Borgwarner Inc.

Abhinav Jain

Travis J Wentz

Mallikarjun Rudagi

Sathya Vaidyanathan

Stephen D Tucker

A transfer case with an actuator for operating a two-speed transmission (i.e., range mechanism) and a clutch (i.e., mode mechanism). The actuator employs a motor-driven cam structure that coordinates the movement of a first fork, which is associated with the range mechanism, and a second fork that is associated with the mode mechanism. A resilient coupling is employed to provide compliance between the motor and the cam structure in the event that tooth-on-tooth contact inhibits the range mechanism from changing from a high-range mode and a low range mode. Compliance is provided between the cam structure and the second fork in the event that tooth-on-tooth contact inhibits the mode mechanism from changing from aWD mode to aWD mode. A sensor system identifies the placement of the first and second forks in various positions and responsively generates associated sensor signals.

Transfer case with range and mode actuator having cam follower mechanism to overcome blocked shift events and sensor configuration permitting detection of fork positions

An actuation system of a transfer case includes a face cam, a motor, a gear reduction assembly, and an intermediate rotating member. The face cam includes a first member and a second member, and rotation of the first member relative to the second annular causes the first member or the second annular member to displace axially relative to the other member for selective operation of a torque transfer mechanism of the torque transfer device. The gear reduction assembly includes a first planetary gear set that increases torque from the motor by a first ratio, and a second planetary gear set that increases torque from the first planetary gear set by a second ratio and is coaxial with the first planetary gear set and the motor. The intermediate rotating member is rotated by the gear reduction assembly and rotates the first annular member for selective operation of the torque transfer mechanism.

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Rochester, MI, United States of America

Abhinav Jain