Actuator mechanism for transfer case

Patent metadata

Field	Value
Publication number	US-10280986-B2
Application number	US-201715429689-A
Country	US
Kind code	B2
Filing date	Feb 10, 2017
Priority date	Feb 12, 2016
Publication date	May 7, 2019
Grant date	May 7, 2019

Abstract

An actuator for a transfer case includes an actuator member, a face cam mechanism, and a motor. The actuator member includes a circumferential flange and an annular body extending from an inner periphery of the circumferential flange. The annular body includes a circumferential slot opposite the flange defined between two end walls formed by the annular body. One of the end walls includes a bearing member coupled thereto. The face cam mechanism includes a follower coupled to a cam member. The cam member is configured to displace axially when rotated. The follower is disposed within the slot. In a first range of motion, the annular member is rotated independent of the face cam mechanism. In a second range of motion, the bearing member engages the follower to rotate the second cam member relative to the first cam member, and the follower moves axially along the bearing member.

First claim

What is claimed is:

1. A transfer case comprising:
a primary output shaft;
a secondary output shaft selectively coupleable to the primary output shaft with a secondary torque transfer mechanism to transfer torque from the primary output shaft to the secondary output shaft and
an actuator comprising:
a hub member comprising an annular body defining a circumferential slot having
a bearing member coupled to the annular body and positioned in the slot, wherein the bearing member includes a bearing surface that extends in an axial direction relative to the annular body; and
a face cam mechanism that displaces in the axial direction when rotated by the hub member to operate the secondary torque transfer mechanism, wherein the face cam mechanism includes a follower member that is engaged by the bearing member and moves axially along the bearing surface when the face cam is rotated by the hub member, wherein the annular body includes an end wall at a circumferential end of the circumferential slot, the bearing member is formed from a material that is harder than another material forming the end wall, and the bearing member distributes localized force from the follower across the end wall.

2. The transfer case according to claim 1 , wherein the bearing member includes a bearing segment forming the bearing surface, and a coupling segment coupled to the annular body.

3. The transfer case according to claim 2 , wherein the bearing segment includes a rear surface opposite the bearing surface, the rear surface being engaged with the end wall to distribute force thereacross.

4. The transfer case according to claim 2 , wherein the bearing member is coupled to the annular body by at least one of a fastener, or the coupling segment being received within a complementary slot of the annular body.

5. The transfer case according to claim 4 , wherein the fastener is a clip member received within an annular groove in the annular body.

6. The transfer case according to claim 1 , wherein the hub member is configured to rotate in a first range of motion independent of the face cam mechanism in which the bearing member does not engage the follower, and in a second range of motion in which the bearing member engages the follower to rotate the face cam mechanism.

7. The transfer case according to claim 6 , wherein the secondary torque transfer mechanism includes a plate clutch, wherein in the second range of motion, the face cam mechanism displaces axially to compress the plate clutch to selectively couple the primary output shaft to the secondary output shaft.

8. The transfer case according to claim 7 , wherein the secondary torque transfer mechanism includes a first sprocket coupled to a housing of the plate clutch to be selectively coupled to the primary output shaft, a second sprocket coupled to the secondary output shaft, and a chain coupling the first sprocket to the second sprocket to transfer torque therebetween.

9. The transfer case according to claim 6 , further comprising an input shaft and a gear reduction mechanism configured to couple the input shaft to the primary output shaft selectively between a first drive ratio and a second drive ratio, wherein the actuator is configured to operate the gear reduction mechanism in the first range of motion to selectively couple the input shaft to the primary output shaft in the first drive ratio or the second drive ratio, and operate the secondary torque transfer mechanism in the second range of motion that is different from the first range of motion.

10. The transfer case according to claim 1 , wherein the follower is a roller configured to roll along the bearing surface.

11. The transfer case according to claim 1 , wherein the hub member includes two slots, each slot being defined by two end walls and having one of the bearing members coupled to each end wall; and
wherein the face cam mechanism includes two followers that are rollers, each follower being positioned in one of the two slots and being configured to roll along the bearing surface of each bearing member of the slot in which the roller is positioned.

12. The transfer case according to claim 1 , wherein the face cam mechanism includes a first cam member and a second cam member, wherein the first cam member is fixed axially with respect to the hub, the follower is coupled to the second cam member, and the second cam member is rotatable by the hub relative to the first cam member to displace axially relative to the first cam member.

13. An actuator for a transfer case comprising:
an actuator member including a circumferential slot defined between two end walls formed by an annular body, at least one of the end walls having a bearing member coupled thereto and forming a bearing surface extending in an axial direction relative to the annular body;
a face cam mechanism including a first cam member, a second cam member, and a follower coupled to the second cam member, wherein the second cam member is configured to displace axially relative to the first cam member when rotated relative to the first cam member, the follower being disposed within the slot; and
a motor configured to rotate the annular body in a first range of motion independent of the face cam mechanism, and in a second range of motion in which the bearing member engages the follower to rotate the second cam member relative to the first cam member and in which the follower moves axially along the bearing surface of the bearing member, wherein the bearing surface is formed from a material that is harder than another material forming the end wall to which the bearing member is coupled.

14. The actuator according to claim 13 , wherein the bearing member includes a bearing segment and a coupling segment, the coupling segment being coupled to the annular body, and the bearing segment forming the bearing surface and a rear surface engaged with the end wall.

15. The actuator according to claim 13 , wherein the actuator member and the second cam member rotate about a common axis.

16. A transfer case comprising:
a primary output shaft;
a secondary output shaft;
a torque transfer mechanism that selectively couples the primary output shaft to the secondary output shaft to transfer torque therebetween; and
an actuator comprising:
a face cam configured to displace axially when rotated for operating the torque transfer mechanism, the face cam including a follower that extends radially outward;
an annular member defining a circumferential slot, the annular member including an end wall at a circumferential end of the circumferential slot, the follower being positioned in the circumferential slot;
a bearing member coupled to the end wall and extending an axial direction relative to the annular member, wherein the bearing member is harder than the end wall; and
an electric motor that rotates the annular member in a first range of motion in which the face cam is stationary and in a second range of motion in which the bearing member engages the follower to rotate the face cam and in which the follow moves axially along the bearing member, the bearing member distributing localized force from the follower across the end wall.

Assignees

• Borgwarner Inc

Inventors

• Palazzolo Michael Robert
• Riggs Paul Matthew
• Chirco Christopher Anthony

Classifications

• B60K17/02

  characterised by arrangement, location, or kind of clutch · CPC title

• F16D13/52

  Clutches with multiple lamellae {; Clutches in which three or more axially moveable members are fixed alternately to the shafts to be coupled and are pressed from one side towards an axially-located member (F16D13/385 takes precedence)} · CPC title

• F16H1/00

  Toothed gearings for conveying rotary motion (specific for conveying rotary motion with variable gear ratio or for reversing rotary motion F16H3/00) · CPC title

• F16D23/12 Primary

  Mechanical clutch-actuating mechanisms arranged outside the clutch as such (specific for combined clutches F16D21/00; mechanisms specific for synchronisation F16D23/02) · CPC title

• B60K17/344

  having a transfer gear · CPC title