Two-speed transfer case
First Claim
1. A transfer case comprising:
- an input shaft;
first and second output shafts;
a range unit driven at a reduced speed relative to said input shaft;
a range clutch operable in a first range position to establish a drive connection between said input shaft and said first output shaft and further operable in a second range position to establish a drive connection between said range unit and said first output shaft;
a mode clutch operable in a first mode position to disengage said second output shaft from driven engagement with said first output shaft and further operable in a second mode position to establish a drive connection between said first output shaft and said second output shaft;
a worm gearset having a worm driving a worm gear;
a motor driving said worm;
an actuator shaft driven by said worm gear;
a range actuator driven by said actuator shaft for moving said range clutch between its first and second range positions;
a mode actuator driven by said actuator shaft for moving said mode clutch between its first and second mode positions; and
a control system for actuating said motor to control the magnitude and direction of rotation of said actuator shaft so as to coordinate movement of said range clutch and said mode clutch, said actuator shaft is rotatable through three distinct ranges of travel wherein a first range of travel causes said range actuator to move said range clutch between its first and second range positions while said mode actuator maintains said mode clutch in its first mode position, and wherein a second range of travel causes said range actuator to maintain said range clutch in its first range position while said mode actuator moves said mode clutch between its first and second mode positions.
1 Assignment
0 Petitions
Accused Products
Abstract
A transfer case includes a two-speed range unit, a mode clutch, an actuation mechanism and a control system. The actuation mechanism includes an electric motor, an actuator shaft driven by the motor, a range actuator assembly and a mode actuator assembly. The range actuator assembly includes range, a cam driven by the actuator shaft and a shift fork having a follower retained in a groove formed in the cam and a fork engaging a shift collar associated with the range unit. The mode actuator assembly has a range cam member with cam surfaces and a control gear with rollers engaging the cam surfaces. The control gear is rotatively driven by the actuator shaft. The cam member is axially moveable for controlling engagement of the mode clutch. An anti-rotation mechanism limits rotation of the cam member in response to continued rotation of the control gear.
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Citations
30 Claims
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1. A transfer case comprising:
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an input shaft; first and second output shafts; a range unit driven at a reduced speed relative to said input shaft; a range clutch operable in a first range position to establish a drive connection between said input shaft and said first output shaft and further operable in a second range position to establish a drive connection between said range unit and said first output shaft; a mode clutch operable in a first mode position to disengage said second output shaft from driven engagement with said first output shaft and further operable in a second mode position to establish a drive connection between said first output shaft and said second output shaft; a worm gearset having a worm driving a worm gear; a motor driving said worm; an actuator shaft driven by said worm gear; a range actuator driven by said actuator shaft for moving said range clutch between its first and second range positions; a mode actuator driven by said actuator shaft for moving said mode clutch between its first and second mode positions; and a control system for actuating said motor to control the magnitude and direction of rotation of said actuator shaft so as to coordinate movement of said range clutch and said mode clutch, said actuator shaft is rotatable through three distinct ranges of travel wherein a first range of travel causes said range actuator to move said range clutch between its first and second range positions while said mode actuator maintains said mode clutch in its first mode position, and wherein a second range of travel causes said range actuator to maintain said range clutch in its first range position while said mode actuator moves said mode clutch between its first and second mode positions. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10)
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11. A transfer case comprising:
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an input shaft; first and second output shafts; a range unit driven by said input shaft and having an output component driven at a reduced speed relative to said input shaft; a dog clutch operable in a first range position to couple said input shaft to said first output shaft for establishing a high-range drive connection, said dog clutch is further operable in a second range position to couple said output component of said range unit to said first output shaft for establishing a low-range drive connection; a mode clutch including a clutch pack operably disposed between said first and second output shafts and a pressure plate moveable between a first mode position whereat a minimum clutch engagement force is exerted on said clutch pack and a second mode position whereat a maximum clutch engagement force is exerted on said clutch pack; and an actuation mechanism including a worm gearset driving an actuator shaft, a motor driving said worm gearset, a range actuator driven by said actuator shaft for moving said dog clutch between its first and second range positions, and a mode actuator driven by said actuator shaft for moving said pressure plate between its first and second mode positions, said actuator shaft being rotatable through three distinct ranges of rotary travel for causing said range and mode actuators to coordinate movement of said dog clutch and said pressure plate, wherein said actuator shaft is rotatable through a first range of travel for causing said range actuator to move said dog clutch between its first and second range positions while said mode actuator maintains said pressure plate in its first mode position, wherein said actuator shaft is rotatable through a second range of travel for causing said range actuator to maintain said dog clutch in its first range position while said mode actuator moves said pressure plate between its first and second mode positions, and wherein said actuator shaft is rotatable through a third range of travel for causing said range actuator to maintain said dog clutch in its second range position while said mode actuator moves said pressure plate between its first and second mode positions. - View Dependent Claims (12, 13, 14, 15, 16)
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17. A transfer case comprising:
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an input shaft; first and second output shafts; a range unit driven at a reduced speed relative to said input shaft; a range clutch operable in a first range position to establish a drive connection between said input shaft and said first output shaft and further operable in a second range position to establish a drive connection between said range unit and said first output shaft; a mode clutch operable in a first mode position to release said second output shaft from driven engagement with said first output shaft and further operable in a second mode position to establish a drive connection between said first and second output shafts; an actuator shaft disposed between said first and second output shafts; a range cam fixed for rotation with said actuator shaft; a drive gear fixed for rotation with said actuator shaft; a worm gearset having a worm gear fixed for rotation with said actuator shaft; a motor driving said worm gearset to control rotation of said actuator shaft; a range actuator assembly operably disposed between said range cam and said range clutch for controlling movement of said range clutch between its first and second range positions in response to rotation of said range cam; a mode actuator assembly having a control gear meshed with said drive gear and a cam unit operable for controlling movement of said mode clutch between its first and second mode positions in response to rotation of said control gear; and a control system for controlling actuation of said motor to control the amount and direction of rotation of said actuator shaft to coordinate movement of said range clutch and said mode clutch. - View Dependent Claims (18, 19, 20, 21, 22, 23, 24, 25, 26)
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27. A transfer case comprising:
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an input shaft; a range unit driven at a reduced speed relative to said input shaft; a range clutch operable in a first range position to establish a drive connection between said input shaft and said first output shaft and further operable in a second range position to establish a drive connection between said range unit and said first output shaft; a mode clutch operable in a first mode position to release said second output shaft from driven engagement with said first output shaft and further operable in a second mode position to establish a drive connection between said first output shaft and said second output shaft; a motor; an actuator shaft having a drive gear; a worm gearset drivingly coupling said actuator shaft to said motor; a range actuator driven by said actuator shaft for moving said range clutch between its first and second range positions; a mode actuator having a control gear driven by said drive gear in response to rotation of said actuator shaft for moving said mode clutch between its first and second mode positions; and a control system for actuating said motor to control the magnitude and direction of rotation of said actuator shaft. - View Dependent Claims (28, 29)
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30. A transfer case comprising:
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an input shaft; first and second output shafts; a differential having an input component, a first output component driving said first output shaft and a second output component driving said second output shaft; a range unit driven at a reduced speed relative to said input shaft; a range clutch operable in a first range position to establish a drive connection between said input shaft and said input component and further operable in a second range position to establish a drive connection between said range unit and said input component; a mode clutch disposed between any two of said input component and first and second output components of said differential, said mode clutch is operable in a first mode position to permit speed differentiation between said first and second output shafts and is further operable in a second mode position to inhibit speed differentiation between said first and second output shafts; an actuator shaft having a drive gear; a motor; a worm gearset drivingly coupling said motor to said actuator shaft; a range actuator driven by said actuator shaft for controlling movement of said range clutch between its first and second range positions; a mode actuator having a control gear meshed with said drive gear for controlling movement of said mode clutch between its first and second mode positions in response to rotation of said control gear; and a control system for controlling actuation of said motor to control the amount and direction of rotation of said actuator shaft so as to coordinate movement of said range clutch and said mode clutch.
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Specification