Motor driven transfer case with modular actuation

Patent metadata

Field	Value
Publication number	US-10066743-B2
Application number	US-201514935505-A
Country	US
Kind code	B2
Filing date	Nov 9, 2015
Priority date	Nov 11, 2014
Publication date	Sep 4, 2018
Grant date	Sep 4, 2018

Abstract

A transfer case ( 30 ) and a method of assembly in an all-wheel drive vehicle can include a range shifting assembly ( 60 ) for shifting between a low-range and high-range drive mode, a normally disengaged clutch assembly ( 80 ) for transferring drive torque to a first and second driveline, a clutch actuator ( 88 ), and an actuating gear ( 48 ). The clutch actuator ( 88 ) can be moveable between an expanded position and a contracted position and engageable with the clutch assembly ( 80 ) for engaging the clutch assembly ( 80 ) when in the expanded position. The actuating gear ( 48 ) can be reversibly rotatable through a predetermined angular arc of movement for operating the clutch actuator ( 88 ) between the contracted and expanded position for actuating the clutch assembly ( 80 ) and for shifting the range shifting assembly ( 60 ) between a low-range drive mode and a high-range mode when the clutch assembly ( 80 ) is in the disengaged position.

First claim

What is claimed is:

1. In a transfer case ( 30 ) of a motor vehicle including an input shaft ( 34 ) having a primary axis of rotation, a first output shaft ( 36 ), a second output shaft ( 38 ), and a power transmission device ( 40 ) located between the first output shaft ( 36 ) and the second output shaft ( 38 ), the improvement comprising:
a range shifting assembly ( 60 ) connected between the input shaft ( 34 ) and the first output shaft ( 36 ) for shifting between a low-range drive mode and a high-range drive mode of operation;
a normally disengaged clutch assembly ( 80 ) connected to the power transmission device ( 40 ) and moveable between an engaged position and a disengaged position to transfer into and out of a state creating driving continuity for transferring drive torque between the first output shaft ( 36 ) and the second output shaft ( 38 );
a clutch actuator ( 88 ) moveable between an expanded position and a contracted position and engageable with the clutch assembly ( 80 ) for engaging the clutch assembly ( 80 ) when in the expanded position; and
an actuating gear ( 48 ) reversibly rotatable through a predetermined angular arc of movement for operating the clutch actuator ( 88 ) between the contracted position and the expanded position for actuating the clutch assembly ( 80 ) between the disengaged position and the engaged position, and for shifting the range shifting assembly ( 60 ) between the low-range drive mode and the high-range drive mode when the clutch assembly ( 80 ) is in the disengaged position.

2. The improvement of claim 1 , wherein the clutch actuator ( 88 ) further comprises:
a clutch actuating cam ( 88 b );
a retainer ( 88 a ) supported for preventing rotation with the actuating gear ( 48 ) and axially interposed between the range shifting assembly ( 60 ) and the clutch actuating cam ( 88 b ), the retainer ( 88 a ) defining a plurality of elongated arcuate recesses ( 90 ) having a deep central portion tapering to a shallow depth at outer ends ( 94 ); and
a corresponding plurality of rolling members ( 92 ), said rolling member ( 92 ) received within each of the plurality of elongated arcuate recesses ( 90 ) for movement along the elongated arcuate recess ( 90 ) between the deep central portion of the recess ( 90 ) and the shallow depth at the outer ends ( 94 ) of each recess ( 90 ), the clutch actuating cam ( 88 b ) trapping the plurality of rolling members ( 92 ) interposed between the retainer ( 88 a ) and the clutch actuating cam ( 88 b ), the clutch actuating cam ( 88 b ) angularly rotatable with respect to the retainer ( 88 a ) and axially moveable toward the clutch assembly ( 80 ) for engaging the clutch assembly ( 80 ) in response to movement of the rolling member ( 92 ) from the deep central portion of the recess ( 90 ) to the shallow depth at the outer ends ( 94 ) of the recess ( 90 ).

3. The improvement of claim 2 , wherein the clutch actuator further comprises:
at least one pin ( 96 ) supported on a surface ( 98 ) of the clutch actuating cam ( 88 b ) for imparting angular rotation to the clutch actuating cam ( 88 b ) with respect to the retainer ( 88 a ) through the actuating gear ( 48 ), while allowing axial movement of the clutch actuating cam ( 88 b ) with respect to the retainer ( 88 a ) providing a free floating movement between the clutch actuating cam ( 88 b ) and the actuating gear ( 48 ).

4. The improvement of claim 3 , wherein the actuating gear ( 48 ) further comprises:
an axially extending collar portion ( 47 ) of the actuating gear ( 48 ) defining at least one arcuate notch ( 53 ), the at least one arcuate notch ( 53 ) corresponding in number to the at least one pin ( 96 ), the at least one arcuate notch ( 53 ) receiving the at least one pin ( 96 ) for allowing angular driven rotation and corresponding axial movement of the clutch actuating cam ( 88 b ) in response to angular rotation of the actuating gear ( 48 ).

5. The improvement of claim 4 , wherein the actuating gear ( 48 ) further comprises:
a retaining plate ( 84 ) engageable with the axially extending collar portion ( 47 ) of the actuating gear ( 48 ) for enclosing the retainer ( 88 a ) and the clutch actuating cam ( 88 b ) and for limiting axial travel of the clutch actuating cam ( 88 b ).

6. The improvement of claim 1 , wherein the range shifting assembly ( 60 ) further comprises:
a barrel cam ( 59 ) connected for rotation in response to rotation of the actuating gear ( 48 ) and including a cam surface groove ( 57 ) having a first end portion, a second end portion, and an intermediate portion extending between the first end portion and the second end portion;
a torsion wrap spring ( 62 ) engageable between the barrel cam ( 59 ) and the actuating gear ( 48 ) for biasing the barrel cam ( 59 ) to follow reversible rotational movement of the actuating gear ( 48 );
a shift fork ( 68 ) for guided travel along the cam surface groove ( 57 ) of the barrel cam ( 59 ) in response to rotation of the barrel cam ( 59 ) by the actuating gear ( 48 ) to shift between the low-range drive mode and the high-range drive mode;
a shift collar ( 70 ) defining an axial groove ( 71 ) and for supporting the shift fork ( 68 ) to allow axial movement of the shift fork ( 68 ) while restricting rotation of the shift fork ( 68 ); and
an internal range sleeve ( 63 ) supported for rotation with respect to the shift fork ( 68 ) while being driven in axial movement in response to axial movement of the shift fork ( 68 ) with respect to the shift collar ( 70 ) in response to rotation of the barrel cam ( 59 ) with respect to the shift collar ( 70 ), the internal range sleeve ( 63 ) connected for driving rotation of the first output shaft ( 36 ).

7. The improvement of claim 6 , wherein the cam surface groove ( 57 ) includes the first end portion having a predetermined circumferential arcuate length lying in a first plane perpendicular to the primary rotational axis, the second end portion having a predetermined circumferential arcuate length lying in a second plane perpendicular to the primary rotational axis and axially spaced from the first plane, and the intermediate portion of the cam surface groove ( 57 ) extending arcuately and axially between the first end portion and the second end portion to define axial shifting movement of the shift fork ( 68 ) between the low-range drive mode and the high-range drive mode of operation, while the first and second end portions define a period of dwell at the first end portion and the second end portion of the cam surface groove ( 57 ) of the barrel cam ( 59 ), each end portion of the cam surface groove ( 57 ) allowing actuation of the clutch actuator ( 88 ) prior to beginning axial shifting movement of the shift fork ( 68 ), such that the shift fork ( 68 ) remains axially stationary at each end portion of the cam surface groove ( 57 ) while the clutch actuator ( 88 ) is operated between the contracted position and the expanded position.

8. The improvement of claim 1 further comprising:
at least one sensing element ( 23 ) located on a peripheral surface of the actuating gear ( 48 ) for detecting a position of the actuating gear ( 48 ); and
an engine control unit ( 21 ) for actuating the range shifting assembly ( 40 ) and the clutch assembly ( 80 ) in response to a detected position of the actuating gear ( 48 ) by the at least one sensing element ( 23 ).

9. The improvement of claim 1 further comprising:
a reversible electric motor ( 44 ) located off axis with respect to the primary axis of rotation; and
a gear train ( 46 ) reversibly driven by the electric motor ( 44 ) for driving the actuating gear ( 48 ) in rotation.

10. A transfer case ( 30 ) comp

Assignees

• Borgwarner Inc

Inventors

• Pritchard Larry A
• Young David E
• Mastie Joseph
• Niffenegger Donn
• Kurmaniak Christopher

Classifications

• F16H61/26

  Generation or transmission of movements for final actuating mechanisms · CPC title

• B60K17/344

  having a transfer gear · CPC title

• F16H37/08 Primary

  with differential gearing · CPC title

• F16H2061/326

  Actuators for range selection, i.e. actuators for controlling the range selector or the manual range valve in the transmission · CPC title

• F16H63/32

  Gear shift yokes, {e.g. shift forks} · CPC title