Two position actuator with sensing and control

• US 9,151,368 B2
• Filed: 04/06/2012
• Issued: 10/06/2015
• Est. Priority Date: 04/07/2011
• Status: Active Grant

• Current Assignee: American AXLE & Manufacturing Incorporated (American AXLE & Manufacturing Holdings Incorporated)
• Original Assignee: American AXLE & Manufacturing Incorporated (American AXLE & Manufacturing Holdings Incorporated)
• Inventors: Downs, James P., Hibbler, John C.
• Primary Examiner(s): Bonck, Rodney H
• Application Number:
  US14/009,120
• Publication Number:
  US 20140144259A1
• Time in Patent Office: 1,278 Days
• Field of Search: None
• US Class Current: 1/1
• CPC Class Codes: B60K 2023/0858 with electric means, e.g. electro-hydraulic means
• 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: B60W 2510/0225 Clutch actuator position
• CPC Class Codes: B60Y 2400/414 Ramp or cam mechanisms
• CPC Class Codes: F16D 2500/1025 with threaded transmission
• CPC Class Codes: F16D 2500/10431 4WD Clutch dividing power between the front and the rear axle
• CPC Class Codes: F16D 2500/10462 Dog-type clutch
• CPC Class Codes: F16D 2500/3026 Stroke
• CPC Class Codes: F16D 2500/3028 Voltage
• CPC Class Codes: F16D 48/064 Control of electrically or electromagnetically actuated clutches F16D48/062, F16D48/068 take precedence
• CPC Class Codes: F16H 25/08 for interconverting rotary motion and reciprocating motion F16H23/00 takes precedence
• CPC Class Codes: Y10T 74/18296 Cam and slide

Abstract

An actuator that causes a mode clutch to shift between an engaged position and a disengaged position is provided. The actuator comprises a motor having an output. A shift cam is caused to rotate based on the output of the motor. The shift cam has a cam profile surface. A cam follower rides along the cam profile surface upon rotation of the shift cam. Movement of the cam follower causes movement of a mode fork resulting in the mode clutch shifting between the engaged and disengaged positions. A sensor outputs a voltage to a controller based on a physical location of the cam follower. The controller activates the motor based on the voltage.

Claims

1. An actuator that causes a mode clutch to shift between an engaged position and a disengaged position, the actuator comprising:

a motor having an output;

a shift cam that is caused to rotate based on the output of the motor, the shift cam having a cam profile surface;

a cam follower that rides along the cam profile surface upon rotation of the shift cam, wherein movement of the cam follower causes movement of a mode fork resulting in the mode clutch shifting between the engaged and disengaged positions; and

a sensor that outputs a voltage to a controller, wherein the voltage varies based on a physical location of the cam follower and wherein the controller controls the motor based on the voltage of the sensor output;

wherein the output of the motor is configured to rotate in a first direction for movement of the mode clutch from the engaged position to the disengaged position as well as from the disengaged position to the engaged position.

2. The actuator of claim 1 wherein the sensor is a Hall effect transducer.

3. The actuator of claim 1 wherein the cam profile surface of the shift cam has a first surface that corresponds to the mode fork being positioned in the engaged position and a second surface that corresponds to the mode fork being positioned in the disengaged position.

4. The actuator of claim 3 wherein the cam profile surface of the shift cam defines a ramp surface between the first and the second surfaces.

5. The actuator of claim 3, wherein the first surface and the second surface are substantially perpendicular to a rotational axis of the shift cam.

6. The actuator of claim 1, further comprising a biasing member that biases the mode fork toward the engaged position.

7. A method of shifting a mode clutch between an engaged position and a disengaged position, the method comprising:

activating a motor based on an output from a mode select mechanism, wherein activating the motor causes a shift cam to rotate, wherein a cam follower rides along a cam profile of the shift cam causing a mode fork to translate;

monitoring an output voltage of a sensor, wherein the output voltage varies to correspond with a position of the mode fork;

deactivating the motor based on the output voltage being less than a first voltage threshold;

subsequent to deactivating the motor, reactivating the motor based on an output from the mode select mechanism, wherein reactivating the motor causes the shift cam to rotate and the cam follower to ride along the cam profile causing the mode fork to translate, wherein activating and reactivating both comprise rotating an output shaft of the motor in the same direction;

monitoring the output voltage of the sensor; and

deactivating the motor based on the output voltage being greater than a second voltage threshold.

8. A method of shifting a mode clutch between an engaged position and a disengaged position, the method comprising:

activating a motor to rotate an output shaft of the motor in a first rotational direction, rotation of the output shaft causes a shift cam to rotate, wherein a cam follower rides along a cam profile of the shift cam causing a mode fork to translate;

monitoring an output of a sensor, wherein the output of the sensor varies to correspond with a position of the mode fork;

deactivating the motor based on the output of the sensor being less than a first output threshold;

subsequent to deactivating the motor, reactivating the motor to rotate the output shaft of the motor in the first rotational direction to cause the shift cam to rotate and the cam follower to ride along the cam profile causing the mode fork to translate; and

deactivating the motor based on the output of the sensor being greater than a second output threshold.

9. The method of claim 8, wherein activating the motor is based on an output from a mode select mechanism.

10. The method of claim 8, wherein reactivating the motor is based on an output from a mode select mechanism.

11. The method of claim 8, wherein the output of the sensor is a voltage.