Four-wheel drive center disconnect electric actuator

• US 7,316,304 B2
• Filed: 06/10/2005
• Issued: 01/08/2008
• Est. Priority Date: 06/10/2005
• Status: Active Grant

• Current Assignee: Warn Automotive LLC (Dover Corporation)
• Original Assignee: Warn Industries Incorporated (LKQ Corporation)
• Inventors: Heravi, Oliver, Ozsvath, Ernest, Clohessy, Kip E., Stocker, Scott, Averill, Bryan M.
• Primary Examiner(s): Lorence; Richard M
• Application Number:
  US11/150,575
• Publication Number:
  US 20060278490A1
• Time in Patent Office: 942 Days
• Field of Search: None
• US Class Current: 192/20
• CPC Class Codes: B60K 23/08 for changing number of driven wheels , for switching from driving one axle to driving two or more axles B60K17/3515 takes precedence
• CPC Class Codes: F16D 2023/123 Clutch actuation by cams, ramps or ball-screw mechanisms
• CPC Class Codes: F16D 28/00 Electrically-actuated clutches arrangements for synchronisation F16D23/02; clutches actuated directly by means of an electromagnet F16D27/00; automatic clutches F16D43/00 - F16D45/00; external control F16D48/00

Abstract

A four-wheel drive center disconnect electric actuator is provided. The actuator includes a one-way motor that actuates a cam mechanism for causing engagement and disengagement of the center disconnect. The actuator achieves improved reliability and efficiency through a less expensive construction than conventional actuators.

Claims

1. A driveline disconnect, comprising:

a first rotatable member;

a second rotatable member;

a coupler device operably engageable and disengageable for providing connection between said first and second rotatable members;

a one-way electric motor mounted to an elongated housing;

a gear mechanism operatively driven by said electric motor;

a cam mechanism operatively driven by said gear mechanism;

a cam follower engaged with said cam mechanism, said cam follower being supported for linear motion relative to said cam mechanism; and

a plunger coupled to a linkage engaged by said cam follower, said plunger and said linkage moving axially with said cam follower, wherein said cam follower is disposed along an axis of said plunger, said plunger having an end portion moving axially outward relative to said housing.

2. The driveline disconnect according to claim 1, further comprising a controller for actuating said motor to rotate to provide rotation of said cam mechanism in 180 degree increments for providing connection and disconnection of said coupler device.

3. The driveline disconnect according to claim 1, wherein said elongated housing supports said electric motor, said gear mechanism, said cam mechanism and said cam follower.

4. The driveline disconnect according to claim 3, further comprising a cover connected to said housing.

5. The driveline disconnect according to claim 3, wherein said cam mechanism is rotatably mounted to said housing.

6. The driveline disconnect according to claim 1, wherein said gear mechanism includes a drive gear mounted to an output shaft of said electric motor and meshingly engaged with a driven gear.

7. The driveline disconnect according to claim 6, wherein said driven gear is connected to a worm that is in meshing engagement with a worm gear.

8. The driveline disconnect according to claim 7, wherein said worm gear is connected to said cam mechanism.

9. The driveline disconnect according to claim 8, wherein said worm gear and said cam mechanism are rotatable about a common axis.

10. The driveline disconnect according to claim 6, wherein said drive gear is smaller than said driven gear.

11. The driveline disconnect according to claim 1, wherein said first rotatable member is a drive axle and said second rotatable member is connected to a component of a differential drive mechanism.

12. The driveline disconnect according to claim 3, further comprising an electrical connector integrated with the housing.

13. The driveline disconnect according to claim 3, further comprising a circuit disposed on said housing for encoding and power control of said motor.

14. The driveline disconnect according to claim 1, further comprising a control circuit for providing dynamic braking of said motor.

15. A center axle disconnect, comprising:

a drive axle member;

a differential system;

a coupler device operable between a coupled position and an uncoupled position for coupling and uncoupling said drive axle member to a component of said differential system;

a one-way electric motor;

a pear mechanism operatively driven by said electric motor;

a cam mechanism operatively driven by said gear mechanism, wherein said cam mechanism is fixedly mounted to said pear mechanism;

a cam follower engaged with said cam mechanism, said cam follower being supported for linear motion relative to said cam mechanisms;

a linkage engaged with said cam follower, said linkage including a slot portion slidably receiving a spindle of said cam follower;

a plunger coupled to said linkage, said plunger and said linkage moving axially with said cam follower, wherein said plunger is engageable to said coupler device for operation between said coupled position and said uncoupled position; and

a spring of said linkage engaging said plunger and applying a biasing force to said plunger to engage said coupling device.

16. The center axle disconnect according to claim 15, further comprising a controller for energizing said motor to rotate to provide rotation of said cam mechanism in 180 degree increments for moving said coupler device between said coupled position and said uncoupled position.

17. The center axle disconnect according to claim 15, further comprising a housing supporting said electric motor, said cam mechanism and said cam follower and a cover connected to said housing.

18. The center axle disconnect according to claim 17, wherein said cam mechanism is rotatably mounted to said housing.

19. The center axle disconnect according to claim 18, further comprising a rotatable wiper switch disposed on said cam mechanism.

20. The center axle disconnect according to claim 15, further comprising a drive gear mounted to an output shaft of said electric motor and meshingly engaged with a driven gear.

21. The center axle disconnect according to claim 20, wherein said driven gear is connected to a worm that is in meshing engagement with a worm gear.

22. The center axle disconnect according to claim 21, wherein said worm gear is connected to said cam mechanism.

23. The center axle disconnect according to claim 22, wherein said worm gear and said cam mechanism are rotatable about a common axis.

24. The center axle disconnect according to claim 15 further comprising a control circuit for providing dynamic braking of said electric motor.

25. A driveline disconnect, comprising:

a first rotatable member;

a second rotatable member;

a coupler device operable between an engaged and a disengaged position for providing connection between said first and second rotatable members;

a one-way electric motor mounted to an elongated housing extending along an axis;

a drive gear mounted to said electric motor, whereby said drive gear and said motor have an angled orientation to said axis of said housing;

a worm gear mounted on said housing and rotating about a perpendicular axis to said housing axis and meshingly engaged with a worm driven by said drive gear;

a cam mechanism mounted on said worm gear and rotating about said perpendicular axis;

a cam follower axially engaged with said cam mechanism along said axis of said housing;

a linkage including a spring oriented axially to said axis of said housing, engaged with said cam follower; and

a plunger oriented axially to said axis of said housing and engaged with said linkage to cause movement of a shift fork, said plunger having an end portion moving axially outward relative to said housing.

26. The driveline disconnect according to claim 25 further comprising a control circuit for providing dynamic braking of said electric motor.