Actuator module for a driveline assembly

1. An actuator module for a driveline assembly comprising:

a cover housing;

a fork driving unit supported by the cover housing, the fork driving unit including:

a fork driver axially slidably supported by an unthreaded portion of a fork shaft between multiple shift positions;

a pusher assembly coupled to the fork driver by spaced apart pusher ends;

a drive assembly arranged parallel to the fork shaft, the drive assembly carried by the pusher assembly to translate the fork driver relative to the cover housing, the drive assembly includes a threaded shaft and a drive nut with a threaded inner diameter that threadingly engages the threaded shaft, the threaded shaft parallel to the fork shaft, the pusher assembly includes first and second pushers joined by the drive nut; and

a spring being axially slidably carried by the threaded shaft, biasing the pusher assembly and fork driver to a neutral position.

2. The actuator module of claim 1 , wherein the fork driver includes first and second walls extending from a central portion, the first and second walls have shaped apertures, and the pusher ends are received in the shaped apertures to permit the pusher assembly to axially slide relative to the fork driver between the neutral position and a transition position while preventing rotation of the pusher assembly relative to the fork driver.

3. An actuator module for a driveline assembly comprising:

a cover housing;

a fork driving unit supported by the cover housing, the fork driving unit including:

a fork driver axially slidably supported by a fork shaft between multiple shift positions;

a pusher assembly coupled to the fork driver by spaced apart pusher ends;

a drive assembly arranged parallel to the fork shaft, the drive assembly carried by the pusher assembly to translate the fork driver relative to the cover housing, the drive assembly includes a threaded shaft and a drive nut with a threaded inner diameter that threadingly engages the threaded shaft, the pusher assembly includes first and second pushers joined by the drive nut; and

a spring biasing the pusher assembly and fork driver to a neutral position;

wherein the fork driver includes first and second walls extending from a central portion, the first and second walls have shaped apertures, and the pusher ends are received in the shaped apertures to permit the pusher assembly to axially slide relative to the fork driver between the neutral position and a transition position while preventing rotation of the pusher assembly relative to the fork driver; and

wherein the drive nut has both left-hand threads and right-hand threads, each of the first and second pushers includes a flange seat received in a respective shape aperture, and one end of the spring engages the first wall and the flange seat of first pusher, and another end of the spring engages the second wall and the flange seat of the second pusher.

4. The actuator module of claim 3 , comprising:

a motor supported relative to the cover housing; and

a gearbox coupling a motor and the drive assembly, the gearbox supported relative to the cover housing, wherein the gearbox is provided by a worm and a worm gear mounted to a worm gear bracket secured directly to the cover housing.

5. The actuator module of claim 4 , wherein the bracket is provided by first and second gear housing brackets having an L-shape, each of the first and second gear housing brackets include a mounting flange secured to the cover housing.

6. The actuator module of claim 5 , wherein the first and second gear housing brackets include holes configured to receive bushings that support cylindrical ends of the worm and the worm gear.

7. The actuator module of claim 4 , wherein the threaded shaft has first and second ends, the first end is coupled to the worm gear, and the second end is supported by another bracket secured to the cover housing.

8. The actuator module of claim 3 , comprising:

a printed circuit board;

a motor supported relative to the cover housing;

wherein the drive assembly has a drive axis;

a rotary sensor is in communication with the printed circuit board and arranged in relation to the fork driving unit to measure a position of the fork driver, the rotary sensor has a sensor axis offset from the drive axis, the rotary sensor operatively coupled to the drive assembly and configured to measure the position of the drive assembly; and

a linear sensor assembly mounted to the fork driver and configured to measure the position of the fork driver.

9. The actuator module of claim 8 , comprising a gearbox coupling the motor and the drive assembly the gearbox is supported relative to the cover housing.

10. The actuator module of claim 8 , wherein the rotary sensor assembly includes a drive pulley attached to threaded shaft, an anchor pin is mounted to the cover housing to support a follow pulley to which the rotary sensor is mounted, and a belt interconnects the drive and follow pulleys.

11. The actuator module of claim 1 , wherein the cover housing assembly includes first and second cover portions enclosing the drive assembly.

12. The actuator module of claim 11 , comprising a motor, and a gearbox coupling the motor and the drive assembly, the motor and the gearbox arranged between the first and second cover portions.

13. The actuator module of claim 12 , wherein the threaded shaft has first and second ends, the first end is coupled to the gearbox, and the second end is supported by a bracket secured to the cover housing.

14. The actuator module of claim 3 , wherein the drive assembly has a drive axis, and comprising a rotary sensor assembly having a rotary sensor with a sensor axis offset from the drive axis, the rotary sensor operatively coupled to the drive assembly and configured to measure a position of the fork driver.

15. The actuator module of claim 3 , comprising a linear sensor assembly mounted to the fork driver and configured to measure a position of the fork driver.

16. The actuator module of claim 3 , comprising a gearbox coupling a motor and the drive assembly, the gearbox has a worm and a worm gear mounted to first and second gear housing brackets having an L-shape, each of the first and second gear housing brackets include a mounting flange secured to the cover housing.

17. The actuator module of claim 16 , wherein the motor is connected to the worm, and the drive assembly is connected to the worm gear.