Electro-mechanical transfer case with range shift on the move

1. In a transfer case ( 21 , 310 ) for a four-wheel drive vehicle having an input shaft ( 15 ) and a first output shaft ( 14 ) located along a common longitudinal axis, a second output shaft ( 16 ), a mode clutch ( 30 ) located along the longitudinal axis for selectively shifting between a two-wheel drive mode and a four-wheel drive mode, and a planetary gear assembly ( 20 ) for providing a different drive ratio between the input shaft ( 15 ) and the first output shaft ( 14 ), the planetary gear assembly ( 20 ) having a sun gear ( 22 ) fixed to the input shaft ( 15 ), a ring gear ( 24 ), and a planetary gear carrier ( 26 ) supporting a plurality of planetary gears ( 28 ) intermeshed between the sun gear ( 22 ) and the ring gear ( 24 ), the improvement comprising:

a range shift mechanism ( 50 , 360 , 460 ) for shifting between a high-range drive mode and a low-range drive mode, the first output shaft ( 14 ) driven by the sun gear ( 22 ) during the high-range drive mode and driven by the planetary gear carrier ( 26 ) during the low-range drive mode, the ring gear ( 24 ) grounded against rotation during the high-range drive mode and the low-range drive mode;

and

a mode shift mechanism ( 56 , 380 , 480 ) located adjacent the range shift mechanism ( 50 , 360 , 460 ) along the longitudinal axis and axially moveable for engaging and disengaging the mode clutch ( 30 ), the mode shift mechanism ( 56 ) including a mode hub ( 42 ) coupled to the first output shaft ( 14 ), an internal mode sleeve ( 54 ) axially moveable and splined for engagement with the mode clutch ( 30 ) through a clutch housing ( 82 ), a power transmission member ( 36 ) having a drive gear ( 38 ) coupled to the first output shaft ( 14 ) for transmitting rotary power to a driven sprocket ( 44 ) coupled to the second output shaft ( 16 ), and a clutch actuator ( 76 ) engageable with the mode hub ( 42 ) for movement of the internal mode sleeve ( 54 ).

2. The improvement of claim 1 further comprising:

a synchronizer ( 40 , 340 ) connected to the first output shaft ( 14 ) and located adjacent the planetary gear assembly ( 20 ) along the longitudinal axis, the synchronizer ( 40 , 340 ) for synchronizing speed of the input shaft ( 15 ) and the first output shaft ( 14 ) before drivingly connecting the first output shaft ( 14 ) with the sun gear ( 22 ) during the high-range drive mode and with the planetary gear carrier ( 26 ) during the low-range drive mode.

3. The improvement of claim 2 , wherein the synchronizer ( 40 ) further comprises:

a first synchronizer assembly ( 66 ) having a first blocker ring ( 90 ) preventing driving connection between a first member ( 114 ) connected to the sun gear ( 22 ) and the first output shaft ( 14 ) during the high-range drive mode until the sun gear ( 22 ) and the first output shaft ( 14 ) are rotating at an approximately common speed; and

a second synchronizer assembly ( 68 ) having a second blocker ring ( 290 ) preventing driving connection between a second member ( 214 ) connected to the planetary gear carrier ( 26 ) and the first output shaft ( 14 ) during the low-range drive mode until the planetary gear carrier ( 26 ) and the first output shaft ( 14 ) are rotating at an approximately common speed.

4. The improvement of claim 3 , wherein the range shift mechanism ( 50 ) further comprises:

a synchronizer hub ( 70 ) interposed between the first and second synchronizer assemblies ( 66 , 68 ), the synchronizer hub ( 70 ) coupled to the first output shaft ( 14 ) and having an outer spline surface ( 120 );

a shift sleeve ( 52 ) moveable along the longitudinal axis engageable with the first and second synchronizer assemblies ( 66 , 68 ), the shift sleeve ( 52 ) having a diameter greater than a diameter of the synchronizer hub ( 70 ) and an inner spline surface ( 118 ) engageable with the outer spline surface ( 120 ) and external teeth ( 90 b , 290 b ) located on the first and second blocker rings ( 90 , 290 );

a shift fork ( 58 ) for axially moving the shift sleeve ( 52 ) along the longitudinal axis engageable with the first and second synchronizer assemblies ( 66 , 68 ); and

a shift actuator ( 74 ) for actuating the shift fork ( 58 ).

5. The improvement of claim 4 , wherein the synchronizer hub ( 70 ) further comprises:

the synchronizer hub ( 70 ) having a plurality of recesses ( 122 ) equally spaced concentrically about the synchronizer hub ( 70 ); and

a plurality of struts ( 84 ) received within the corresponding plurality of recesses ( 122 ) formed in the synchronizer hub ( 70 ), the plurality of struts ( 84 ) having splined surfaces ( 128 ) engageable with the inner spline surface ( 118 ) of the shift sleeve ( 52 ) and normally biased radially inward toward the longitudinal axis, the plurality of struts ( 84 ) shifted radially within the plurality of recesses ( 122 ) during axial movement of the shift sleeve ( 52 ).

6. The improvement of claim 3 , wherein each of the first and second synchronizer assemblies ( 66 , 68 ) further comprises:

a cone shaped body ( 92 , 292 ) having a first cone surface ( 92 a , 292 a );

an inner cone ring ( 94 , 294 ) having a second cone surface ( 100 , 200 );

an outer cone ring ( 96 , 296 ) having a first blocking surface ( 104 , 204 ) engageable with the first cone surface ( 92 a , 292 a ) and a second blocking surface ( 106 , 206 ) engageable with second cone surface ( 100 , 200 ); and

each of the first and second blocker rings ( 90 , 290 ) having a third cone surface ( 102 , 202 ), the inner cone ring ( 94 , 294 ) having a third blocking surface ( 108 , 208 ) engageable with the third cone surface ( 102 , 202 ).

7. In a transfer case ( 21 , 310 ) for a four-wheel drive vehicle having an input shaft ( 15 ) and a first output shaft ( 14 ) located along a common longitudinal axis, a second output shaft ( 16 ), a mode clutch ( 30 ) located along the longitudinal axis for selectively shifting between a two-wheel drive mode and a four-wheel drive mode, and a planetary gear assembly ( 20 ) for providing a different drive ratio between the input shaft ( 15 ) and the first output shaft ( 14 ), the planetary gear assembly ( 20 ) having a sun gear ( 22 ) fixed to the input shaft ( 15 ), a ring gear ( 24 ), and a planetary gear carrier ( 26 ) supporting a plurality of planetary gears ( 28 ) intermeshed between the sun gear ( 22 ) and the ring gear ( 24 ), the improvement comprising:

a range shift mechanism ( 50 , 360 , 460 ) for shifting between a high-range drive mode and a low-range drive mode, the first output shaft ( 14 ) driven by the sun gear ( 22 ) during the high-range drive mode and driven by the planetary gear carrier ( 26 ) during the low-range drive mode, the ring gear ( 24 ) grounded against rotation during the high-range drive mode and the low-range drive mode;

a mode shift mechanism ( 56 , 380 , 480 ) located adjacent the range shift mechanism ( 50 , 360 , 460 ) along the longitudinal axis and axially moveable for engaging and disengaging the mode clutch ( 30 );

a clutch actuator ( 388 , 488 ) moveable between an expanded position and a contracted position engageable with the mode clutch ( 30 );

an actuating gear ( 348 , 448 ) axially interposed between the range shift mechanism ( 360 , 460 ) and the mode shift mechanism ( 380 , 480 ), the actuating gear ( 348 , 448 ) reversibly rotatable through a predetermined angular arc of movement for operating the clutch actuator ( 388 , 488 ) between the contracted position and the expanded position for actuating the mode clutch ( 30 ) between a disengaged position and an engaged position, and for shifting the range shift mechanism ( 360 , 460 ) between the low-range drive mode and the high-range drive mode when the mode clutch ( 30 ) is in the disengaged position; and

a barrel cam ( 359 , 459 ) connected for rotation in response to rotation of the actuating gear ( 348 , 448 ) defining a cam surface groove ( 357 , 457 ), the cam surface groove having end portions and an intermediate portion extending between the end portions, each end portion corresponding to one of the low-range drive mode and the high-range drive mode and allowing actuation of the clutch actuator ( 388 , 488 ) while in one of the low-range drive mode and the high-range drive mode.

8. The improvement of claim 7 further comprising:

a synchronizer ( 40 , 340 ) connected to the first output shaft ( 14 ) and located adjacent the planetary gear assembly ( 20 ) along the longitudinal axis, the synchronizer ( 40 , 340 ) for synchronizing speed of the input shaft ( 15 ) and the first output shaft ( 14 ) before drivingly connecting the first output shaft ( 14 ) with the sun gear ( 22 ) during the high-range drive mode and with the planetary gear carrier ( 26 ) during the low-range drive mode.

9. The improvement of claim 8 , wherein the range shift mechanism ( 360 , 460 ) further comprises:

at least one spring ( 362 , 462 ) engageable between the barrel cam ( 359 , 459 ) and the actuating gear ( 348 , 448 ) for biasing the barrel cam ( 359 , 459 ) to follow reversible rotational movement of the actuating gear ( 348 , 448 );

a shift fork ( 368 ) for guided travel along the cam surface groove ( 357 , 457 ) of the barrel cam ( 359 , 459 ) in response to rotation of the barrel cam ( 359 , 459 ) by the actuating gear ( 348 , 448 ) to shift between the low-range drive mode and the high-range drive mode;

a shift collar ( 370 ) defining an axial groove ( 371 ) and for supporting the shift fork ( 368 ) to allow axial movement of the shift fork ( 368 ) while restricting rotation of the shift fork ( 368 ); and

a range sleeve ( 363 ) supported for rotation with respect to the shift fork ( 368 ) while being driven in axial movement in response to axial movement of the shift fork ( 368 ) with respect to the shift collar ( 370 ) in response to rotation of the barrel cam ( 359 , 459 ) with respect to the shift collar ( 370 ), the range sleeve ( 363 ) connected for driving rotation of the first output shaft ( 14 ) through the synchronizer ( 340 ).

10. The improvement of claim 9 , wherein the synchronizer ( 340 ) further comprises:

a transmitter connected to a flange ( 364 ) of the range sleeve ( 363 ) extending radially outwardly with respect to the longitudinal axis, the transmitter having an external splined surface ( 342 a , 342 b ) and axially moveable for transferring torque from the input shaft ( 15 ) to the first output shaft ( 14 ) through the planetary gear carrier ( 26 ) in the low-range drive mode and through the sun gear ( 22 ) in the high-range drive mode;

a first gear ( 345 a ) mounted to the longitudinal axis and adjacent the transmitter, the first gear ( 345 a ) connected to the planetary gear carrier ( 26 ) and having an internal splined surface engageable with the external splined surface ( 342 a ) of the transmitter for establishing the low-range drive mode;

a second gear ( 345 b ) mounted to the longitudinal axis and adjacent the transmitter, the transmitter interposed between the first gear ( 345 a ) and the second gear ( 345 b ), the second gear ( 345 b ) connected to the sun gear ( 22 ) and having an internal splined surface engageable with the external splined surface ( 342 b ) of the transmitter for establishing the high-range drive mode;

a first synchronizer ring ( 349 a ) interposed between the transmitter and the first gear ( 345 a ), the first synchronizer ring ( 349 a ) having an internal splined surface engageable with the external splined surface ( 342 a ) of the transmitter for preventing driving connection between the transmitter and the first gear ( 345 a ) until the transmitter and the first gear ( 345 a ) are rotating at an approximately common speed in the low-range drive mode; and

a second synchronizer ring ( 349 b ) interposed between the transmitter and the second gear ( 345 b ), the second synchronizer ring ( 349 b ) having an internal splined surface engageable with the external splined surface ( 342 b ) of the transmitter for preventing driving connection between the transmitter and the second gear ( 345 b ) until the transmitter and the second gear ( 345 b ) are rotating at an approximately common speed in the high-range drive mode.

11. The improvement of claim 7 , wherein the clutch actuator ( 488 ) further comprises:

the clutch actuator ( 488 ) engageable with a face of the actuating gear ( 448 ) opposite from the range shift mechanism ( 460 ), the clutch actuator ( 488 ) including a plurality of clutch-actuating tabs ( 489 ) engageable with a corresponding plurality of elongated arcuate pocket slots ( 461 ) defined by the actuating gear ( 448 ), the clutch actuator ( 488 ) defining a plurality of elongated arcuate recesses ( 490 ) having a deep central portion tapering to a shallow depth at outer ends ( 494 );

a corresponding plurality of rolling members ( 492 ), a rolling member ( 492 ) received within each of the plurality of elongated arcuate recesses ( 490 ) for movement along the elongated arcuate recess ( 490 ) between a deeper central portion of the recess ( 490 ) and a shallower outer end ( 494 ) of the recess ( 490 ); and

an axially movable intermediate plate ( 478 ) trapping the plurality of rolling members ( 492 ) interposed between the intermediate plate ( 478 ) and the clutch actuator ( 488 ), the intermediate plate ( 478 ) for shifting the mode clutch between a first axial clutch position and a second axial clutch position in response to movement of the rolling member from the deeper central portion of the recess ( 490 ) to the shallower outer end ( 494 ) of the recess ( 490 ).

12. The improvement of claim 7 , wherein the clutch actuator ( 388 ) further comprises:

a clutch actuating cam ( 388 b ) rotatable in response to rotation of the actuating gear ( 348 ) and axially moveable towards the mode clutch ( 30 ) for engaging the mode clutch ( 30 );

a retainer ( 388 a ) supported for preventing rotation with the actuating gear ( 348 ) and axially interposed between the range shift mechanism ( 360 ) and the clutch actuating cam ( 388 b ), the retainer ( 388 a ) defining a plurality of elongated arcuate recesses ( 390 ) having a deep central portion tapering to a shallow depth at outer ends ( 394 );

a corresponding plurality of rolling members ( 392 ), a rolling member ( 392 ) received within each of the plurality of elongated arcuate recesses ( 390 ) for movement along the elongated arcuate recesses ( 390 ) between the deep central portion of the recess and the shallow depth at outer ends ( 394 ) of each recess, the clutch actuating cam ( 388 b ) trapping the plurality of rolling members ( 392 ) interposed between the retainer ( 388 a ) and the clutch actuating cam ( 388 b ), the clutch actuating cam ( 388 b ) angularly rotatable with respect to the retainer ( 388 a ) and axially moveable toward the mode clutch ( 30 ) for engaging the mode clutch ( 30 ) in response to movement of the rolling member ( 392 ) from the deep central portion of the recess ( 390 ) to the shallow depth at outer ends ( 394 ) of the recess; and

a plurality of pins ( 396 ) located on a surface ( 398 ) of the clutch actuating cam ( 388 b ) for imparting angular rotation to the clutch actuating cam ( 388 b ) with respect to the retainer ( 388 a ) through the actuating gear ( 348 ), while allowing axial movement of the clutch actuating cam ( 388 b ) with respect to the retainer ( 388 a ) providing a free floating movement between the clutch actuating cam ( 388 b ) and the actuating gear ( 348 ).

13. The improvement of claim 7 further comprising:

a reversible electric motor ( 344 ) located off axis with respect to the longitudinal axis; and

a gear train ( 346 ) reversibly driven by the electric motor ( 344 ) for driving the actuating gear ( 348 , 448 ) in rotation.

14. The improvement of claim 7 further comprising:

at least one sensing element ( 323 ) located on a peripheral surface of the actuating gear ( 348 ) for detecting a position of the actuating gear ( 348 ); and

an engine control unit ( 321 ) for actuating the range shift mechanism ( 360 ) and the mode shift mechanism ( 380 ) in response to a detected position of the actuating gear ( 348 ) by the at least one sensing element ( 323 ).

15. A method for assembling a transfer case ( 21 , 310 ) for a four-wheel drive vehicle having an input shaft ( 15 ) rotatably driven by an engine and located along a longitudinal axis, a first output shaft ( 14 ) and a second output shaft ( 16 ) corresponding to a front driveline and a rear driveline, the first output shaft ( 14 ) located along the longitudinal axis, a planetary gear assembly ( 20 ) for changing a drive ratio between the input shaft ( 15 ) and the first output shaft ( 14 ), and a mode clutch ( 30 ) located along the longitudinal axis for selectively shifting between a two-wheel drive mode and a four-wheel drive mode, the planetary gear assembly ( 20 ) having a sun gear ( 22 ) fixed to the input shaft ( 15 ), a ring gear ( 24 ), a planetary gear carrier ( 26 ) supporting a plurality of planetary gears ( 28 ) intermeshed between the sun gear ( 22 ) and the ring gear ( 24 ), the method comprising:

inserting a range shift mechanism ( 50 , 360 , 460 ) along the longitudinal axis for shifting between a high-range drive mode and a low-range drive mode, wherein the first output shaft ( 14 ) is driven by the sun gear ( 22 ) during the high-range drive mode and is driven by the planetary gear carrier ( 26 ) during the low-range drive mode;

mounting the ring gear ( 24 ) in a fixed stationary position with respect to the planetary gear assembly ( 20 ), the ring gear ( 24 ) fixed during the high-range drive mode and the low-range drive mode;

mounting a synchronizer ( 40 , 340 ) to the first output shaft ( 14 ) and adjacent the planetary gear assembly ( 20 ) along the longitudinal axis, the synchronizer ( 40 , 340 ) for synchronizing speed of the input shaft ( 15 ) and the first output shaft ( 14 ) before drivingly connecting the first output shaft ( 14 ) with the sun gear ( 22 ) during the high-range drive mode and with the planetary gear carrier ( 26 ) during the low-range drive mode; and

inserting a mode shift mechanism ( 56 , 380 , 480 ) adjacent the range shift mechanism ( 50 , 360 , 460 ) along the longitudinal axis, the mode shift mechanism ( 56 , 380 , 480 ) axially moveable for engaging and disengaging the mode clutch ( 30 ).

16. The method of claim 15 , wherein the mode shift mechanism ( 56 ) includes a mode hub ( 42 ) coupled to the first output shaft ( 14 ), an internal mode sleeve ( 54 ) axially moveable and splined for engagement with the mode clutch ( 30 ) through a clutch housing ( 82 ), a power transmission member ( 36 ) having a drive gear ( 38 ) coupled to the first output shaft ( 14 ) for transmitting rotary power to a driven sprocket ( 44 ) coupled to the second output shaft ( 16 ), and a clutch actuator ( 76 ) engageable with the mode hub ( 42 ) for movement of the internal mode sleeve ( 54 ).

17. The method of claim 15 further comprising:

inserting a clutch actuator ( 388 , 488 ) moveable between an expanded position and a contracted position engageable with the mode clutch ( 30 );

connecting an actuating gear ( 348 , 448 ) axially interposed between the range shift mechanism ( 360 , 460 ) and the mode shift mechanism ( 380 , 480 ), the actuating gear ( 348 , 448 ) reversibly rotatable through a predetermined angular arc of movement for operating the clutch actuator ( 388 , 488 ) between the contracted position and the expanded position for actuating the mode clutch ( 30 ) between a disengaged position and an engaged position, and for shifting the range shift mechanism ( 360 , 460 ) between the low-range drive mode and the high-range drive mode when the mode clutch ( 30 ) is in the disengaged position; and

connecting a barrel cam ( 359 , 459 ) for rotation in response to rotation of the actuating gear ( 348 , 448 ), the barrel cam ( 359 , 459 ) defining a cam surface groove ( 357 , 457 ) having end portions and an intermediate portion extending between the end portions, each end portion corresponding to one of the low-range drive mode and the high-range drive mode and allowing actuation of the clutch actuator ( 388 , 488 ) while in one of the low-range drive mode and the high-range drive mode.