Axle assembly with sector cam

Abstract

An axle assembly includes a sector cam. The sector cam is rotatable about a sector cam axis and is operatively connected to a first shift collar and a second shift collar. Rotation of the sector cam about the sector cam axis controls movement of the first shift collar and the second shift collar.

Description

Technical Field

[0001] The present invention relates to an axle assembly having a sector cam for controlling the movement of at least one shift collar. background

[0002] A powertrain assembly having a shift mechanism including a sector cam is disclosed in US Pat. No. 10,900,564.

[0003] Overview

[0004] In at least one embodiment, an axle assembly is provided. The axle assembly may include a first shaft, a second shaft, a first gear set, a second gear set, a first shift collar, a second shift collar, and a cam segment. The first shaft may be rotatable about a first axis. The second shaft may be rotatable about a second axis. The first gear set may be rotatable about the first axis. The second gear set may be rotatable about the second axis. Each member of the second gear set may mesh with a different member of the first gear set. The first shift collar may be rotatable with the first shaft about the first axis and may be movable relative to the first shaft along the first axis to selectively connect members of the first gear set to the first shaft. The second shift collar may be rotatable with the second shaft about the second axis and may be movable relative to the second shaft along the second axis to selectively connect members of the second gear set to the second shaft. The cam segment may be rotatable about a cam segment axis and may be operatively connected to the first shift collar and the second shift collar. Rotation of the cam segment about the cam segment axis may control movement of the first shift collar along the first axis and movement of the second shift collar along the second axis. BRIEF DESCRIPTION OF THE DRAWINGS

[0005] Figure 1 is a schematic diagram of an example of an axle assembly.

[0006] Figure 2 is a perspective view of an example of a transmission and shifting mechanism that may be provided with an axle assembly.

[0007] Figure 3 is a perspective view of a portion of the transmission associated with the first shaft.

[0008] Figure 4 is a cross-sectional view along section line 4-4.

[0009] Figure 5 is a perspective view of a portion of the transmission associated with the second shaft.

[0010] Figure 6 is a cross-sectional view along section line 6-6.

[0011] Figure 7It is a perspective view of the gear shift mechanism.

[0012] Figure 8 is a side view showing the shift mechanism in the low speed position.

[0013] Figure 9 It is a side view showing the shift mechanism in the middle speed position.

[0014] Figure 10 is a side view showing the shift mechanism in the neutral position.

[0015] Figure 11 is a side view showing the shift mechanism in the high speed position. DETAILED DESCRIPTION

[0016] As required, detailed embodiments of the present invention are disclosed herein; however, it should be understood that the disclosed embodiments are merely examples of the invention that may be embodied in various and alternative forms. The drawings are not necessarily to scale; some features may be exaggerated or minimized to illustrate details of particular components. Therefore, the specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention.

[0017] refer to Figure 1 , shows an example of an axle assembly 10. The axle assembly 10 may be provided for a vehicle, such as a truck, a bus, farm equipment, mining equipment, a military transport or armored vehicle, or cargo loading equipment for land, air, or marine vessels. In one or more embodiments, the vehicle may include a trailer for transporting cargo.

[0018] The axle assembly 10 may provide torque to one or more traction wheel assemblies, which may include tires 12 mounted on wheels 14. The wheels 14 may be mounted to hubs that may be rotatable about a wheel axis 16.

[0019] The axle assembly 10 may include or be operatively connected to a torque source 20. The torque source 20 may be of any suitable type. For example, the torque source 20 may be a non-electric torque source, an electric torque source, or a combination thereof. An example of a non-electric torque source is an internal combustion engine. An example of an electric torque source is an electric motor 22. The electric motor 22 may include a stator 24 and a rotor 26 rotatable about an axis. A power source 28 (such as a battery, a capacitor, a generator, etc.) may be electrically connected to the electric motor 22 in a manner known to those skilled in the art.

[0020] In at least one configuration, the axle assembly 10 may include a differential assembly 30, at least one half shaft 32, and a transmission 34. The axle assembly 10 may also include Figure 2 The shift mechanism 36 is shown.

[0021] refer to Figure 1 The differential assembly 30 can transfer torque to the vehicle's traction wheel assembly and allow the traction wheel assembly to rotate at different speeds. Furthermore, the differential assembly 30 can be operatively connected to the axle shafts 32 and can allow the axle shafts 32 to rotate at different rotational speeds in a manner known to those skilled in the art. For example, the differential assembly 30 can be rotatable about a differential axis 40 and can transfer torque to the axle shafts 32 and the wheels. In one or more configurations, the differential axis 40 can be coaxially arranged with the wheel axis 16. In at least one configuration, the differential assembly 30 can include a ring gear 42 having teeth that mate or mesh with teeth on a gear portion 44 of a drive pinion 46, which can be associated with the transmission 34. Accordingly, the differential assembly 30 can receive torque from the drive pinion 46 via the ring gear 42 and transfer the torque to the axle shafts 32.

[0022] Axle shafts 32 can transfer torque between the differential assembly 30 and the traction wheel assembly. Two axle shafts 32 can be provided, extending in opposite directions from the differential assembly 30. Each axle shaft 32 can have a first end and a second end. The first end can be operatively connected to the differential assembly 30. The second end can be arranged opposite the first end and can be operatively connected to the wheel. Axle shafts 32, or portions thereof, can extend along an axis, such as the differential axis 40, and can be rotatable about the axis.

[0023] The transmission 34 can transfer torque between the torque source 20 and the differential assembly 30. The torque transfer can be bidirectional. Figure 3 and Figure 4 In at least one configuration shown, the transmission 34 can include a first shaft 50, a first gear set 52, and a first shift collar 54. Figure 5 and Figure 6 As best shown in FIG, the transmission 34 may also include a second shaft 60 , a second gear set 62 , and a second shift collar 64 .

[0024] Main references Figure 3 and Figure 4 , the first shaft 50 can be rotatable around the first axis 70. Figure 1As shown, the first axis 70 can be substantially perpendicular to the differential axis 40. The term "substantially perpendicular" is used herein to refer to features (such as axes) that are perpendicular or very close to perpendicular relative to each other, and includes features that are perpendicular to each other within ±2°. For example, the first shaft 50 can be rotatably supported by one or more bearings (such as a first bearing 72 and a second bearing 74). The first bearing 72 and the second bearing 74 can have any suitable configuration. For example, the first bearing 72 and the second bearing 74 can be configured as a roller bearing assembly that can surround the first shaft 50. In at least one configuration, the first shaft 50 can be part of the drive pinion 46 or can be rotatable with the drive pinion 46.

[0025] The first gear set 52 can include a plurality of gears rotatable about a first axis 70. In the illustrated configuration, the first gear set 52 includes a first drive gear 80, a second drive gear 82, and a third drive gear 84; however, it should be understood that a greater or fewer number of gears can be provided. When the gears are coupled to the first shaft 50, the components of the first gear set 52 can rotate with the first shaft 50 about the first axis 70. Conversely, the first shaft 50 can rotate about the first axis 70 relative to the components of the first gear set 52 that are decoupled from or not coupled to the first shaft 50. The components of the first gear set 52 can be selectively coupled to the first shaft 50 via the first shift collar 54, as will be discussed in more detail below.

[0026] The first drive gear 80 can receive the first shaft 50. For example, the first drive gear 80 can have a through-hole through which the first shaft 50 can extend. The first drive gear 80 can extend about the first axis 70 and the first shaft 50 and can have a plurality of teeth that can be arranged about the first axis 70 and facing away from the first axis. The teeth of the first drive gear 80 can contact and mate or mesh with the teeth of the first gear of the second gear set 62, as will be discussed in more detail below. In at least one configuration, the first drive gear 80 can be fixedly coupled to the first shaft 50 such that the first drive gear 80 can rotate with the first shaft 50 about the first axis 70 and such that the first drive gear 80 cannot rotate relative to the first shaft 50 about the first axis 70. In at least one configuration, the first drive gear 80 can be axially positioned between the gear portion 44 and the second drive gear 82 along the first axis 70. For example, the first drive gear 80 can be axially positioned between the first bearing 72 and the spacer 86.

[0027] The second drive gear 82 can receive the first shaft 50. For example, the second drive gear 82 can have a through-hole through which the first shaft 50 can extend. The second drive gear 82 can extend about the first axis 70 and the first shaft 50 and can have a plurality of teeth that can be arranged about the first axis 70 and facing away from the first axis. The teeth of the second drive gear 82 can contact and mate or mesh with the teeth of the second gear of the second gear set 62, as will be discussed in more detail below. In at least one configuration, the second drive gear 82 can be fixedly coupled to the first shaft 50 such that the second drive gear 82 can rotate with the first shaft 50 about the first axis 70 and such that the second drive gear 82 does not rotate relative to the first shaft 50 about the first axis 70. In at least one configuration, the second drive gear 82 can be axially positioned between the first drive gear 80 and the third drive gear 84 along the first axis 70. Furthermore, the second drive gear 82 can be axially positioned closer to the third drive gear 84 than to the first drive gear 80. For example, a spacer 86 can be positioned between the first drive gear 80 and the second drive gear 82 to separate the first drive gear 80 from the second drive gear 82 or increase the axial distance therebetween, thereby providing alignment with corresponding components of the second gear set 62, which can be arranged to accommodate the second shift collar 64, as will be discussed in more detail below. Additionally, the second drive gear 82 can have a different diameter than the first drive gear 80. For example, the second drive gear 82 can have a larger diameter than the first drive gear 80.

[0028] The third drive gear 84 can receive the first shaft 50. For example, the third drive gear 84 can have a through-hole through which the first shaft 50 can extend. The third drive gear 84 can extend about the first axis 70 and the first shaft 50 and can have a plurality of teeth that can be arranged about the first axis 70 and facing away from the first axis. The teeth of the third drive gear 84 can contact and mate or mesh with the teeth of the third gear of the second gear set 62, as will be discussed in more detail below. The third drive gear 84 can be rotatably disposed on the first shaft 50. A bearing or bushing 88 can be received in the hole of the third drive gear 84 to rotatably support the third drive gear 84 on the first shaft 50. The bushing 88 can also have a flange that can extend away from the first axis 70 and can help separate the third drive gear 84 from the second drive gear 82.

[0029] like Figure 4As best shown in FIG, the third drive gear 84 may include clutch engaging teeth 90 that can be engaged by the first shift collar 54 to selectively couple the third drive gear 84 to the first shaft 50, as will be discussed in more detail below. The clutch engaging teeth 90 may have any suitable configuration. In the illustrated configuration, the clutch engaging teeth 90 are configured as spline gears or spline teeth, wherein the teeth may be arranged about the first axis 70 and may extend radially away from and away from the first axis 70. Alternatively, or in addition, the clutch engaging teeth 90 may be configured as face gears, wherein the teeth may be arranged about the first axis 70 and may extend axially from one side of the third drive gear 84 toward the first shift collar 54. The third drive gear 84 may be positioned axially along the first axis 70 between the second drive gear 82 and the first shift collar 54. Furthermore, the third drive gear 84 may have a different diameter than the first and second drive gears 80, 82. For example, the third drive gear 84 may have a larger diameter than the second drive gear 82.

[0030] The first shift collar 54 can be axially positioned between the third drive gear 84 and the second bearing 74. The first shift collar 54 can receive the first shaft 50 and can be rotatable with the first shaft 50 about the first axis 70. In addition, the first shift collar 54 can be movable along the first axis 70 relative to the first shaft 50 to selectively couple or connect components of the first gear set 52 to the first shaft 50. For example, the first shift collar 54 can selectively couple the third drive gear 84 to the first shaft 50, as shown in FIG. Figure 4 As shown by the shading in FIG and as will be discussed in more detail below. In at least one configuration and as Figure 7 As best shown in FIG, the first shift collar 54 may include a first shift collar bore 100 and first shift collar splines 102 .

[0031] The first shift collar bore 100 may extend along the first axis 70. The first shift collar bore 100 may be a through-bore through which the first shaft 50 may extend.

[0032] The first shift collar splines 102 can operatively connect the first shift collar 54 to the first shaft 50. The first shift collar splines 102 can be disposed in the first shift collar bore 100 and can include spline teeth that can extend toward the first axis 70. The spline teeth can mesh or mate with corresponding spline teeth on the first shaft 50 or disposed on an intermediate component that can be fixedly mounted to the first shaft 50, such as Figure 41 and 2. For example, the first ring 110 may have spline teeth 112 that may extend away from the first axis 70 and may mesh with teeth of the first shift collar splines 102. The first ring 110 may at least partially surround the first shaft 50 and may extend axially between the second bearing 74 and the third drive gear 84 and / or its bushing 88.

[0033] The first shift collar splines 102 can selectively engage the third drive gear 84 to permit or inhibit rotation of the third drive gear 84 relative to the first shaft 50. When the first shift collar 54 is disengaged from the third drive gear 84, the third drive gear 84 can rotate relative to the first shaft 50 about the first axis 70. For example, when the first shift collar splines 102 are not mated or meshed with the clutch engagement teeth 90 of the third drive gear 84 and, therefore, the first shift collar 54 does not connect the third drive gear 84 to the first shaft 50, the third drive gear 84 can rotate relative to the first shaft 50. When the first shift collar 54 connects the third drive gear 84 to the first shaft 50, such as when the first shift collar splines 102 are mated or meshed with the clutch engagement teeth 90 of the third drive gear 84, the third drive gear 84 can rotate with the first shaft 50 about the first axis 70. It is also contemplated that the first shift collar 54 may be provided with a face gear that can mate or mesh with the clutch engagement teeth 90 of the third drive gear 84, which may also be configured as a face gear. In such a configuration, the first shift collar splines 102 would not be able to mate or mesh with the clutch engagement teeth 90.

[0034] Main references Figure 5 and Figure 6 , the second shaft 60 can be spaced apart from the first shaft 50 and can be rotatable about a second axis 120. The second axis 120 can be arranged substantially parallel to the first axis 70. The term "substantially parallel" is used herein to refer to features (such as axes) that are parallel or very nearly parallel relative to each other, and includes features that are parallel to each other within ±2°. The second shaft 60 can be rotatably supported by one or more bearings (such as a first bearing 122 and a second bearing 124). The first bearing 122 and the second bearing 124 can have any suitable configuration. For example, the first bearing 122 and the second bearing 124 can be configured as a roller bearing assembly that can surround the second shaft 60. The second shaft 60 can be operatively connected to the torque source 20. For example, torque can be transferred from the torque source 20 to the second shaft 60, and then the torque can be transferred from the second shaft 60 to the first shaft 50 via gears. In a configuration with a power source, the second shaft 60 can be operatively connected to the rotor 26, such as by directly connecting the rotor shaft to the second shaft 60 or by using a connecting gear set 126, an example of which is shown in FIG. Figure 1For example, the connecting gear set 126 can have a first connecting gear that rotates with the rotor 26 and meshes with a second connecting gear that rotates with the second shaft 60. In at least one configuration, the transmission 34 can be positioned on a side of the differential assembly 30 opposite the torque source 20.

[0035] Reference again Figure 5 and Figure 6 , the second gear set 62 can include a plurality of gears that can rotate about a second axis 120. Each member of the second gear set 62 can mesh with a different member of the first gear set 52. In the illustrated configuration, the second gear set 62 includes a first gear 130, a second gear 132, and a third gear 134; however, it should be understood that a greater or fewer number of gears can be provided. When the gears are coupled to the second shaft 60, the members of the second gear set 62 can rotate with the second shaft 60 about the second axis 120. Conversely, the second shaft 60 can rotate about the second axis 120 relative to the members of the second gear set 62 that are decoupled from or not coupled to the second shaft 60. The members of the second gear set 62 can be selectively coupled to the second shaft 60 via a second shift collar 64, as will be discussed in more detail below.

[0036] The first gear 130 can receive the second shaft 60. For example, the first gear 130 can have a through-hole through which the second shaft 60 can extend. The first gear 130 can extend about the second axis 120 and the second shaft 60 and can have a plurality of teeth that can be arranged about the second axis 120 and facing away from the second axis. The teeth of the first gear 130 can contact and mate or mesh with the teeth of the first drive gear 80 of the first gear set 52. In at least one configuration, the first gear 130 can be rotatably disposed on the second shaft 60. A bearing or bushing 140 can be received in the hole of the first gear 130 and can rotatably support the first gear 130 on the second shaft 60.

[0037] like Figure 6As best shown in FIG, the first gear 130 may include clutch engaging teeth 150 that may be engaged by the second shift collar 64 to selectively couple the first gear 130 to the second shaft 60, as will be discussed in more detail below. The clutch engaging teeth 150 may have any suitable configuration. In the configuration shown, the clutch engaging teeth 150 are configured as spline gears or spline teeth, wherein the teeth may be arranged about the second axis 120 and may extend radially away from and away from the second axis 120. Alternatively, or in addition, the clutch engaging teeth 150 may be configured as face gears, wherein the teeth may be arranged about the second axis 120 and may extend axially from one side of the first gear 130 toward the second shift collar 64. The first gear 130 may be positioned axially along the second axis 120 between the first bearing 122 and the second gear 132.

[0038] The second gear 132 can receive the second shaft 60. For example, the second gear 132 can have a through-hole through which the second shaft 60 can extend. The second gear 132 can extend about the second axis 120 and the second shaft 60 and can have a plurality of teeth that can be arranged about the second axis 120 and facing away from the second axis. The teeth of the second gear 132 can contact and mate or mesh with the teeth of the second drive gear 82 of the first gear set 52. In at least one configuration, the second gear 132 can be rotatably disposed on the second shaft 60. A bearing or bushing 140 can be received in the hole of the second gear 132 and can rotatably support the second gear 132 on the second shaft 60.

[0039] In at least one configuration, the second gear 132 can include second clutch teeth 160 that can be engaged by the second shift collar 64 to selectively couple the second gear 132 to the second shaft 60, as will be discussed in more detail below. The second clutch teeth 160 can have any suitable configuration. In the illustrated configuration, the second clutch teeth 160 are configured as spline gears or spline teeth, wherein the teeth can be arranged about the second axis 120 and can extend radially away from and away from the second axis 120. Alternatively, or in addition, the second clutch teeth 160 can be configured as face gears, wherein the teeth can be arranged about the second axis 120 and can extend axially from one side of the second gear 132 toward the second shift collar 64. The second gear 132 can be axially positioned along the second axis 120 between the first gear 130 and the third gear 134. For example, the second gear 132 can be axially positioned between the second shift collar 64 and the third gear 134. Furthermore, the second gear 132 can be axially positioned closer to the third gear 134 than to the first gear 130. For example, a spacer 170 can be positioned between the first gear 130 and the second gear 132 to separate the first gear 130 and the second gear 132 or increase the axial distance therebetween, thereby providing sufficient space for moving the second shift collar 64, as will be discussed in greater detail below. The spacer 170 can be integrally formed with the second shaft 60 or can be provided as a separate component that can extend from the second shaft 60. Furthermore, the second gear 132 can have a different diameter than the first gear 130. For example, the second gear 132 can have a smaller diameter than the first gear 130.

[0040] The third gear 134 can receive the second shaft 60. For example, the third gear 134 can have a through-hole through which the second shaft 60 can extend. The third gear 134 can extend about the second axis 120 and the second shaft 60 and can have a plurality of teeth that can be arranged about the second axis 120 and facing away from the second axis. The teeth of the third gear 134 can contact and mate or mesh with the teeth of the third drive gear 84 of the first gear set 52, as will be discussed in more detail below. In at least one configuration, the third gear 134 can be fixedly coupled to the second shaft 60 such that the third gear 134 can rotate with the second shaft 60 about the second axis 120 and such that the third gear 134 does not rotate relative to the second shaft 60 about the second axis 120. In at least one configuration, the third gear 134 can be axially positioned between the second bearing 124 and the second drive gear 82 along the second axis 120. Furthermore, the third gear 134 can have a different diameter than the first gear 130 and the second gear 132. For example, the third gear 134 may have a smaller diameter than the second gear 132 .

[0041] The second shift collar 64 may be positioned axially between the first gear 130 and the second gear 132. The second shift collar 64 may receive the second shaft 60 and may be rotatable with the second shaft 60 about the second axis 120. Furthermore, the second shift collar 64 may be movable relative to the second shaft 60 along the second axis 120 to selectively couple or connect components of the second gear set 62 to the second shaft 60. For example, the second shift collar 64 may selectively couple the first gear 130 or the second gear 132 to the second shaft 60, as will be discussed in more detail below. Figure 6 In the middle portion shown in hatching, the second shift collar 64 can also decouple the first gear 130 and the second gear 132 from the second shaft 60. In at least one configuration and as shown in FIG. Figure 7 As best shown in FIG, the second shift collar 64 may include a second shift collar bore 180 and second shift collar splines 182 .

[0042] The second shift collar bore 180 may extend along the second axis 120. The second shift collar bore 180 may be a through-bore through which the second shaft 60 may extend.

[0043] The second shift collar splines 182 may operatively connect the second shift collar 64 to the second shaft 60. The second shift collar splines 182 may be disposed in the second shift collar bore 180 and may include spline teeth that may extend toward the second axis 120. The spline teeth may mesh or mate with corresponding spline teeth on the second shaft 60 or an intermediate component that may be fixedly mounted to the second shaft 60.

[0044] The second shift collar splines 182 can selectively engage the first gear 130 or the second gear 132 to allow or inhibit rotation of the first gear 130 or the second gear 132 relative to the second shaft 60. For example, the second shift collar splines 182 can cooperate or mesh with the clutch engaging teeth 150 of the first gear 130 to rotatably couple the first gear 130 to the second shaft 60, as shown. Figure 6 . When the second shift collar 64 is disengaged from the first gear 130 or does not connect the first gear 130 to the second shaft 60, the first gear 130 can be rotatable relative to the second shaft 60 about the second axis 120. For example, when the second shift collar splines 182 are not mated or engaged with the clutch engaging teeth 150 of the first gear 130, the first gear 130 can be rotatable relative to the second shaft 60 about the second axis 120.

[0045] When in the intermediate position shown in hatching at position B, the second shift collar splines 182 cannot mate or engage with the clutch engaging teeth 150 of the first gear 130 and the second clutch engaging teeth 160 of the second gear 132 , thereby allowing the second shaft 60 to rotate relative to the first gear 130 and the second gear 132 .

[0046] When the second shift collar 64 is Figure 6 When the perspective shown is moved rightward to position C, the second shift collar splines 182 can cooperate or mesh with the second clutch engaging teeth 160 of the second gear 132 to rotatably couple the second gear 132 to the second shaft 60. When the second shift collar 64 is disengaged from the second gear 132 or does not connect the second gear 132 to the second shaft 60, the second gear 132 can be rotatable relative to the second shaft 60 about the second axis 120. For example, when the second shift collar splines 182 are not cooperating or meshing with the second clutch engaging teeth 160 of the second gear 132, the second gear 132 can be rotatable relative to the second shaft 60 about the second axis 120.

[0047] It is also contemplated that the second shift collar 64 may be provided with a face gear that may mate or mesh with the clutch engagement teeth 150 of the first gear 130, which may also be configured as a face gear; may be provided with a face gear that may mate or mesh with the second clutch engagement teeth 160 of the second gear 132, which may also be configured as a face gear; or a combination thereof.

[0048] Main references Figure 2 and Figure 7 , the shift mechanism 36 can control the positioning of shift collars such as the first shift collar 54 and the second shift collar 64. In at least one configuration, the shift mechanism 36 can include a shift rail 200, a first shift fork 202, a second shift fork 204, a sector cam 206, or a combination thereof.

[0049] The shift rail 200 can extend along a shift rail axis 210. The shift rail axis 210 can be arranged generally parallel to the first axis 70, the second axis 120, or both. In at least one configuration, the shift rail axis 210 can be arranged closer to the first axis 70 than to the second axis 120. The shift rail 200 can be fixedly positioned such that the shift rail 200 cannot move along or rotate about the shift rail axis 210. The shift rail 200 can be spaced apart from the sector cam 206 and can support the first shift fork 202 and the second shift fork 204.

[0050] refer to Figure 3 and Figure 7The first shift fork 202 can operatively connect the first shift collar 54 to the sector cam 206. The first shift fork 202 can be slidable relative to the shift rail 200 along the shift rail axis 210. In at least one configuration, the first shift fork 202 can include a tubular portion 220 and a fork arm 222. Optionally, a shift carrier 224 can be associated with the first shift fork 202.

[0051] The tubular portion 220 can receive the shift rail 200. In at least one configuration, the tubular portion 220 can have a first end 230, a second end 232, and a shift fork bore 234.

[0052] The first end 230 may face the second shift fork 204 .

[0053] The second end portion 232 may be disposed opposite the first end portion 230 . In this manner, the second end portion 232 may face away from the second shift fork 204 .

[0054] The shift fork bore 234 may extend from the first end 230 to the second end 232. The shift rail 200 may extend through the shift fork bore 234.

[0055] The fork arm 222 can extend from the tubular portion 220 to the first shift collar 54. The fork arm 222 can have any suitable configuration. For example, the fork arm 222 can have a pair of prongs that can be received in grooves in the first shift collar 54 and can allow the first shift collar 54 to rotate relative to the prongs about the first axis 70. The fork arm 222 can be disposed proximate the second end 232 of the tubular portion 220.

[0056] Main references Figure 7 , the shift carrier 224 can operatively connect the first shift fork 202 to the sector cam 206. For example, the shift carrier 224 can be slidable along the shift rail 200 with the first shift fork 202 and can support a guide feature 226 that can engage the sector cam 206. In at least one configuration, the shift carrier 224 can have a first flange 240, a second flange 242, and a body portion 244.

[0057] The first flange 240 may be disposed at a first end of the body portion 244. The first flange 240 may define a hole through which the shift rail 200 may extend. The first flange 240 may engage the first end 230 of the tubular portion 220.

[0058] A second flange 242 may be disposed at a second end of the main body portion 244, which may be disposed opposite the first end. The second flange 242 may define a hole through which the shift rail 200 may extend. The second flange 242 may engage the second end 232 of the tubular portion 220. Thus, the first flange 240 and the second flange 242 may engage opposite ends of the first shift fork 202, and the first shift fork 202 may be positioned between the first flange 240 and the second flange 242 to inhibit relative axial movement of the shift carrier 224 relative to the first shift fork 202.

[0059] The body portion 244 may extend from the first flange 240 to the second flange 242. The body portion 244 may extend generally parallel to the shift rail 200 and may be spaced apart from the shift rail 200 and the sector cam 206.

[0060] A guide feature 226 can operatively connect the first shift fork 202 to the sector cam 206. The guide feature 226, which may be referred to as a first guide feature, may extend from the main body portion 244 in a direction extending toward the sector cam 206. The guide feature 226 may have any suitable configuration. For example, the guide feature 226 may be a roller that can be received in a first groove of the sector cam 206, as will be discussed in more detail below. The guide feature 226 may be positioned closer to the first flange 240 than to the second flange 242. It is also contemplated that the shift carrier 224 may be omitted and the guide feature 226 may be provided with the first shift fork 202.

[0061] The second shift fork 204 can be spaced apart from the first shift fork 202. The second shift fork 204 can operatively connect the second shift collar 64 to the sector cam 206. The second shift fork 204 can have a similar configuration to the first shift fork 202. The second shift fork 204 can be slidable relative to the shift rail 200 along the shift rail axis 210. In at least one configuration, the second shift fork 204 can include a tubular portion 220' and a fork arm 222'. Optionally, a shift bracket 224' can be associated with the second shift fork 204.

[0062] The tubular portion 220' can receive the shift rail 200. In at least one configuration, the tubular portion 220' can have a first end 230', a second end 232', and a shift fork bore 234'.

[0063] The first end 230 ′ may face away from the first shift fork 202 .

[0064] The second end portion 232 ′ may be disposed opposite to the first end portion 230 ′. In this manner, the second end portion 232 ′ may face the first shift fork 202 .

[0065] The shift fork bore 234' may extend from the first end 230' to the second end 232'. The shift rail 200 may extend through the shift fork bore 234'.

[0066] The fork arm 222' can extend from the tubular portion 220' of the second shift fork 204 to the second shift collar 64. The fork arm 222' can have any suitable configuration. For example, the fork arm 222' can have a pair of prongs that can be received in grooves in the second shift collar 64 and can allow the second shift collar 64 to rotate relative to the fork about the second axis 120. In at least one configuration, the fork arm 222' can be positioned closer to the first end 230' of the tubular portion 220' than to the second end 232'.

[0067] The shift bracket 224' can operatively connect the second shift fork 204 to the sector cam 206. For example, the shift bracket 224' can slide along the shift rail 200 with the second shift fork 204 and can support a guide feature 226' that can engage the sector cam 206. The shift bracket 224' can have the same configuration as the shift bracket 224. In at least one configuration, the shift bracket 224' can have a first flange 240', a second flange 242', and a body portion 244'.

[0068] A first flange 240' may be disposed at a first end of the body portion 244'. The first flange 240' may define a hole through which the shift rail 200 may extend. The first flange 240' may engage the first end 230' of the tubular portion 220'.

[0069] A second flange 242' can be disposed at a second end of the main body portion 244', which second end can be disposed opposite the first end. The second flange 242' can define a hole through which the shift rail 200 can extend. The second flange 242' can engage the second end 232' of the tubular portion 220'. In this way, the first flange 240' and the second flange 242' can engage opposite ends of the second shift fork 204, and the second shift fork 204 can be positioned between the first flange 240' and the second flange 242' to inhibit relative axial movement of the shift carrier 224' relative to the second shift fork 204.

[0070] The body portion 244 ′ may extend from the first flange 240 ′ to the second flange 242 ′. The body portion 244 ′ may extend generally parallel to the shift rail 200 and may be spaced apart from the shift rail 200 and the sector cam 206 .

[0071] The guide feature 226' can operatively connect the second shift fork 204 to the sector cam 206. The guide feature 226', which can be referred to as the second guide feature, can extend from the main body portion 244' in a direction extending toward the sector cam 206. The guide feature 226' can have the same configuration as the guide feature 202 associated with the first shift fork 226. For example, the guide feature 226' can be a roller that can be received in the second groove of the sector cam 206, as will be discussed in more detail below. The guide feature 226' can be axially positioned closer to the second flange 242' than to the first flange 240'. It is also contemplated that the shift bracket 224' can be omitted and the guide feature 226' can be provided with the second shift fork 204.

[0072] Main references Figure 2 and Figure 7 The sector cam 206 can be operatively connected to the first shift collar 54, the second shift collar 64, or both. The sector cam 206 can be spaced apart from the transmission 34 and the shift rail 200. In at least one configuration, the sector cam 206 can have a generally flat or planar configuration.

[0073] like Figure 2 As best shown in FIG, the sector cam 206 can be rotatable about a sector cam axis 250. The sector cam axis 250 can be arranged substantially perpendicular to the first axis 70, the second axis 120, the shift rail axis 210, or a combination thereof. Rotation of the sector cam 206 about the sector cam axis 250 can control movement of the first shift collar 54 along the first axis 70, can control movement of the second shift collar 64 along the second axis 120, or both. In at least one configuration, the sector cam 206 can have a coupling feature 260 and an arcuate outer side 262. The sector cam 206 can define one or more grooves, such as a first groove 264 and a second groove 266.

[0074] The coupling feature 260 can facilitate coupling the sector cam 206 to an actuator that can rotate the sector cam 206 about the sector cam axis 250. The coupling feature 260 can have any suitable configuration. For example, the coupling feature 260 can have a male configuration, a female configuration, or a combination thereof. The actuator can have any suitable configuration. For example, the actuator can be an electrical actuator, a mechanical actuator, an electromechanical actuator, etc.

[0075] The arcuate outer side 262 may face away from the sector cam axis 250. The arcuate outer side 262 or a portion thereof may extend along an arc, such as an arc that may be radially disposed relative to the sector cam axis 250. A plurality of detent features 270 may be provided with the arcuate outer side 262. The detent features 270 may be spaced apart from one another and may be positioned to align with the rotational position of the sector cam 206 (e.g., Figures 8 to 11 The detent feature 270 may have any suitable configuration. For example, the detent feature 270 may be configured as a depression that may extend toward the sector cam axis 250. The detent feature 270 may be engaged by a detent mechanism 272 that is engaged by a detent mechanism 272. Figures 8 to 11 . The detent feature 270 can be mounted to a stationary component, such as a housing of the axle assembly 10. The detent feature 270 can help maintain the sector cam 206 in a desired rotational position. As the sector cam 206 rotates about the sector cam axis 250 between different rotational positions and its associated detent feature 270, the detent mechanism 272 can slide along the arcuate outer side 262.

[0076] Main references Figure 2 The first groove 264 can guide the movement of the first shift fork 202 and, therefore, the first shift collar 54. The first groove 264 can be defined by the cam segment 206, such that the first groove 264 can be completely disposed within or surrounded by the cam segment 206. The first groove 264 can be spaced apart from the cam segment axis 250 and the second groove 266 and can receive the guide feature 226 of the first shift fork 202. The guide feature 226 can extend into the first groove 264. The first groove 264 can be positioned radially between the cam segment axis 250 and the arcuate outer side 262. For example, the first groove 264 can be positioned radially between the coupling feature 260 and the second groove 266. As such, the first groove 264 can be positioned closer to the cam segment axis 250 than the second groove 266 is positioned closer to the cam segment axis 250.

[0077] The first groove 264 can extend in a non-linear manner between the first end and the second end.In at least one configuration, the first groove 264 can have a first groove side 280 and a second groove side 282.

[0078] The first groove side 280 and the second groove side 282 can be spaced apart from each other and can extend between the first end and the second end of the first groove 264. For example, the first groove side 280 and the second groove side 282 can be mirror images of each other and can be equally spaced apart from each other. In one or more embodiments, the first groove side 280 and the second groove side 282 can be arranged substantially parallel to each other. The first groove side 280 and the second groove side 282 can cooperate to constrain and control axial movement of the first shift fork 202. For example, the guide feature 226 of the first shift fork 202 can engage the first groove side 280 to inhibit movement of the first shift fork 202 to the right from the perspective shown, while the guide feature 226 can engage the second groove side 282 to inhibit movement of the first shift fork 202 to the left from the perspective shown.

[0079] The second groove 266 can guide the movement of the second shift fork 204 and, therefore, the second shift collar 64. The second groove 266 can be defined by the cam segment 206, such that the second groove 266 can be completely disposed within or surrounded by the cam segment 206. The second groove 266 can be spaced apart from the first groove 264 and the arcuate outer side 262 and can receive the guide feature 226' of the second shift fork 204. The guide feature 226' can extend into the second groove 266. The second groove 266 can be positioned radially between the cam segment axis 250 and the arcuate outer side 262. For example, the second groove 266 can be positioned radially between the first groove 264 and the arcuate outer side 262.

[0080] The second groove 266 can extend in a nonlinear manner between the first end and the second end. The second groove 266 can have a greater length between the first end and the second end than the first groove 264. In at least one configuration, the second groove 266 can have a first groove side 280' and a second groove side 282'.

[0081] The first groove side 280' and the second groove side 282' can be spaced apart from each other and can extend between the first end and the second end of the second groove 266. For example, the first groove side 280' and the second groove side 282' can be mirror images of each other and can be equally spaced apart from each other. In one or more embodiments, the first groove side 280' and the second groove side 282' can be arranged substantially parallel to each other. The first groove side 280' and the second groove side 282' can cooperate to constrain and control axial movement of the second shift fork 204. For example, the guide feature 226' of the second shift fork 204 can engage the first groove side 280' to inhibit movement of the second shift fork 204 to the right from the perspective shown, while the guide feature 226' can engage the second groove side 282' to inhibit movement of the second shift fork 204 to the left from the perspective shown.

[0082] refer to Figures 8 to 11 An example illustrating the operation of the shift mechanism 36 and the movement of the first and second shift collars 54, 64 will now be described. Rotation of the sector cam 206 and shifting of the shift collars can occur in response to an operator command, can be automatic, or a combination thereof. In at least one configuration, shifting can be performed when the rotational speeds of the shift collars and the gear being engaged or disengaged are sufficiently synchronized. Synchronizers can be used to achieve sufficient synchronization to allow shifting or movement of the collars by controlling the rotational speed of the first shaft 50, by controlling the rotational speed of the second shaft 60, or by a combination thereof.

[0083] exist Figures 8 to 11Examples of shift collar positions are shown in FIG; however, it should be understood that the shift collar positions may be rearranged or additional shift collar positions may be added, in which case the length of the first groove 264, the length of the second groove 266, the manner in which the first groove 264 and the second groove 266 curve or jog relative to each other, or a combination thereof, may vary from the examples shown.

[0084] refer to Figure 8 , the sector cam 206 is shown in the low-speed position. The first shift collar 54 can couple the third drive gear 84 to the first shaft 50 so that the third drive gear 84 can rotate with the first shaft 50. The second shift collar 64 cannot couple the first gear 130 or the second gear 132 to the second shaft 60. Thus, torque can be transferred between the first shaft 50 and the second shaft 60 via the third drive gear 84 and the third gear 134. When the sector cam 206 is in the low-speed position, the guide feature 226 of the first shift fork 202 can be positioned adjacent to the first end of the first groove 264, and the guide feature 226' of the second shift fork 204 can be positioned adjacent to the first end of the second groove 266.

[0085] refer to Figure 9 , the sector cam 206 is shown in the mid-speed position. The first shift collar 54 cannot couple the third drive gear 84 to the first shaft 50 and Figure 8 The second shift collar 64 is moved from the position shown in FIG. Figure 8 The illustrated position is shifted to the right, and the second gear 132 can be coupled to the second shaft 60, but the first gear 130 cannot be coupled to the second shaft 60. In this way, torque can be transmitted between the first shaft 50 and the second shaft 60 via the second drive gear 82 and the second gear 132. When the sector cam 206 is in the mid-speed position, the guide feature 226 of the first shift fork 202 and the guide feature 226' of the second shift fork 204 can be arranged closer to the sector cam axis 250 than in the low-speed position.

[0086] refer to Figure 10 , the sector cam 206 is shown in the neutral position. The first shift collar 54 is in the neutral position. Figure 9 The second shift collar 64 is in the same position as the first shaft 50. Figure 8 The first gear 130 or the second gear 132 is not coupled to the second shaft 60. Thus, torque cannot be transmitted between the first shaft 50 and the second shaft 60. In the neutral and intermediate speed positions, the guide feature 226 of the first shift fork 202 can be positioned the same distance from the sector cam axis 250. The guide feature 226' of the second shift fork 204 can be positioned farther from the sector cam axis 250 in the neutral position than in the intermediate speed position.

[0087] refer to Figure 11 , the sector cam 206 is shown in the high speed position. The first shift collar 54 is in the Figure 9 The second shift collar 64 is in the same position as the first shaft 50 and cannot couple the third drive gear 84 to the first shaft 50. Figure 8 The illustrated position is moved to the left to couple the first gear 130 to the second shaft 60, but not the second gear 132 to the second shaft 60. In this way, torque can be transmitted between the first shaft 50 and the second shaft 60 via the first drive gear 80 and the first gear 130. When the sector cam 206 is in the high speed position, the guide feature 226 of the first shift fork 202 can be arranged adjacent to the second end of the first groove 264, and the guide feature 226' of the second shift fork 204 can be arranged adjacent to the second end of the second groove 266.

[0088] As discussed above, the axle assembly can allow the torque source and transmission to be arranged on opposite sides of the differential assembly. In configurations where the torque source is an electric motor, such a configuration can help thermally decouple the electric motor from heat generated by its rapidly rotating rotor bearings (which can rotate at speeds exceeding 50,000 rpm) from other components of the axle assembly, such as the transmission and lubricant within the axle assembly. This thermal decoupling can improve thermal management of the axle assembly and reduce lubricant heating, which can help increase lubricant life. Additionally, compared to configurations where the electric motor and transmission extend from the same side of the housing assembly, such an arrangement can provide better weight distribution by positioning the axle assembly's center of mass closer to the axle shafts. As a result, the "protrusion" or distance that the housing assembly extends from the axle shafts can be reduced, and the structural integrity of the housing can be improved, compared to configurations where the electric motor and transmission extend from the same side of the housing assembly. An axle assembly having a sector cam as described above can allow for a compact shift mechanism, which can help reduce packaging space, weight, associated costs, or a combination thereof. Furthermore, the sector cams may allow the shift collars to be actuated simultaneously or independently and with a high degree of accuracy.

[0089] While exemplary embodiments have been described above, these embodiments are not intended to describe all possible forms of the present invention. Rather, the terms used in this specification are illustrative rather than restrictive, and it should be understood that various changes may be made without departing from the spirit and scope of the present invention. Furthermore, the features of various implemented embodiments may be combined to form additional embodiments of the present invention.

Claims

1. An axle assembly comprising: a first shaft rotatable about a first axis; a second shaft rotatable about a second axis; a first gear set rotatable about the first axis, wherein the first gear set includes a first drive gear, a second drive gear, and a third drive gear; as well as a second gear set rotatable about the second axis, wherein the second gear set includes a first gear, a second gear, and a third gear meshing with the first drive gear, the second drive gear, and the third drive gear, respectively, wherein each member of the second gear set meshes with a different member of the first gear set; a first shift collar rotatable with the first shaft about the first axis and movable relative to the first shaft along the first axis to selectively connect a member of the first gear set to the first shaft; a second shift collar rotatable with the second shaft about the second axis and movable relative to the second shaft along the second axis to selectively connect members of the second gear set to the second shaft; as well as a sector cam rotatable about a sector cam axis and operatively connected to the first shift collar and the second shift collar, wherein rotation of the sector cam about the sector cam axis controls movement of the first shift collar along the first axis and controls movement of the second shift collar along the second axis; wherein the first drive gear and the second drive gear are fixedly coupled to the first shaft, and the third drive gear is rotatably disposed on the first shaft such that the third drive gear is rotatable relative to the first shaft about the first axis when the first shift collar does not connect the third drive gear to the first shaft, and such that the third drive gear is rotatable with the first shaft when the first shift collar connects the third drive gear to the first shaft; wherein the third gear is fixedly coupled to the second shaft, and the first gear and the second gear are rotatably disposed on the second shaft and selectively coupleable to the second shaft via the second shift collar; and When the sector cam is in the low speed position, the first shift collar couples the third drive gear to the first shaft so that the third drive gear can rotate with the first shaft, and the second shift collar does not couple the first gear or the second gear to the second shaft.

2. The axle assembly of claim 1, wherein: When the sector cam is in a neutral speed position, the first shift collar does not couple the third drive gear to the first shaft, and the second shift collar couples the second gear to the second shaft.

3. The axle assembly of claim 1, wherein: When the sector cam is in the high speed position, the first shift collar does not couple the third drive gear to the first shaft, and the second shift collar couples the first gear to the second shaft.

4. The axle assembly of claim 1, wherein: When the sector cam is in a neutral position, the first shift collar does not couple the third drive gear to the first shaft, and the second shift collar does not couple the first gear or the second gear to the second shaft.

5. The axle assembly of claim 1, wherein: The second drive gear is positioned axially along the first shaft between the first drive gear and the third drive gear, and the third drive gear is positioned axially along the first shaft between the second drive gear and the first shift collar.

6. The axle assembly of claim 5, wherein: The second shift collar is positioned axially between the first gear and the second gear, and the second gear is positioned axially between the second shift collar and the third gear.

7. The axle assembly of claim 1, wherein: A first shift fork couples the first shift collar to the sector cam, and the sector cam defines a first groove disposed completely within the sector cam and receiving a first guide feature operatively connected to the first shift fork.

8. The axle assembly of claim 7, wherein: The first groove has a first groove side and a second groove side disposed opposite the first groove side, wherein the first guide feature engages the first groove side and the second groove side to constrain axial movement of the first shift fork.

9. The axle assembly of claim 7, wherein: A second shift fork couples the second shift collar to the sector cam, and the sector cam defines a second groove disposed entirely within the sector cam that receives a second guide feature operatively connected to the second shift fork.

10. The axle assembly of claim 9, wherein: The second groove has a first groove side and a second groove side disposed opposite the first groove side, wherein the second guide feature engages the first groove side of the second groove and the second groove side of the second groove to constrain axial movement of the second shift fork.

11. The axle assembly of claim 9, wherein: The first groove is positioned closer to the sector cam axis than the second groove is positioned closer to the sector cam axis, and the second groove has a greater length than the first groove.

12. The axle assembly of claim 9, wherein: The first and second shift forks are slidable along a shift rail spaced apart from the sector cam, wherein the shift rail extends along a shift rail axis that extends generally parallel to the first and second axes.

13. The axle assembly of claim 12, wherein: The shift rail axis is arranged closer to the first axis than it is arranged closer to the second axis.

14. The axle assembly of claim 12 , further comprising a second shift carrier having a first flange and a second flange defining a hole through which the shift rail extends, wherein the second shift fork is positioned between the first flange and the second flange and engages the first flange and the second flange such that the second shift fork and the second shift carrier are movable together along the shift rail axis.

15. The axle assembly of claim 14, wherein: The second guide feature extends from the second shift carrier and is received in the second groove.

16. An axle assembly comprising: a first shaft rotatable about a first axis; a second shaft rotatable about a second axis; a first gear set rotatable about the first axis; as well as a second gear set rotatable about the second axis, wherein each member of the second gear set meshes with a different member of the first gear set; a first shift collar rotatable with the first shaft about the first axis and movable relative to the first shaft along the first axis to selectively connect a member of the first gear set to the first shaft; a second shift collar rotatable with the second shaft about the second axis and movable relative to the second shaft along the second axis to selectively connect members of the second gear set to the second shaft; a sector cam rotatable about a sector cam axis and operatively connected to the first shift collar and the second shift collar, wherein rotation of the sector cam about the sector cam axis controls movement of the first shift collar along the first axis and controls movement of the second shift collar along the second axis; as well as a first shift fork coupling the first shift collar to the sector cam, wherein the first shift fork is slidable along a shift rail; a first shift carrier having a first flange and a second flange defining a hole through which the shift rail extends, wherein the first shift fork is positioned between and engages the first and second flanges such that the first shift fork and the first shift carrier are movable together along the shift rail axis.

17. The axle assembly of claim 16, wherein: The sector cam defines a first groove disposed entirely within the sector cam and receiving a first guide feature operatively connected to the first shift fork, wherein the first guide feature extends from the first shift carrier.

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