 and is operably coupled with the feedback potentiometer assembly 42 in order to inform the controller 28 of the current position of the gear train 18. The controller 28 is configured to control the electric motor 16 of the modular actuator base assembly 12, and thus control the actuator output 22 through the gear train 18 in accordance with the informed current position of the gear train 18. In some cases, the controller 28 may be configured to, after the modular control assembly 14 is field-attached to the modular actuator base assembly 12, actuate the electric motor 16 to drive the actuator output 22 to the end stop position to self-synchronize the feedback potentiometer assembly 42 with the actuator output 22 at the end stop position.

Figure 4 is a schematic block diagram of a plurality of illustrative modular actuator base assemblies 12 and a plurality of illustrative modular control assemblies 14. The plurality of modular actuator base assemblies 12 includes a first modular actuator base assembly 12a, a second modular actuator base assembly 12b and a third modular actuator base assembly 12c. The plurality of modular control assemblies 14 includes a first modular control assembly 14a, a second modular control assembly 14b and a third modular control assembly 14c.

While a total of three modular actuator base assemblies 12 and a total of three modular control assemblies 14 are shown, it will be appreciated that this is merely illustrative, as there may be one, two, four or more modular actuator base assemblies 12. There may be one, two, four or more modular control assemblies 14. Depending on the desired characteristics of the modular actuator 10, a particular one of the modular actuator base assemblies 12 may be combined with a particular one of the modular control assemblies 14. As an example, the second modular actuator base assembly 12b may be combined with the first modular control assembly 14a. It will be appreciated that there are a number of possible permutations.

With respect to notation, it may be considered that the first modular actuator base assembly 12a includes a first gear train 18. The second modular actuator base assembly 12b may include a second gear train. The third modular actuator base assembly 12c may include a third gear train. Reference to first gear train, second gear train, third gear train and so on, or reference to first, second, third with respect to any of the modular actuator base assemblies 12 or the modular control assemblies 14 is arbitrary. In the example shown, each of the modular actuator base assemblies 12 has its own gear train, regardless of how it is referenced.

Figure 5 is a perspective view of an illustrative modular actuator 46 that may be considered as being an example of the modular actuator 10. The illustrative modular actuator 46 includes an actuator output 48 that may be considered as being an example of the actuator output 22. In this example, the actuator output 48 is configured to operatively receive and connect to a damper shaft or valve shaft. The modular actuator 46 includes a first adjustable stop 50 and a second adjustable stop 52. In some cases, each of the first adjustable stop 50 and the second adjustable stop 52 include a fastener 54 that may be loosened in order to allow either of the first adjustable stop 50 or the second adjustable stop 52 to be moved relative to a track 50a or a track 50b, respectively, prior to tightening the fastener 54 to hold the first adjustable stop 50 and/or the second adjustable stop 52 in position.

The illustrative modular actuator 46 includes an electric motor 56 that drives a gear train 104 (see Figure 12) that may be considered as being an example of the gear train 18. The illustrative modular actuator 46 includes an auxiliary switch 58 including several terminals 60, individually labeled as 60a, 60b and 60c. The auxiliary switch 58 and terminals 60 may be considered as being an example of the auxiliary switch 34 and accompanying terminals 36. The illustrative modular actuator 46 includes an auxiliary switch cam assembly 62 that interacts with the auxiliary switch 58. As seen for example in Figure 6, the auxiliary switch 58 includes a switch 64 that is configured to be compressed or otherwise actuated in response to rotation of the auxiliary switch cam assembly 62. The auxiliary switch cam assembly 62 may be seen as including a rounded portion 66 that, when it contacts the switch 64, causes the switch 64 to be compressed or pushed in to the auxiliary switch 58, and a cam portion 68 that allows the switch 64 to extend out from the auxiliary switch 58 without being actuated. The auxiliary switch cam assembly 62 also includes a toothed gear 70 that allows the auxiliary switch cam assembly 62 to be put into rotation. A D-shaped recess 72 allows a knob (not shown) to be inserted, thereby allowing a user to manually rotate the auxiliary switch cam assembly 62 using the knob.

Returning to Figure 5, the illustrative modular actuator 46 also includes a feedback potentiometer assembly 74. In some cases, the toothed gear 70 of the auxiliary switch cam assembly 62 may be driven into rotation by interacting with a complementary toothed gear provided as part of the feedback potentiometer assembly 74.

Figure 7 is a perspective view of the auxiliary switch cam assembly 62 and the feedback potentiometer assembly 74 removed from the modular actuator 46. As can be seen, the auxiliary switch cam assembly 62 includes an adjustable switch cam 76 and a switch cam gear 78. The feedback potentiometer assembly 74 includes a feedback potentiometer actuator 80 and a feedback gear 82. In this example, the feedback gear 82 includes a toothed gear 83 that is configured to engage the toothed gear 70 such that rotation of the feedback gear 82 causes rotation of the auxiliary switch cam assembly 62. In some cases, the feedback gear 82 may be considered as being part of the modular control assembly 14. In some cases, the feedback gear 82 may be considered as being part of the modular actuator base assembly 12. The feedback gear 82 may include a toothed gear 84 that engages the gear train 18.

The auxiliary switch cam assembly 62 may be considered as rotating about a rotational axis that is labeled R ₁ and the feedback potentiometer assembly 74 may be considered as rotating about a rotational axis that is labeled R ₂. In some cases, the rotational axis R ₁ is offset from the rotational axis R ₂. In some cases, as shown, the rotational axis R ₁ is offset from the rotational axis R ₂ and is parallel with the rotational axis R ₂.

Figures 8 and 9 are perspective views of the adjustable switch cam 76 and the switch cam gear 78, respectively. The adjustable switch cam 76 includes an aperture 86 that serves to center and locate the adjustable switch cam 76 relative to a corresponding post 88 that is formed as part of the switch cam gear 78. The auxiliary switch cam assembly 62 includes a clutch mechanism that allows the adjustable switch cam 76 to slip relative to the switch cam gear 78 when appropriate. The adjustable switch cam 76 includes several toothed surfaces 90 that are configured to engage with a corresponding toothed surface 92 formed on the switch cam gear 78. The toothed surfaces 90 and 92 are configured such that movement of the switch cam gear 78 causes movement of the adjustable switch cam 76, but manual movement of the adjustable switch cam 76 may cause the adjustable switch cam gear 76 to slip relative to the switch cam gear 78.

Figures 10 and 11 are perspective views of the feedback potentiometer actuator 80 and the feedback gear 82, respectively. The feedback potentiometer actuator 80 includes a D-shaped segment 94 that is configured to engage a feedback potentiometer (not shown) in order to actuate the feedback potentiometer. The feedback potentiometer actuator 80 also includes several toothed surfaces 96 that are configured to engage a corresponding toothed surface 98 that is formed within the feedback gear 82. The toothed surfaces 96 and 98 are configured such that movement of the feedback gear 82 causes movement of the feedback potentiometer actuator 80, but allows the feedback potentiometer actuator 80 to slip relative to the feedback gear 82 to self-synchronize the feedback potentiometer actuator 80 with a known position (e.g. an end stop) of the actuator.

As noted, the feedback gear 82 includes the toothed gear 84 that engages the drive train 18. In some cases, the feedback gear 82 also includes one or more attachment tabs 100 that may be used to help secure a control assembly housing (such as the control assembly housing 32) in place relative to the feedback gear 82 when a modular control assembly is secured relative to the feedback gear 82 (and hence the rest of the modular actuator base assembly 12) . The feedback gear 82 includes a post 102 that serves to center and locate the feedback gear 82 relative to a corresponding aperture (not shown) formed as part of the feedback potentiometer actuator 80.

In some cases, the auxiliary switch cam assembly 62 and the feedback potentiometer assembly 74 may not have parallel but offset rotational axes, but may instead be concentric, having a common rotation of axis. Figure 13 is a perspective view of an illustrative modular actuator 106 having an adjustment assembly 108 that provides the functionality of the auxiliary switch cam assembly and the feedback potentiometer assembly in a concentric arrangement. The modular actuator 106 includes a schematically shown actuator output 110 and an electric motor 112. An auxiliary switch 114 interacts with the adjustment assembly 108 in a manner similar to that of the auxiliary switch 58.

As seen in Figure 14, the adjustment assembly 108 includes a feedback potentiometer actuator 116, a linking mechanism 118, an adjustable switch cam 120 and a feedback gear 122 (teeth not shown) that may be configured to engage the gear train (not shown) . Figures 15 through 19 provide additional views of the feedback potentiometer actuator 116, the linking mechanism 118, the adjustable switch cam 120 and the feedback gear 122.

Figure 15 is a lower perspective view of the illustrative feedback potentiometer actuator 116, showing that the feedback potentiometer actuator 116 includes a toothed surface 124 that will, as be discussed, interact with a corresponding toothed surface formed as part of the linking mechanism 118, such that rotation of the linking mechanism 118 causes a corresponding rotation of the feedback potentiometer actuator 116. However, when a stop 117 of the feedback potentiometer actuator 116 hits a stop (not shown) , and the linking mechanism 118 continues to be turned by the feedback gear 122, the toothed surface 124 acts as a clutch that allows the feedback potentiometer actuator 116 to slip relative to the linking mechanism 118 and thus the feedback gear 122 to self-synchronize the feedback potentiometer actuator 116 with a known position (e.g. an end stop) of the actuator. The feedback potentiometer actuator 116 includes an annular recess 126 that serves to center and locate the feedback potentiometer actuator 116 relative to the linking mechanism 118.

Figure 16 is a perspective view of the illustrative linking mechanism 118. The linking mechanism 118 includes a post 128 that is complementary to the annular recess 126 in locating the feedback potentiometer actuator 116 relative to the linking mechanism 118. The linking mechanism 118 includes a first toothed surface 130 that is configured to engage the toothed surface 124 of the feedback potentiometer actuator 116. The linking mechanism 118 includes a second toothed surface 132 that is configured to engage a corresponding toothed surface formed as part of the adjustable switch cam 120. The linking mechanism 118 also includes a keyed section 134 that, as will be discussed, allows the linking mechanism 118 to engage with and be driven into rotation by the feedback gear 122.

Figure 17 is a lower perspective view of the adjustable switch cam 120. The adjustable switch cam 120 includes several toothed surfaces 136 that are configured to engage the second toothed surface 132 formed as part of the linking mechanism 118. The toothed surfaces 136 engage the second toothed surface 132 such that rotation of the linking mechanism 118 causes rotation of the adjustable switch cam 120, but manual rotation of the adjustable switch cam 120 can cause the adjustable switch cam 120 to rotate relative to the linking mechanism 118. It will be appreciated that the adjustable switch cam 120 includes a rounded portion 138 and a cam portion 140. The cam portion may be aligned with an auxiliary switch to switch the auxiliary switch at a switchpoint as described above. The rounded portion 138 may include teeth (not shown) that engage a gear (not shown) that is operatively coupled to a switchpoint adjustment knob (not shown) . When so provided, the user may adjust the switchpoint by manually turning the switchpoint adjustment knob, which causes the toothed surfaces 136 to slip relative to the second toothed surface 132 of the linking mechanism 118. This results in the adjustable switch cam 120 being turning relative to the linking mechanism 118 (and thus the feedback gear 122) , which changes the switchpoint of the auxiliary switch.

Figure 18 is a perspective view of the feedback gear 122. While not expressly shown, it will be appreciated that the feedback gear 122 will include one or more toothed gears that are configured to engage the gear train. The feedback gear 122 includes a keyed aperture 142 that is configured to accept the keyed section 134 of the linking mechanism 118 such that rotation of the feedback gear 122 causes rotation of the linking mechanism 118.

Those skilled in the art will recognize that the present disclosure may be manifested in a variety of forms other than the specific embodiments described and contemplated herein. Accordingly, departure in form and detail may be made without departing from the scope and spirit of the present disclosure as described in the appended claims.

Claims

An actuator comprising:

an actuator output movable along an output stroke between a first end stop and an opposing second end stop, the actuator output having a current position along the output stroke;

a driver assembly for driving the actuator output along the output stroke, the driver assembly including an electric motor and one or more gears;

a controller operatively coupled to the driver assembly for controlling the electric motor to drive the actuator output to a desired position along the output stroke;

a feedback potentiometer assembly configured to provide to the controller a measure that indicates the current position of the actuator output along the output stroke;

a feedback clutch assembly operatively coupled between the feedback potentiometer assembly and the driver assembly, wherein the feedback clutch assembly is configured to slip once the feedback potentiometer assembly engages a feedback potentiometer stop, and continues to slip as the driver assembly continues to drive the actuator output to the first stroke end stop, which self-synchronizes the feedback potentiometer assembly with the actuator output at the first stroke end stop;

an auxiliary switch with a first terminal and a second terminal;

an auxiliary switch cam assembly configured to switch the auxiliary switch when the current position of the actuator output reaches a desired auxiliary switch position along the output stroke of the actuator output; and

an auxiliary switch clutch assembly operatively coupled between the auxiliary switch cam assembly and the driver assembly, wherein the auxiliary switch clutch assembly is configured to slip when the auxiliary switch cam assembly is manually moved by a user to set the desired auxiliary switch position of the auxiliary switch cam assembly along the output stroke of the actuator output.
The actuator of claim 1, wherein the auxiliary switch cam assembly includes an adjustment knob that the user uses to manually move the auxiliary switch cam assembly.
The actuator of claim 1, wherein the feedback clutch assembly is operatively coupled between the feedback potentiometer assembly and a feedback gear of the driver assembly, and the auxiliary switch clutch assembly is operatively coupled between the auxiliary switch cam assembly and the feedback gear of the driver assembly.
The actuator of claim 1, wherein the feedback clutch assembly and the auxiliary switch clutch assembly are each configured to rotate about a respective rotation axis.
The actuator of claim 4, wherein the rotation axis of the feedback clutch assembly is parallel but offset from the rotation axis of the auxiliary switch clutch assembly.
The actuator of claim 5, wherein the feedback potentiometer assembly rotates about the rotation axis of the feedback clutch assembly, and the auxiliary switch cam assembly rotates about the rotation axis of the auxiliary switch clutch assembly.
The actuator of claim 4, wherein the rotation axis of the feedback clutch assembly and the rotation axis of the auxiliary switch clutch assembly are a common rotation axis.
The actuator of claim 7, wherein the feedback potentiometer assembly and at least part of the auxiliary switch cam assembly each rotate about the common rotation axis.
A modular actuator, comprising:

a modular actuator base assembly comprising:

a modular actuator base housing;

a electric motor operatively coupled to a gear train, wherein the gear train includes two or more reduction gears for driving an actuator output, the electric motor and the gear train carried by the modular actuator base housing;

a modular control assembly that is field-attachable to the modular actuator base assembly, the modular control assembly comprising:

a control assembly housing;

an auxiliary switch with a first terminal and a second terminal;

a user adjustable auxiliary switch cam configured to be operatively coupled to the gear train once the modular control assembly has been field-attached to the modular actuator base assembly, the user adjustable auxiliary switch cam is configured to switch the auxiliary switch when a current position of the actuator output reaches a desired auxiliary switch position;

an auxiliary switch clutch assembly operatively coupled between the user adjustable auxiliary switch cam and the gear train once the modular control assembly has been field-attached to the modular actuator base assembly, wherein the auxiliary switch clutch assembly is configured to slip when the user adjustable auxiliary switch cam is manually moved by a user to set the desired auxiliary switch position of the user adjustable auxiliary switch cam;

a feedback potentiometer assembly configured to be operatively coupled to the gear train once the modular control assembly has been field-attached to the modular actuator base assembly, the feedback potentiometer assembly configured to provide a measure that indicates the current position of the actuator output;

a feedback clutch assembly operatively coupled between the feedback potentiometer assembly and the gear train once the modular control assembly has been field-attached to the modular actuator base assembly, wherein the feedback clutch assembly is configured to slip once the feedback potentiometer assembly engages a feedback potentiometer stop, and continues to slip as the modular actuator base assembly continues to drive the actuator output to an end stop position, which self-synchronizes the feedback potentiometer assembly with the actuator output at the end stop position;

a controller carried by the control assembly housing and operably coupled with the feedback potentiometer assembly in order to inform the controller of the current position of the gear train; and

wherein the controller is configured to control the electric motor of the modular actuator base assembly, and thus control the actuator output through the gear train in accordance with the informed current position of the gear train.
The modular actuator of claim 9, wherein the auxiliary switch clutch assembly comprises an interference connection that is overcome when the user adjustable auxiliary switch cam is manually moved by the user to set the desired auxiliary switch position of the user adjustable auxiliary switch cam.
The modular actuator of claim 9, wherein the feedback clutch assembly comprises an interference connection that is overcome when the feedback potentiometer assembly engages the feedback potentiometer stop, and while the modular actuator base assembly continues to drive the actuator output to the end stop position.
The modular actuator of claim 9, wherein the controller is configured to, after the modular control assembly is field-attached to the modular actuator base assembly, actuate the electric motor to drive the actuator output to the end stop position to self-synchronize the feedback potentiometer assembly with the actuator output at the end stop position.
The modular actuator of claim 12, wherein the end stop position is a full open position or a full closed position of the actuator output of the modular actuator.
The modular actuator of claim 9, wherein the modular actuator base assembly is field-removed from the modular actuator and field-replaced with a replacement modular actuator base, and wherein the controller is configured to control the electric motor of the replacement modular actuator base assembly, and thus control the actuator output through the gear train in accordance with an informed current position of the gear train.
A modular control assembly that is field-attachable to a modular actuator base assembly, the modular actuator base assembly including a modular actuator base housing, an electric motor operatively coupled to a gear train that includes two or more reduction gears for driving an actuator output of the modular actuator base assembly, the modular control assembly comprising:

a control assembly housing;

an auxiliary switch with a first terminal and a second terminal;

a user adjustable auxiliary switch cam assembly configured to be operatively coupled to the gear train once the modular control assembly has been field-attached to the modular actuator base assembly, the user adjustable auxiliary switch cam assembly is configured to switch the auxiliary switch when a current position of the actuator output reaches a desired auxiliary switch position, wherein the desired auxiliary switch position is adjustable by a user;

a feedback potentiometer assembly configured to be operatively coupled to the gear train once the modular control assembly has been field-attached to the modular actuator base assembly, the feedback potentiometer assembly configured to provide a measure that indicates the current position of the actuator output, and is further configured to self-synchronize the feedback potentiometer assembly with the actuator output;

a controller carried by the control assembly housing and operably coupled with the feedback potentiometer assembly in order to inform the controller of the current position of the gear train; and

wherein the controller is configured to control the electric motor of the modular actuator base assembly, and thus control the actuator output through the gear train in accordance with the informed current position of the gear train.
The modular control assembly of claim 15, wherein the feedback potentiometer assembly includes a feedback clutch assembly that is used to self-synchronize the feedback potentiometer assembly with the actuator output.
The modular control assembly of claim 15, wherein the user adjustable auxiliary switch cam assembly includes an auxiliary switch clutch assembly that is used to adjust the desired auxiliary switch position by the user.
The modular control assembly of claim 15, wherein the controller is configured to, after the modular control assembly is field-attached to the modular actuator base assembly, actuate the electric motor to drive the actuator output to an end stop position to self-synchronize the feedback potentiometer assembly with the actuator output.
The modular control assembly of claim 15, wherein the user adjustable auxiliary switch cam assembly includes an adjustment knob that the user uses to adjust the desired auxiliary switch position.
The modular control assembly of claim 15, wherein at least part of user adjustable auxiliary switch cam assembly and at least part of the feedback potentiometer assembly are each configured to rotate about a respective rotation axis.