Borgwarner Inc.

Travis J Wentz

Christopher Anthony Chirco

Michael Robert Palazzolo

Bruce Alan Churchill

Paul Matthew Riggs

Stephen D Tucker

Abhinav Jain

Ryo Takagi

Jagdish Daphal

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 or tooth-on-tooth contact inhibits the mode mechanism from changing between a two-wheel drive mode and a four-wheel drive mode. A sensor target and sensor are employed to identify the rotational positioning of the cam structure placement, which is indicative of the modes in which the transmission and the clutch are operating.

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

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.

A chain drive system having chain links, guide links disposed on opposite lateral sides of the chain links, and pivot pins that extend through the chain links and are fixedly coupled to the guide links. Mating anti-rotation features are employed between each pivot pin and a corresponding one of the guide links to resist rotation between the pivot pin and the guide link.

Chain drive system having anti-rotation features between pivot pin and guide link and related assembly method

A transfer case having an actuator assembly with a plastic actuator structure and a cam follower. The actuator structure defines a sleeve structure, a fork structure and a follower mount. The sleeve structure defines a shaft aperture that extends longitudinally along an actuation axis. The fork structure extends radially outwardly from the sleeve structure and defines a U-shaped fork member having a pair of tines that are disposed about an engagement axis that is parallel to and radially offset from the actuation axis. The follower mount extends radially outwardly from the sleeve structure. The cam follower is formed of metal and is partly encapsulated in the plastic material of the actuator structure. The cam follower extends from the follower mount along a follower axis that is parallel to the actuation axis. The follower axis is rotated about the actuation axis relative to the engagement axis.

Transfer case having an actuator assembly with cam follower that is molded into a plastic actuator structure

A transfer case includes an input shaft, a primary output shaft, a secondary output shaft, and an actuator. The primary output shaft is coupled to the input shaft with a gear reduction mechanism. The secondary output shaft is selectively coupleable to the primary output shaft with a secondary torque transfer mechanism. The actuator includes a first actuation mechanism, a second actuation mechanism, and a driver gear assembly. The first actuation mechanism is configured to operate the gear reduction mechanism. The second actuation mechanism is configured to operate the secondary torque transfer mechanism. The drive gear assembly includes a gear plate member, a sense plate member configured to engage the first actuation mechanism, and a hub member configured to engage the second actuation. The sense plate member and the hub member are independently coupled to the gear plate member to rotate in unison with the gear plate member.

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Rochester, MI, United States of America

Travis J Wentz