New Venture Gear, Inc.

Joseph A Winks

David Sperduti

Richard E Eastman

Robert J Wilson

Randy W Adler

Neville K Divecha

Bradley T Fox

A clutched actuator for use in a transfer case is disclosed which may be used in conjunction with electronic traction control systems and anti-lock braking systems where the clutched actuator system is required to quickly disengage the four-wheel drive of the vehicle. The clutched actuator is operably coupled to the transfer case of the vehicle drive system through a sector plate. The clutched actuator includes a worm drive motor assembly providing the base driving mechanism, a clutching mechanism, and a gear reduction mechanism for reducing the torque capacity required of the clutch mechanism. When the clutching mechanism is engaged, power is transmitted from the worm drive through the gear reduction mechanism to the output shaft to selectively engage the mode of operation of the transfer case, i.e., two-wheel or four-wheel drive mode, and the drive torque distribution between the front and rear wheels. The worm gear is non-backdrivable such that the motor need not provide a holding torque. When the clutching mechanism is disengaged, the worm drive is decoupled from the gear reduction mechanism for eliminating the holding torque and inertia associated with those components such that the energy stored in the transfer clutch can be quickly released.

Clutching actuator for clutch control system in a drive line apparatus

A transfer case includes an input shaft driven by the output of an engine and transmission, a first output shaft connected to a first driveline, a second output shaft connected to a second driveline, and a power transfer mechanism for transferring drive torque from the input shaft to at least one of the output shafts. The power transfer mechanism includes a gear reduction unit driven by the input shaft and a range clutch operable for engaging the gear reduction unit to establish high-range and low-range drive modes between the input shaft and the first output shaft. A transfer case shift control system controls actuation of the range clutch during motive operation of the motor vehicle, thereby permitting on-the-move shifting of the transfer case between its high-range and low-range drive modes. The transfer case shift control system includes a mode selector for generating a mode signal, a relay circuit interconnected between the engine's fuel and ignition systems and a powertrain control module of the motor vehicle, and a transfer case control module receiving the mode signal and vehicle input signals from the powertrain control module. The transfer case module generates a control signal based on the mode signal and the input signals and, if necessary, sends the control signal to the relay circuit for varying characteristics of the vehicle's fuel and ignition systems to reduce the amount of engine torque delivered to the input shaft independent of the powertrain control module. Thereafter, the transfer case control module generates a shift signal for actuating the range clutch to establish the selected one of the high-range and low-range drive modes.

Transfer case shift control system using automatic shutdown relay circuit

The present invention provides a clutch assembly operative to transmit forces between an input and an output and includes a first set of plates connected to the input and a second set of plates connected to the output. The first and second plates are alternately interleaved to form a clutch pack and friction material is disposed on both sides of each of the second plates. An engagement mechanism is coupled for rotation with the input and is operable for applying a compressive force to the interleaved clutch pack thereby creating friction forces that transfer forces between the input and the output. By placing the friction material on both sides of the second clutch plates rather than the first clutch plates, the improvement provides for greater torque transfer efficiency and heat dissipation over existing clutch assemblies.

Clutch pack with double-sided clutch plates

The present invention provides a power transfer system for a four-wheel drive vehicle which permits the vehicle operator to choose between operation in two-wheel drive and part-time four-wheel drive modes or an 'on-demand' four-wheel drive mode. The power transfer system is operable for disabling the on-demand four-wheel drive feature upon the vehicle operator subsequently shifting into any of the two-wheel drive and part-time four-wheel drive modes.

Power transfer system for a four-wheel drive vehicle

The present invention is directed to an improved 'on-demand' power transfer system of the type having a transfer mechanism incorporated into the driveline of a four-wheel drive vehicle. The transfer mechanism is arranged to deliver drive torque to the driven wheels so as to establish a two-wheel drive mode of operation. In addition, the transfer mechanism is equipped with a clutch assembly for selectively delivering drive torque to the non-driven wheels for establishing a four-wheel drive mode of operation. The transfer mechanism is further equipped with a rotary actuator mechanism for actuating the clutch assembly. The rotary actuator mechanism is preferably mounted directly to the transfer mechanism to substantially minimize the packaging requirements associated with the on-demand power transfer system while concomitantly enhancing in-service reliability and allowing pre-assembly of the transfer mechanism prior to final installation into the vehicle driveline. The power transfer system further includes sensors for detecting various dynamic and operational characteristics of the vehicle and generating sensor input signals indicative thereof, and a controller for controlling actuation of the rotary actuator means in response to the sensor input signals.

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West Monroe, NY, United States of America

Joseph A Winks