Differential disconnect system and lock assembly

Abstract

A differential disconnect system and lock assembly for a vehicle includes a fixed housing, a rotatable ring gear, a differential housing and a cover, a pinion assembly including a pinion drivingly connectable with the ring gear and a side gear meshing with the pinion. The assembly includes a differential disconnect system assembly operably connected between the ring gear and the pinion assembly, the differential disconnect system assembly actuatable to operably disconnect the ring gear and the pinion assembly. The assembly also includes a differential lock slidably coupled with the differential housing or cover and operably connected with the side gear. The differential lock is actuatable to operably disconnect the differential housing or cover from the side gear, allowing the side gear to rotate relative to the differential housing or cover.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to U.S. Provisional Application No. 63 / 358,890 filed on July 7, 2022 and U.S. Provisional Application No. 63 / 446,060 filed on February 16, 2023, the disclosures of which are incorporated herein by reference in their entireties. Technical Field

[0003] The present invention relates to a differential disconnect system assembly for use in a drive train of a motor vehicle. More particularly, the present invention relates to a differential disconnect system assembly for a motor vehicle having a locking differential. Background Art

[0004] An automotive all-wheel drive (AWD) vehicle can be driven primarily by the front axle, which is powered by the vehicle engine through a gearbox. Power can also be transmitted to the rear axle through a power take-off, a drive axle, and a rear drive unit. The rear drive unit converts the rotational power of the drive axle to a left shaft and a right shaft to drive each of the left rear wheel and the right rear wheel of the vehicle. The side shafts are driven by side gears in the differential, which is supported by a differential housing and a cover plate, and the side shafts are driven by the rotation of the ring gear. The side gears meshingly engage with the pinion gears, which are driven by the ring gear and thus the side gear drives torque to the side shafts. As is well known, the vehicle includes a disconnect system assembly that engages between the ring gear and the pinion gear to connect and disconnect the ring gear from the differential pinion gear of the differential.

[0005] It is well known that vehicles include locking differentials to prevent relative rotation of one driven wheel with respect to the other driven wheel. This is typically accomplished by locking one differential side gear to the differential housing or casing, thereby preventing rotation of the side gear with respect to the housing or casing. It is also known to provide a hydraulically or electrically actuated clutch for locking and unlocking the side gears of the differential assembly with respect to the differential casing. However, such a design may be undesirable because the differential casing or casing must be strong enough to handle the torsional loads transmitted between the ring gear and the side gears.

[0006] It is desirable to remove the torsional loads on the differential housing, allowing the housing to be smaller while still being able to handle the axial and radial load requirements on the side gears, or even allowing the differential housing to be eliminated. It is also desirable to provide a single actuator configured to selectively engage the disconnect system assembly and engage the locking differential. Summary of the invention

[0007] According to one embodiment, a differential disconnect system and lock assembly for a vehicle is provided. The differential disconnect system and lock assembly includes a fixed housing, a rotatable ring gear rotatably supported by the fixed housing, a pinion gear assembly including a plurality of pinion gears drivingly connectable to the ring gear, and a plurality of side gears, the plurality of side gears being rotatably disposed in the fixed housing and meshing with the pinion gears so that the side gears and the pinion gears rotate together. The differential disconnect system and lock assembly also include a differential housing and a differential cover rotatably supported on the fixed housing. The ring gear rotates with at least one of the differential housing and the differential cover. In addition, the disconnection of the ring gear from the pinion gear assembly allows the ring gear, the differential housing, and the differential cover to stop rotating when the side gears rotate. The differential disconnect system and lock assembly also include a differential disconnect system assembly, the differential disconnect system assembly being operably connected between respective surfaces of the ring gear and the pinion gear assembly so that the ring gear, the pinion gears, and the side gears rotate together when connected. The differential disconnect system assembly is actuatable to operably disconnect the ring gear and pinion gear assembly to disconnect torque transmission between the ring gear and the pinion gear and prevent drive rotation of the ring gear through the pinion gear during wheel rotation. The differential disconnect system and locker assembly also includes a differential locker that is slidably coupled to one or more of the differential case and the differential cover and is operably connected to one of the plurality of side gears so that the differential case and the differential cover and one of the plurality of side gears rotate together when connected. The differential locker is actuatable to operably disconnect one or more of the differential case and the differential cover from one of the plurality of side gears, allowing one of the plurality of side gears to rotate relative to one or more of the differential case and the differential cover.

[0008] According to another embodiment, a differential disconnect system and locker assembly for a vehicle is provided. The differential disconnect system and locker assembly includes a fixed housing, a rotatable ring gear rotatably supported by the fixed housing, and a differential housing rotatably supported on the fixed housing. The ring gear rotates with the differential housing. The differential disconnect system and locker assembly also includes: a pinion assembly, which includes a plurality of pinions that are drivingly connectable to the ring gear, a gear socket radially and axially supported by the differential housing, which can rotate freely relative to the differential housing, and a plurality of side gears, which are rotatably arranged in the fixed housing and mesh with the pinion gears so that the side gears and the pinion gears rotate together. The differential disconnect system and locker assembly also includes a differential disconnect system assembly, which includes a spline ring that is movable into and out of engagement with one or more of the ring gear and the gear socket so that the ring gear, the pinion gears and the side gears rotate together when connected. The differential disconnect system assembly also includes a shift ring fixedly coupled to the spline ring, the shift ring being movable into and out of engagement with one of the plurality of side gears to respectively lock or unlock the side gear with the gear socket. The differential disconnect system assembly is actuatable to operably disconnect the ring gear from the gear socket to disconnect torque transmission between the ring gear and the pinion gear and prevent drive rotation of the ring gear through the pinion gear during wheel rotation. Disconnection of the pinion gear assembly from the ring gear allows the ring gear and the differential case to stop rotating when the side gears rotate. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The advantages of the present invention will be readily appreciated as the present invention becomes better understood from the following detailed description when considered in conjunction with the accompanying drawings, in which:

[0010] Figure 1 is a cross-sectional side view of a differential disconnect system and a locker assembly according to a first embodiment of the present invention;

[0011] Figure 2 According to the first embodiment of the present invention Figure 1 An enlarged cross-sectional side view of a portion of a differential disconnect system and a locker assembly showing the differential disconnect system in a disconnected state and the differential locker in an unlocked state;

[0012] Figure 3 yes Figure 2 A cross-sectional side view of a differential disconnect system and locker assembly showing the differential disconnect system in an engaged state and the differential locker in an unlocked state;

[0013] Figure 4 yes Figure 3 A cross-sectional side view of a differential disconnect system and locker assembly showing the differential disconnect system in an engaged state and the differential locker in a locked state;

[0014] Figure 5 yes Figure 4 A front view of the differential disconnect system and locker assembly with a shift ring and a portion of the differential housing;

[0015] Figure 6 yes Figure 4 front view of the shift ring and side gears of the differential disconnect system and locker assembly;

[0016] Figure 7 is a perspective view of a differential disconnect system and a lock assembly according to a second embodiment of the present invention in a disconnected and unlocked state, wherein the cam actuator is in a disconnected and unlocked position relative to the cam ring;

[0017] Figure 8 yes Figure 7 a cross-sectional side view of the differential disconnect system and locker assembly of the invention showing the spline ring in a disconnected unlocked position separated from the gear socket and separated from the side gear;

[0018] Fig. 9 According to the second embodiment of the present invention Figure 8 a cross-sectional end view of a portion of a differential disconnect system and a locking assembly showing a cam actuator and a cam ring;

[0019] Fig.10 yes Fig. 9 A perspective side view of a cam actuator and a cam ring showing the cam actuator in a disconnected unlocked position relative to the cam ring;

[0020] Fig.11 yes Figure 8 an enlarged cross-sectional side view of a portion of a center differential disconnect system and lock assembly showing the spline ring in a disconnected unlocked position;

[0021] Fig.12 yes Figure 7 A perspective view of a portion of a differential disconnect system and a lock assembly showing the cam actuator in a connected unlocked position relative to the cam ring;

[0022] Fig.13 yes Fig.12 An enlarged cross-sectional side view of the differential disconnect system and lock assembly of the embodiment of the present invention showing the spline ring in a connected unlocked position engaged with the gear socket and disengaged from the side gear;

[0023] Fig.14 yes Fig.12 a perspective view of a portion of a differential disconnect system and a locking assembly showing the cam actuator in a connected locked position relative to the cam ring; and

[0024] Fig.15 yes Fig.14An enlarged cross-sectional side view of the differential disconnect system and lock assembly of , showing the spline ring in a connected locked position engaged with the gear socket and engaged with the side gear. DETAILED DESCRIPTION

[0025] Figure 1-15 Components of a differential disconnect system and lock assembly 10 for use in an automobile according to an embodiment described herein are illustrated. Directional references used or shown in the specification, drawings, or claims, such as top, bottom, above, below, upward, downward, lengthwise, widthwise, left, right, etc., are relative terms used for ease of description and are not intended to limit the scope of the invention in any way. Referring to the drawings, like numerals throughout the several views represent like or corresponding parts.

[0026] refer to Figure 1 , a differential disconnect system and a lock assembly 10 (hereinafter "disconnect system / lock") is disposed in a vehicle gearbox 12, which is disposed on the vehicle. The gearbox 12 may also be referred to as an axle, as will be understood from the following description. The gearbox 12 includes a fixed housing 14 defining an internal compartment, in which a ring gear 16, a differential housing 18, and a differential cover 20 are housed. In addition, the fixed housing 14 is fixedly supported on the vehicle. The gearbox 12 is operably connected to a drive shaft or a vehicle drive train and an engine or a motor, wherein the ring gear 16 is rotatably driven by the drive train. The ring gear 16 is configured to engage with and be driven by a vehicle drive shaft or a drive train, which in turn is driven by a vehicle engine or a motor. The ring gear 16 is supported both axially and radially by the differential housing 18 and the differential cover 20. Therefore, the ring gear 16, the differential housing 18, and the differential cover 20 rotate together in the internal compartment of the fixed housing 14. The differential housing 18 and differential cover 20 include respective end flanges 22 and 24 that are rotatably supported on the stationary housing 14 by sets of bearings 26. The stationary housing 14 defines a pair of bearing seats 28 that support the bearings 26. Alternatively, it will be appreciated that the design of the present invention also allows the ring gear 16 to be directly supported by bearings on the stationary housing 14, which would allow the elimination of one or both of the differential housing 18 or differential cover 20.

[0027] Figure 1The gearbox 12 shown in FIG. 1 includes a pinion gear assembly 30 rotatably supported within a stationary housing 14. The pinion gear assembly 30 includes opposing differential pinions 32, a pinion shaft 34, a differential gear nest 36, and opposing differential side gears 38. The differential pinions 32 (hereinafter "pinions") are rotatably connected together by the pinion shaft 34, which is mechanically connected to the differential gear nest 36 (hereinafter "gear nest"). In addition, the pinion gears 32 are meshingly engaged with the differential side gears 38 (hereinafter "side gears") so that torque can be transferred from the gear nest 36 to the pinion gears 32 and then to the side gears 38.

[0028] The pinion shaft 34 rotatably supports the pinion gear 32 at both ends thereof and rotates with the pinion gear 32 as the pinion gear 32 travels around the side gears 38. The disconnect system / locker 10 also includes a connecting pin 40 that fixedly couples the pinion shaft 34 with the gear socket 36 so that the pinion gear 32, the pinion shaft 34, and the gear socket 36 all travel together around the same axis as the side gears 38. The gear socket 36 is supported both radially and axially by the differential case 18 and the differential cover 20, and thus the gear socket 36 can freely rotate relative to the differential case 18 and the differential cover 20 as the gear socket 36 and the pinion gear 32 travel around the side gears 38. The gear socket 36 may be supported by other components, such as the ring gear 16, the stationary case 14, bearings, or the like.

[0029] exist Figure 1 , the side gears 38 are supported by the stationary housing 14, preferably by the differential housing 18 and the differential cover 20, respectively. The side gears 38 operate to drive torque to any combination of shafts 42, which may be any type of output shafts, half shafts, connecting shafts, etc. known in the art. Thus, these shafts 42 rotate with the wheels connected thereto and selectively drive the wheels connected thereto. The housing end flange 22 and the cover end flange 24 are open to allow the shafts 40 of the side gears 38 to extend axially therefrom for wheel driving. Due to the connection of the shafts 42 and side gears 38 to the wheels, when the wheels rotate, the shafts 42 and side gears 38 will rotate. The side gears 38 are meshingly engaged with the pinion gears 32, and the ring gear 16 is engaged with the gear sockets 36, so that torque can be transmitted from the ring gear 16 through the gear sockets 36, the pinion gears 32 and then the side gears 38, thereby driving the shafts 42.

[0030] However, as described above, it is desirable to decouple the ring gear 16 and the side gears 38 so that the ring gear 16 does not need to rotate all the time when the wheels rotate. As such, the gearbox 12 includes a disconnect system / locker 10 having a differential disconnect system assembly 44 (hereinafter "differential disconnect system") disposed between the ring gear 16 and the pinion gear assembly 30, preferably between the ring gear 16 and the gear nest 36, wherein the differential disconnect system 44 selectively operates to connect and disconnect the ring gear 16 with the pinion gears 32. Disconnection of the ring gear 16 and the gear nest 36 allows the ring gear 16, the differential housing 18, the bearings 26, and the remainder of the gearbox 12 to stop rotating when the wheels of the vehicle rotate.

[0031] In this embodiment, the differential disconnect system 44 is normally disconnected. To connect the gear socket 36 and the ring gear 16, the differential disconnect system 44 includes a spline ring 46 that is radially guided and axially slidable on the inside of the differential housing 18. Figure 2 , the spline ring 46 has an outer surface that preferably includes radial connector projections 48 that engage with complementary connector formations 50 on the inside surface of the ring gear 16 to define a mechanical connection that rotationally locks the spline ring 46 to the ring gear 16. The connector projections 48 may form spline teeth or other similar structures that lock relative rotation of the ring gear 16 and the spline ring 46 when engaged while permitting rotation of the ring gear 16 and the spline ring 46 when engaged. Figure 2 The disconnect position and Figure 3 Alternatively, it will be appreciated that the spline ring 46 may be mechanically connected to the gear socket 36 and slidably engage and disengage with the ring gear 16, particularly if the differential housing 18 and / or differential cover 20 are eliminated.

[0032] refer to Figure 2 and Figure 3 During the axial sliding of the spline ring 46, the spline ring 46 is releasably connected and disconnected from the gear socket 36 to releasably connect the ring gear 16 to the gear socket 36 and the pinion gear 32. Figure 2, the differential disconnect system 44 includes a releasable disconnect clutch 52, which is preferably defined by a set of clutch teeth or other similar locking formations 54 on the inner diameter or surface of the spline ring 46 and a complementary locking formation 56 on the outer diameter or surface of the gear socket 36. Alternatively, it will be appreciated that the spline ring 46 can be mechanically connected to the gear socket 36 and slidingly engaged and disengaged with the ring gear 16 to connect and disconnect torque transmission, particularly if the differential case 18 and / or differential cover 20 are eliminated. Further, the differential disconnect system 44 includes a disconnect return spring 58 (hereinafter "disconnect spring") operably coupled between the proximal end of the spline ring 46 and the differential cover 20 and configured to bias the spline ring 46 toward the disconnect position relative to the locking formations 56 on the gear socket 36. In addition, the spline ring 46 includes one or more drive arms 60 extending axially away from the proximal end of the spline ring 46. The disconnect spring 58 acts as a biasing member to normally bias the spline ring 46 into or out of engagement with the ring gear 16 and the gear socket 36 .

[0033] exist Figure 2 As depicted in FIG. 1 , the differential disconnect system 44 further includes a disconnect actuator 62, which is operably coupled to the drive arm 60 and configured to be in a disconnect position ( Figure 2 ) and the connection location ( Figure 3 ) to selectively reposition the spline ring 46 between the gear pockets 36 and the gear pockets 36. In operation, when the disconnect actuator 62 is activated, the disconnect actuator 62 will move the spline ring 46 axially inward (arrow 64), causing the spline ring 46 to engage the disconnect clutch 52 between the spline ring 46 and the gear pocket 36, as shown in FIG. Figure 3 As can be seen, torque is allowed to pass from the ring gear 16 through the spline ring 46 and into the gear socket 36. When the disconnect actuator 62 is deactivated, the disconnect spring 58 will cause the spline ring 46 to move axially outward (arrow 64') and disengage the disconnect clutch 52 between the spline ring 46 and the gear socket 36, thereby allowing the gear socket 36 to rotate freely relative to the ring gear 16. In this embodiment, the spline ring 46 is normally biased to the left by the disconnect spring 58. Figure 2 The disconnect actuator 62 is then activated or operated to drive the spline ring 46 axially inward (arrow 64) to Figure 3 The connection or closing status of the

[0034] exist Figure 2 As shown in FIG. 1 , the disconnect spring 58 normally biases the spline ring 46 to Figure 2The open position of the clutch 52 is shown in FIG. 1 , wherein the locking formations 54 and 56 are separated and disengaged to rotatably disconnect the ring gear 16 from the gear socket 36. However, when the disconnect actuator 62 is operated and activated, the spline ring 46 can be axially driven by the disconnect actuator 62 to engage the locking formations 54 and 56 of the disconnect clutch 52, as in FIG. Figure 3 See . Figure 2 The inner surface of the ring gear 16 and the outer surface of the gear pocket 36, in conjunction with the side wall 66 of the differential case 18 and the opposing radial wall 68 of the differential cover 20, substantially define opposing surfaces that are spaced apart to permit axial sliding of an outer shoulder 70 of the spline ring 46 during movement of the spline ring 46. In addition, the drive arm 60 extends axially through a complementary window 72 in the differential case 18. Figure 3 As shown in FIG. 1 , when the disconnect actuator 62 is activated, the ring gear 16 is now rotatably connected to the gear socket 36 to transfer torque from the ring gear 16 through the spline ring 46 to the gear socket 36, as illustrated by arrow 74. When the disconnect actuator 62 is deactivated, the disconnect spring 58 returns the spline ring 46 to the gear socket 36. Figure 2 The open disconnect position is characterized in that the disconnect clutch 52 is disengaged to allow the gear socket 36 to rotate freely relative to the ring gear 16.

[0035] refer to Figure 1 To drive the spline ring 46, the disconnect actuator 62 includes a drive unit 76 fixedly supported on the fixed housing 14. The drive unit 76 includes Figure 2 and Figure 3 The disconnect actuator 62 is preferably an electromagnetic actuator 62, wherein the pusher 78 is axially driven by a drive unit 76 utilizing electromagnetic force. It will be appreciated that other types of actuators are also suitable, such as motors, worm gears, cams, ball ramps, hydraulic or pneumatic pistons or other suitable actuators. Figure 1 8, and the pusher 78 can axially drive the intermediate collar 80, which in turn drives the radial plate 82. The intermediate collar 80 is made of a non-magnetic material so that the intermediate collar 80 does not interfere with the function of the pusher 78. A shim 84 is provided to control the radial and axial position of the pusher 78. The drive arm 60 extends axially through a complementary window 72 in the differential case 18 so that the drive arm 60 can contact the radial plate 82 and be driven by the pusher 78 through the intermediate collar 80. The drive arm 60 preferably does not contact the window 72 of the differential case 18 to permit axial movement of the spline ring 46.

[0036] The drive unit 76 remains stationary, while the pusher 78, the intermediate shaft ring 80 and the radial plate 82 can move axially, but preferably do not rotate with the spline ring 46 during rotation of the ring gear 16. The fixed housing 14 may include an anti-rotation feature (not shown) to prevent rotation of the radial plate 82. In addition, the drive unit 76 includes a position sensor (not shown) to read the position of the radial plate 82, for which the radial plate 82 serves as a target. The spline ring 46 can rotate and slide along the radial plate 82. It will be appreciated that other types of drive units 76 can be used to selectively shift the spline ring 46. When the drive unit 76 is deactivated, the disconnect spring 58 biases the spline ring 46, the radial plate 82, the intermediate shaft ring 80 and the pusher 78 outward (arrow 64') back to the original position. Figure 1 and Figure 2 The position of the spline connection 52 is opened (i.e., the disconnect clutch), and when the drive unit 76 is started, the reverse movement of these components (arrow 64) occurs to close the disconnect clutch 52, such as Figure 3 shown.

[0037] This system is essentially monostable because the spline ring 46 normally stays in Figure 1 and Figure 2 The disconnect position is not affected unless and until the disconnect actuator 62 is activated to move the spline ring 46 to the Figure 3 When the disconnect actuator 62 is deactivated, the spline ring 46 then returns to the disconnect position ( Figure 1 and Figure 2 ).further, Figure 1 and Figure 2 The normal position is preferably the open disconnected position, Figure 3 The active position is the closed connected position. It will be appreciated that the configuration of the spline ring 46 and the disconnect spring 58 can be modified to operate so that the normal position is the closed connected position and the active position is the open disconnected position. It will be appreciated that the system can be configured to be bistable so that the spline ring 46 stays in its current position until the system repositions the spline ring 46.

[0038] exist Figure 1 , to reduce the space requirements of the disconnect actuator 62, the drive unit 76 is preferably positioned in an annular recess 88 defined axially between the side wall 66 of the differential housing 18 and the adjacent bearing 26 and radially outward of the end flange 22 of the differential housing 18. This allows the drive unit 76 to be mounted radially inward of the pusher 78, the intermediate collar 80 and the spacer 84 to reduce the radial size of the gearbox 12 in this area. These components are in turn surrounded by a radial wall section 90 and an annular wall section 92 of the stationary housing 14 to define an actuator compartment 94.

[0039] However, the spline ring 46 is radially disposed between the ring gear 16 and the gear socket 36, and the spline ring 46 can be selectively axially disposed between the modified ring gear and the modified gear socket to perform the functions described herein. Further, the differential disconnect system 44 can include other structures in place of the spline ring 46, such as a dog clutch or clutch plate, which selectively connects and disconnects the torque transfer between the ring gear 16 and the pinion gear 32. In these selective designs, torque transfer through the differential case does not occur. This three-piece differential design removes the torsional load from the differential case 18, allowing the differential case 18 to be smaller and / or made of different materials, which can still handle the axial and radial load requirements on the disconnect system / locker 10 or allow the differential case 18 to be eliminated entirely.

[0040] As described above, it is desirable to selectively couple the differential cover 20 with one of the plurality of side gears 38. As such, the disconnect system / locker 10 further includes a differential locker 96 that selectively operates to connect or disconnect the differential cover 20 with the side gears 38. Disconnection of the differential cover 20 from the adjacent side gears 38 allows the side gears 38 to rotate independently of the differential cover 20. In this embodiment, the differential locker 96 is normally unlocked. When the differential locker 96 is in the unlocked state, the side gears 38 can rotate freely relative to the differential cover 20, and the disconnect system / locker 10 acts as a standard open differential. However, when the differential locker 96 is in the locked state, the differential locker 96 prevents one of the plurality of side gears 38 from rotating relative to the differential cover 20. It can be appreciated that the differential locker 96 can be disposed between the differential case 18 and another side gear 38 without changing the scope of the present invention.

[0041] refer to Figure 2 In order to connect one of the plurality of side gears 38 and the differential cover 20, the differential locker 96 includes a shift collar 98 which is radially guided and axially slidable on the outside of the differential cover 20. Figure 2 and Figure 4 During the axial sliding of the shift collar 98, the shift collar 98 and the side gears 38 are releasably connected and disconnected to releasably connect the differential cover 20 and the side gears 38. Figure 2 and Figure 6, the differential locker 96 includes a releasable locker clutch 100, which is preferably defined by a set of clutch teeth or similar locking formations 102 on the outer diameter or surface of the side gears 38 and a complementary locking projection 104 on the inner diameter or surface of the shift collar 98. The locking formations 102 on the side gears 38 engage with the complementary locking projections 104 on the shift collar 98 to define a mechanical connection that rotationally locks the shift collar 98 with the side gears 38. The locking formations 102 and the complementary locking projections 104 may form spline teeth or other similar structures that prevent relative rotation of the differential cover 20 and the side gears 38 when engaged while permitting the shift collar 98 to rotate when engaged. Figure 2 The unlock position and Figure 4 Axial displacement between the locked positions.

[0042] exist Figure 2 , the differential cover 20 includes a pocket wall 106 that extends axially from the radial wall 68 toward the end flange 24 and terminates at a stop wall 108 that extends radially inward from the pocket wall 106. In addition, the differential cover 20 includes an intermediate flange 110 that extends axially outward from the stop wall 108. Further, the differential cover 20 includes a connector wall 112 that extends radially inward from an inner surface 114 of the intermediate flange 110 and abuts the end flange 24. Figure 5 , the differential cover 20 includes a plurality of spaced apart channels 116 extending in an axial direction and spaced circumferentially about the center flange 110. Each channel 116 includes a channel base 118 extending circumferentially between opposing channel walls 120, 122 extending radially inwardly from an outer surface of the center flange 110.

[0043] refer to Figure 2 and Figure 5Shift collar 98 is generally annular with a main ring 124 having an inner surface configured to slide along the outer surface of intermediate flange 110. Shift collar 98 includes an outer rim 126 extending radially outward from the outer surface of main ring 124. In addition, shift collar 98 includes a plurality of circumferentially spaced locking projections 104 extending radially inward from the inner surface of main ring 124. The number of spaced locking projections 104 corresponds to the number of channels 116 in differential cover 20. Further, when shift collar 98 is assembled with differential cover 20, the size and shape of locking projections 104 cooperate to engage with respective channels 116. Each locking projection 104 includes opposing projection walls 128, 130 extending radially inward from main ring 124 and an end wall 132 extending circumferentially between the distal ends of the opposing projection walls 128, 130. It will be appreciated that the projection walls 128, 130 and end wall 132, the channel walls 120, 122 and the channel base 118 may be tapered in the radial direction and / or in the axial direction without changing the scope of the present invention. Figure 2 As shown in FIG. 8 , the end wall 132 of the locking projection 104 is spaced radially inward from the inner surface 114 of the intermediate flange 110 .

[0044] exist Figure 6 , wherein one of the plurality of side gears 38 includes an outer ring 134 that extends radially outward from the side gear 38. In addition, the side gear 38 includes a plurality of circumferentially spaced locking formations 102 that extend axially through the outer ring 134 and extend radially inward from an outer surface 136 of the outer ring 134. The locking formation 102 is defined by a formation base 138 that extends circumferentially between opposing formation walls 140, 142 that extend radially inward from the outer surface 136 of the outer ring 134. The locking formation 102 is sized and shaped to cooperatively engage with respective locking projections 104 on the shift collar 98. It will be appreciated that the formation walls 140, 142 and the formation base 138 may be tapered in the axial direction and / or radial direction without varying the scope of the invention. The number of locking formations 102 is equal to or greater than the number of locking projections 104. Reference Figure 2 The outer surface 136 of the side gear 38 is radially inwardly spaced from the inner surface 114 of the center flange 110 on the differential cover 20 so that the side gear 38 can rotate relative to the differential cover 20. In addition, the outer surface 136 of the side gear 38 is radially outwardly spaced from the end wall 132 of the shift collar 98, and the formation base 138 is radially inwardly spaced from the end wall 132 of the shift collar 98 so that when the shift collar 98 moves axially along the differential cover 20, the locking projections 104 can engage and disengage with the respective locking formations 102 in the side gear 38.

[0045] refer to Figure 2 and Figures 4 to 6The shift collar 98 is radially guided and axially slidable along the intermediate flange 110 of the differential cover 20 as the locking projections 104 slide along respective channels 116 in the intermediate flange 110. Figure 2 The unlock position and Figure 4 The axially slidable locking device is provided between the locking positions in the Figure 2 In the unlocked position illustrated in FIG. 1 , the locking projections 104 of the shift collar 98 are axially spaced from the locking formations 102 in the side gears 38, allowing the side gears 38 to rotate independently of the differential cover 20. Figure 4 In the locked position illustrated in FIG. 1 , the locking projection 104 of the shift collar 98 is at least partially inserted into the locking formation 102 in the side gear 38 , preventing the side gear 38 from rotating relative to the differential cover 20 , and thereby the side gear 38 and the ring gear 16 .

[0046] Still Figure 2 , the differential locker 96 includes a locker return spring 144 (hereinafter "locker spring") operably coupled between the radial wall 68 of the differential cover 20 and the outer edge 126 on the shift collar 98. The locker spring 144 is configured to move toward the side gear 38 relative to the locking formation 102. Figure 2 The unlocked position in the shift collar 98 is biased. The locker spring 144 acts as a biasing member to normally bias the shift collar 98 to engage or exit engagement with the side gear 38.

[0047] exist Figure 2 , the differential lock 96 also includes a lock actuator 146 operably connected to the outer edge 126 and configured to be in the unlocked position ( Figure 2 ) and locked position ( Figure 4 ) to selectively reposition the shift collar 98 between the shift collar 98 and the side gear 38. In operation, when the lock actuator 146 is activated, the lock actuator 146 will move the shift collar 98 axially inward (arrow 64'), causing the shift collar 98 to engage the lock clutch 100 between the shift collar 98 and the side gear 38, as shown in FIG. Figure 4 14, allowing torque to travel from the ring gear 16, through the differential cover 20, through the shift collar 98, and to the side gears 38, as shown by arrow 147. When the lock actuator 146 is deactivated, the lock spring 144 will move the shift collar 98 axially outward (arrow 64), which will disengage the lock clutch 100 between the shift collar 98 and the side gears 38, thereby allowing the side gears 38 to rotate freely relative to the ring gear 16. In this embodiment, the shift collar 98 is normally biased to the left by the lock spring 144. Figure 2 The lock actuator 146 is again activated or operated to drive the shift collar 98 axially inward (arrow 64′) to the unlocked or open state. Figure 4 locked or closed state.

[0048] refer to Figure 1 To drive the shift collar 98, the lock actuator 146 includes a drive unit 148 fixedly supported on the stationary housing 14. The drive unit 148 includes Figure 2 Location and Figure 4 The embodiment of the present invention is a sliding ring or pusher 150 axially displaceable between the positions of the shift collar 98 and the radial plate 154. Preferably, the lock actuator 146 is an electromagnetic actuator 146, wherein the pusher 150 is axially driven by a drive unit 148 using electromagnetic force. It is understood that other types of actuators are also suitable, such as motors, worm gears, cams, ball ramps, hydraulic or pneumatic pistons or other suitable actuators. The pusher 150 can then axially drive the intermediate collar 152, which in turn drives the radial plate 154. The spacer 156 can be provided to control the radial and axial position of the pusher 150. The shift collar 98 contacts the radial plate 154, which is driven by the pusher 150 through the intermediate collar 152. The lock spring 144 biases the shift collar 98 toward an engagement state with the radial plate 154.

[0049] The drive unit 148 remains stationary, while the pusher 150, the intermediate collar 152, and the radial plate 154 can move axially, but preferably do not rotate with the shift collar 98 during rotation of the ring gear 16. The stationary housing 14 may include an anti-rotation feature (not shown) to prevent rotation of the radial plate 154. In addition, the drive unit 148 also includes a position sensor (not shown) to read the position of a target (not shown) on the intermediate collar 152. The shift collar 98 can rotate and slide along the radial plate 154. It will be appreciated that other types of drive units 148 may be used to selectively shift the shift collar 98. When the drive unit 148 is deactivated, the locker spring 144 biases the shift collar 98, the radial plate 154, the intermediate collar 152, and the pusher 150 back into position. Figures 1 to 3 position to open the lock-up clutch 100, and when the drive unit 148 is activated, the reverse movement of these components occurs to close the lock-up clutch 100, such as Figure 4 Hint.

[0050] The system is essentially monostable because the shift collar 98 normally stays in Figures 1 to 3 The unlocked position is not activated unless and until the detent actuator 146 is activated to move the shift collar 98 to the Figure 4 When the lock actuator 146 is deactivated, the shift collar 98 then returns to the unlocked position ( Figures 1 to 3 ).further, Figures 1 to 3 The normal position is preferably the open unlocked position, Figure 4 The active position is the closed locked position. In operation, the differential locker 96 selectively operates to connect the differential cover 20 with the side gears 38, while the differential disconnect system 44 connects the ring gear 16 with the gear nest 36, such as Figure 4 It will be appreciated that the configuration of the shift collar 98 and the locker spring 144 can be modified to operate so that the normal position is the closed locked position and the active position is the open unlocked position.

[0051] exist Figure 1 , in order to reduce the space requirements of the lock actuator 146, the drive unit 148 is preferably positioned in an annular pocket 158, which is axially defined between the intermediate flange 110 of the differential cover 20 and the adjacent bearing 26 and radially defined outwardly of the end flange 24 of the differential cover 20. This allows the drive unit 148 to be mounted radially inwardly of the pusher 150, the intermediate shaft ring 152 and the spacer 156 to reduce the radial size of the gearbox 12 in this area. These components are in turn surrounded by a radial wall portion 160 and an annular wall portion 162 of the stationary housing 14 to define an actuator compartment 164.

[0052] A second embodiment of the disconnect system / lock 10' is shown in Figures 7 to 15 , which use common parts designated by common reference numerals, wherein like primary reference numerals represent similar elements as described above. Figure 8 In this modified gearbox 12', the functions of the specific components of the differential disconnect system 44 and the differential lock 96 have been merged so that the disconnect system / locker 10' includes a single actuator 166 that replaces the disconnect actuator 62 and the locker actuator 146 of the disconnect system / locker 10 described above. The actuator 166 actuates the disconnect clutch 52' between the spline ring 46' and the gear socket 36' and the locker clutch 100' between the spline ring 46' and the side gear 38'. The obvious differences between the two embodiments are only reflected in the drawings and the following description.

[0053] In more detail, the modified gearbox 12' operates substantially the same as the gearbox 12, wherein a rotatable ring gear 16 is disposed within a stationary housing 14' and is rotatably supported both axially and radially by a differential housing 18' and a differential cover 20', wherein the ring gear 16, the differential housing 18' and the differential cover 20' rotate together within an interior compartment of the stationary housing 14'.

[0054] The side gears 38' are selectively driven by the pinion gears 32 through the rotation of the ring gear 16, and the pinion gears 32 are operably connected between the side gears 38' and the ring gear 16. The pinion gears 32 are rotatably connected together in the pinion gear assembly 30', wherein the pinion gears 32 travel around the side gears 38'. The pinion gear assembly 30' also includes a gear socket 36', wherein the side gears 38' are meshingly engaged with the pinion gears 32, and the ring gear 16 is engaged with the gear socket 36', so that torque can be transmitted through the gear socket 36', the pinion gears 32, and then to the side gears 38', thereby driving the shaft 42.

[0055] like Figure 8 As shown, the disconnect system / locker 10' is disposed between the ring gear 16 and the gear socket 36', wherein the disconnect system / locker 10' selectively or intermittently operates to connect and disconnect the ring gear 16 with the gear socket 36'. The disconnect system / locker 10' includes a modified spline ring 46' that is radially guided and axially slides inside the differential case 18', just like the spline ring 46 of the previous embodiment. The spline ring 46' has an outer surface that preferably includes radial connector protrusions 48' that engage with complementary connector formations 50' on the inner surface of the ring gear 16 to define a mechanical connection that rotationally locks the spline ring 46' with the ring gear 16. The connector protrusions 48' may be formed as spline teeth or other similar structures that lock relative rotation between the ring gear 16 and the spline ring 46' when engaged while permitting the spline ring 46' to rotate axially when engaged. Figure 8 and Fig.11 The disconnected unlocked position, Fig.13 The connection unlock position and Fig.15 Alternatively, it will be appreciated that the spline ring 46 ′ may be mechanically connected to the gear socket 36 ′ and slidably engage and disengage with the ring gear 16 .

[0056] refer to Fig.11 and 13 During axial sliding of the spline ring 46', the spline ring 46' releasably connects and disconnects with the gear socket 36' to releasably connect the ring gear 16 to the gear socket 36' and the pinion gear 32. In particular, the disconnect system / locker 10' includes a releasable disconnect clutch 52', which is preferably defined by a set of clutch teeth or other similar locking formations 54' on the inner diameter or surface of the spline ring 46' and a complementary locking formation 56' on the outer diameter or surface of the gear socket 36'.

[0057] The disconnect system / lock 10' also includes a return spring 58' that is operably coupled between the proximal end of the spline ring 46' and the differential cover 20' and is configured to move toward a disconnect unlocked position ( Fig.11 ) biases the spline ring 46'. In addition, the spline ring 46' includes one or more drive arms 60' that extend axially away from the proximal end of the spline ring 46' and through respective windows 72' in the differential case 18'. The return spring 58' acts as a biasing member to normally bias the spline ring 46' into or out of engagement with the side gears 38, and into or out of engagement with the gear sockets 36'.

[0058] The spline ring 46' is also configured to selectively couple the gear socket 36' and one of the plurality of side gears 38' to provide torque directly to one of the side gears 38', which provides a locker function. Disconnection of the gear socket 36' and the side gears 38' allows the side gears 38' to rotate independently of the gear socket 36'. In this embodiment, the disconnect system / locker 10' is normally in the disconnected unlocked state, and the spline ring 46' is in the unlocked state. Fig.11 When the disconnect system / lock 10′ is in the connected unlocked state ( Fig.12 and Fig.13 ) and the spline ring 46' is in the connected unlocked position, the side gear 38' can rotate freely relative to the gear socket 36' and the disconnect system / locker 10' acts as a standard open differential. However, when the disconnect system / locker 10' is in the connected locked state ( Fig.14 and Fig.15 ), the spline ring 46' is in the connection locking position and prevents one of the side gears 38' from rotating relative to the gear socket 36'. It can be appreciated that the spline ring 46' can be disposed between the differential cover 20' and the other side gear 38' without changing the scope of the present invention.

[0059] refer to Fig.11 In order to connect one of the side gears 38' and the gear socket 36', the spline ring 46' includes a shift ring 168 extending radially inwardly from the spline ring 46' and fixedly connected to the spline ring 46'. The shift ring 168 is axially positioned between the locking formation 54' and the drive arm 60' along the inner surface of the spline ring 46'. Fig.11 and Fig.15, during axial sliding of the spline ring 46', the shift ring 168 is releasably connected and disconnected with the side gears 38' to releasably connect the gear sockets 36' with the side gears 38'. The disconnect system / locker 10' includes a releasable locker clutch 100', which is preferably defined by a set of clutch teeth or similar locking formations 102' on the outer diameter or surface of the side gears 38' and complementary locking projections 104' on the inner diameter or surface of the shift ring 168. The locking formations 102' on the side gears 38' engage with the complementary locking projections 104' on the shift ring 168 to define a mechanical connection that rotationally locks the spline ring 46' with the side gears 38'. The locking formations 102' and complementary locking projections 104' may form spline teeth or other similar structures that lock relative rotation of the gear socket 36' and the side gear 38' when engaged while permitting the spline ring 46' to rotate. Fig.11 The disconnected unlocked position, Fig.13 The connection unlock position and Fig.15 axial displacement between the connected locking positions.

[0060] exist Figure 7 and Figure 8 , the actuator 166 includes a motor 170, a drive gear 172, a sector gear 174, a cam ring 176, an outer thrust ring 178, and an inner thrust ring 180. The motor 170 is fixedly coupled to the stationary housing 14' and drives the drive gear 172 which meshingly engages with the sector gear 174. The drive gear 172 is rotatably supported within the stationary housing 14'. The sector gear 174 is fixed to a cam actuator 182 which is axially supported by an outer thrust ring 178 which abuts against a radial wall portion 184 of the stationary housing 14' and is rotatably supported by a thrust collar 186 which abuts against an annular boss 188 extending axially from the radial wall portion 184. The sector gear 174 includes circumferentially spaced cam projections 190 for engaging with the cam ring 176.

[0061] Cam ring 176, outer thrust ring 178 and inner thrust ring 180 are generally annular in shape and include circumferentially spaced locator tabs 192, 194 and 196 that extend radially outwardly from the outer diameter or surface of each of rings 176, 178 and 180. Figure 8 , the sector gear 174, cam ring 176, outer thrust ring 178, inner thrust ring 180 and thrust collar 186 are positioned within a cam cavity 198 within the stationary housing 14′, the cam cavity 198 being defined between the outer surface of the differential housing 18′, the adjacent bearing 26 and the radial wall portion 184, the annular boss 188 and the annular wall portion 200 of the stationary housing 14′. The annular wall portion 200 is spaced radially outward from the annular boss 188.

[0062] refer to Figure 8 and Fig. 9 , the fixed housing 14' includes a sector-shaped cavity 202 adjacent to the cam cavity 198 and extending radially outward from the cam cavity 198. The cam cavity 198 also includes a locator groove 204 that is circumferentially spaced around the outer diameter or surface of the cam cavity 198 and extends in the axial direction. The size and shape of the locator groove 204 cooperate with the locator tabs 192, 194, 196 on the cam ring 176, the outer thrust ring 178, and the inner thrust ring 180 to prevent rotation of the rings 176, 178, 180 while allowing the cam ring 176 and the inner thrust ring 180 to move axially along the locator groove 204.

[0063] exist Figure 8 , the outer thrust ring 178 abuts against the radial wall portion 184 of the stationary housing 14′, and the locator tabs 194 are positioned in respective locator grooves 204. The cam actuator 182 is positioned axially inward from the outer thrust ring 178, and the sector gear 174 is positioned in the sector cavity 202. The sector gear 174 is rotatable in the sector cavity 202. The cam ring 176 is positioned axially inward from the cam actuator 182. The inner thrust ring 180 is positioned axially inward from the cam ring 176 and axially outward from the spline ring 46′. In addition, the cam actuator 182, the cam ring 176, and the outer thrust ring 178 and the inner thrust ring 180 are positioned radially outward from the end flange 22′ of the differential housing 18′. The outer and inner thrust rings 178, 180 and the cam ring 176 are rotationally locked to the stationary housing 14' by the locator tabs 192, 194, 196 positioned in the locator grooves 204. However, because the locator tabs 192, 196 are axially slidable along the respective locator grooves 204, the inner thrust ring 180 and the cam ring 176 are rotatably locked to the stationary housing 14'. Fig.11 The disconnected unlocked position and Fig.15 The return spring 58' biases the spline ring 46', the inner thrust ring 180, the cam ring 176, the cam actuator 182 and the outer thrust ring 178 axially outward toward the stationary housing 14'. In this way, the return spring 58' biases the spline ring 46' toward the disconnect unlocked position relative to the disconnect clutch 52' and the locker clutch 100'.

[0064] refer to Fig.10The cam protrusion 190 of the cam actuator 182 includes a ramp portion 206 adjacent to a cam peak 208, and the cam protrusion 190 extends axially toward the cam ring 176. The ramp portion 206 includes an intermediate portion 210, which is circumferentially spaced between a base portion 212 and a peak portion 214 adjacent to the cam peak 208. The peak portion 214 selectively includes the cam peak 208. The cam ring 176 is generally annular and includes an annular base 216 and circumferentially spaced cam ramps 218, which are away from the annular base 216 and extend axially toward the cam actuator 182. The number of cam ramps 218 generally corresponds to the number of cam protrusions 190 on the cam actuator 182. The cam projections 190 on the cam actuator 182 and the cam ramps 218 of the cam ring 176 are sized and shaped such that rotation of the cam actuator 182 causes the cam projections 190 to axially displace the cam ring 176, which also causes the spline ring 46' to axially move. The axial position of the spline ring 46' is controlled by the contact of the cam ramps 218 with the respective ramp portions 206 of the cam actuator 182. In addition, the annular base 216 is configured to provide axial clearance for the cam peaks 208 when the cam actuator 182 rotates relative to the cam ring 176. The intermediate portion 210 and the peak portion 214 may be inclined portions to make the actuator 166 monostable, as further described below.

[0065] In this embodiment, the spline ring 46' is normally biased to the position by the return spring 58'. Fig.11 The disconnected unlocked state (i.e., the open state) shown in FIG. 1 is then activated or operated to rotate the cam actuator 182 and cause the cam ring 176 to axially move the spline ring 46′ to the connected unlocked position ( Fig.12 and Fig.13 ), which engages the disconnect clutch 52' and allows torque to be transferred from the ring gear 16 through the spline ring 46' to the gear socket 36'. Additionally, the actuator 166 also causes the cam ring 176 to axially move the spline ring 46' to the connection locking position ( Fig.14 and Fig.15 ), which in turn engages the locking clutch 100′, which rotationally secures the side gear 38′ with the gear socket 36′ and prevents rotation of the side gear 38′ relative to the gear socket 36′. Thus, a single actuator 166 is capable of actuating the disconnect clutch 52′ between the ring gear 16 and the gear socket 36, as well as the locking clutch 100′ between the side gear 38′ and the gear socket 36′.

[0066] Initially, the disconnect system / lock 10' is Figure 7 , Figure 8 and Fig.11In the disconnect unlocked state shown, the disconnect clutch 52' is disengaged, the locker clutch 100' is unlocked, the spline ring 46' is in the disconnect unlocked position, and the base portion 212 of the cam projection 190 is engaged with the cam ramp 218. When the disconnect system / locker 10' is in the disconnect unlocked state, the gear socket 36' is free to rotate relative to the ring gear 16, and the side gear 38' is free to rotate relative to the gear socket 36'. Figure 7 To selectively engage the disconnect clutch 52', the actuator 166 activates the motor 170, which drives the drive gear 172 in the forward rotational direction 220 causing the sector gear 174 and the attached cam actuator 182 to rotate in the first rotational direction 222. It can be appreciated that the forward rotational direction 220 can be either a clockwise or counterclockwise rotational direction without changing the scope of the present invention. In addition, it can be appreciated that the first rotational direction 222 can be either a clockwise or counterclockwise rotational direction without changing the scope of the present invention. Fig.12 and Fig.13 , the cam actuator 182 is rotated in the first rotational direction 222 until the intermediate portion 210 of the cam projection 190 engages the respective cam ramp 218, which causes the cam ring 176 to move axially in the inward direction (arrow 224). The axial movement of the cam ring 176 in the inward direction (arrow 224) causes the spline ring 46' to move axially in the inward direction (arrow 224) to the connection unlocking position ( Fig.13 ), causing the spline ring 46' to engage the disconnect clutch 52' between the spline ring 46' and the gear socket 36', allowing torque to travel from the ring gear 16, through the spline ring 46', to the gear socket 36'.

[0067] After the disconnect system / locker 10' is in the connected unlocked state, the actuator 166 holds the motor 170 in a predetermined first rotational position, which holds the disconnect system / locker 10' in the connected unlocked state, the disconnect clutch 52' is in the engaged state, the locker clutch 100' is in the disengaged state, the spline ring 46' is in the connected unlocked position, and the intermediate portion 210 of the cam protrusion 190 is engaged with the cam ramp 218 of the cam ring 176. Because the peak portion 214 of the cam protrusion 190 is spaced apart from the cam ramp 218, when the disconnect clutch 52' is engaged, the locker clutch 100' is held in the disengaged state. It can be appreciated that the motor 170 can include a motor encoder (not shown) configured to provide feedback to the actuator 166 indicating the rotational position of the motor 170. The actuator 166 can be configured to be monostable in the connected unlocked state to hold the motor 170 in the first predetermined rotational position to hold the disconnect system / locker 10' in the connected unlocked state. Because the middle portion 210 is tilted, the actuator 166 is monostable in the connected unlocked state. Thus, when the disconnect system / lock 10′ is in the connected unlocked state and the motor 170 is deactivated (i.e., power is removed from the motor 170), the return spring 58′ will reverse drive the motor 170 due to the tilt of the middle portion 210. Thus, when the actuator 166 provides power to the motor 170, the disconnect system / lock 10′ remains in the connected unlocked state, and when the motor 170 is deactivated, the disconnect system / lock 10′ automatically returns to the disconnected unlocked state by the return spring 56′.

[0068] When the disconnect system / locker 10' is in the connected unlocked state, the disconnect system / locker 10' can be placed in the connected locked state by the actuator 166 by engaging the locker clutch 100'. Fig.14 To engage the locker clutch 100′, the actuator 166 activates the motor 170, which drives the drive gear 172 in a forward rotational direction 220, causing the sector gear 174 and the attached cam actuator 182 to rotate in a first rotational direction 222, causing the peak portions 214 of the cam lobes 190 to engage with the respective cam ramps 218. The alignment of the peak portions 214 with the respective cam ramps 218 causes the cam ring 176 to move axially in an inward direction (arrow 224), thereby causing the spline ring 46′ to move axially in an inward direction (arrow 224) to a connected locking position ( Fig.14 and Fig.15 ), causing the spline ring 46' to engage the locker clutch 100' between the shift ring 168 and the side gear 38'. The engagement of the disconnect clutch 52' is maintained between the spline ring 46' and the gear pocket 36' while the spline ring 46' is repositioned to engage the locker clutch 100'. When the spline ring 46' is in the connected locking position ( Fig.14 and Fig.15 ), the spline ring 46' allows torque to travel from the ring gear 16 through the spline ring 46', through the disconnect clutch 52' to the gear socket 36', while also allowing torque to travel from the ring gear 16 through the spline ring 46', through the locker clutch 100' to the side gear 38'. After the disconnect system / locker 10' is connected to the locked state, the actuator 166 maintains the motor 170 in a second predetermined rotational position, which maintains the disconnect clutch 52' in the engaged state and maintains the locker clutch 100' in the engaged state.

[0069] The actuator 166 can be configured to be monostable so that the motor 170 is held in a first predetermined rotational position to maintain the disconnect system / lock 10' in the connected locked state. Because the peak portion 214 is inclined, the actuator 166 is monostable in the connected locked state. As such, when the disconnect system / lock 10' is in the connected locked state and the motor 170 is deactivated, the return spring 58' will reverse drive the motor 170 due to the inclination of the peak portion 214. Thus, the disconnect system / lock 10' is maintained in the connected locked state while the actuator 166 supplies power to the motor 170, and when the motor 170 is deactivated, the disconnect system / lock 10' automatically returns to the connected unlocked state by the return spring 56'.

[0070] refer to Fig.14 and Fig.15 , in order to disengage the locker clutch 100' while maintaining the engagement of the disconnect clutch 52', the actuator 166 deactivates the motor 170. After the motor 170 is deactivated, the return spring 58' drives the motor 170 in reverse, and the motor 170 drives the drive gear 172 in the reverse rotational direction 220' to drive the sector gear 174 and the attached cam actuator 182 in the second rotational direction 222'. The forward and reverse rotational directions 220, 220' are opposite rotational directions. Likewise, the first and second rotational directions 222, 222' are opposite rotational directions. The cam actuator 182 rotates in the second rotational direction 222' until the intermediate portion 210 of the cam protrusion 190 is circumferentially aligned with the respective cam ramps 218 of the cam ring 176. The return spring 58′ moves the cam ring 176, the inner thrust ring 178 and the spline ring 46′ axially in the outward direction (arrow 224′) to the connection unlocking position ( Fig.12 and Fig.13), causing the spline ring 46' to move to the connection unlocked position, which disengages the locker clutch 100' while maintaining the disconnect clutch 52' in an engaged state. When the spline ring 46' is in the connection unlocked position, torque is allowed to travel from the ring gear 16, through the spline ring 46', through the disconnect clutch 52' to the gear socket 36', while allowing the side gear 38' to rotate relative to the gear socket 36'. After the disconnect system / locker 10' is in the connection unlocked state, the actuator 166 selectively activates the motor 170, which maintains the motor 170 in the first predetermined rotational position, the disconnect clutch 52' remains in the engaged state, and the locker clutch 100' remains in the disengaged state.

[0071] refer to Fig.12 and Fig.13 , in order to disengage the disconnect clutch 52′ between the spline ring 46′ and the gear socket 36′ while the locker clutch 100 is disengaged, the actuator 166 causes the motor 170 to be deactivated, which allows the return spring 58′ to reverse drive the motor 170 and drive the drive gear 172 in the reverse rotational direction 220′, causing the sector gear 174 and the attached cam actuator 182 to rotate in the second rotational direction 222′. The cam actuator 182 rotates in the second rotational direction 222′ until the base portion 212 of the cam protrusion 190 is circumferentially aligned with the respective cam ramps 218 of the cam ring 176. In response to the base portion 212 of the cam protrusion 190 being rotationally repositioned to align with the cam ramps 218, the return spring 58′ causes the cam ring 176, the inner thrust ring 178 and the spline ring 46′ to move axially in the outward direction (arrow 224′) to the disconnect unlocked position ( Figure 7 and Fig.11 ), causing the spline ring 46' to move to the disconnect unlocked position, which disengages the disconnect clutch 52' between the spline ring 46' and the gear socket 36', thereby allowing the gear socket 36' to rotate freely relative to the ring gear 16. After the disconnect system / locker 10' is in the disconnect unlocked state, the actuator 166 maintains the motor 170 in the deactivated state, which keeps the disconnect clutch 52' in the disengaged state and keeps the locker clutch 100' in the unlocked state.

[0072] A third embodiment of a disconnect system / lock 10' is shown in Figures 10 to 15 1 , which uses common parts designated by common reference numerals, wherein like primary reference numerals represent similar elements as described above. In this modified disconnect system / lock 10', the actuator 166 is configured to be bi-stable so that the disconnect system / lock 10' remains in the current state until the actuator 166 activates the motor 170 to reposition the cam actuator 182' between the connection unlocked state and the connection locked state. The significant differences between the embodiments are only reflected in the drawings and the following description.

[0073] refer to Fig.10 , the cam actuator 182' includes a modified ramp portion 206' on the cam protrusion 190', the modified ramp portion 206' includes an intermediate flat portion 210' and a peak flat portion 214'. The flat portions 210', 214' allow the actuator 166 to be bistable, that is, the flat portions 210', 214' prevent the return spring 56' from driving the motor 170 in reverse when the motor 170 is deactivated, and the disconnect system / lock 10' is in a connected unlocked state and a connected locked state, respectively. In addition, the modified ramp portion 206' includes a ramp portion 228 extending circumferentially between the intermediate flat portion 210' and the peak flat portion 214'. Further, the ramp portion 206' also includes a ramp portion 226 extending circumferentially between the base portion 212 and the intermediate flat portion 210'.

[0074] Initially, the disconnect system / lock 10' is Figure 7 , Figure 8 and Fig.11 In the disconnect unlocked state shown, the disconnect clutch 52' is disengaged, the locker clutch 100' is unlocked, the spline ring 46' is in the disconnect unlocked position, and the base portion 212 of the cam projection 190' is engaged with the cam ramp 218. When the disconnect system / locker 10' is in the disconnect unlocked state, in order to selectively engage the disconnect clutch 52', the actuator 166 activates the motor 170, and the motor 170 drives the drive gear 172 in the forward rotational direction 220, causing the sector gear 174 and the attached cam actuator 182' to rotate in the first rotational direction 222. Fig.12 and Fig.13 , the cam actuator 182' is rotated in the first rotational direction 222 until the intermediate flat portion 210' of the cam projection 190' engages the respective cam ramp 218, which causes the cam ring 176 to axially move in the inward direction (arrow 224). The axial movement of the cam ring 176 in the inward direction (arrow 224) causes the spline ring 46' to axially move in the inward direction (arrow 224) to the connection unlocking position ( Fig.13 ), causing the spline ring 46' to engage the disconnect clutch 52' between the spline ring 46' and the gear socket 36', allowing torque to travel from the ring gear 16, through the spline ring 46', to the gear socket 36'.

[0075] After the disconnect system / locker 10' is in the connected unlocked state, the actuator 166' deactivates the motor 170 in a predetermined first rotational position, which maintains the disconnect system / locker 10' in the connected unlocked state, the disconnect clutch 52' in the engaged state, the locker clutch 100' in the disengaged state, and the spline ring 46' in the connected unlocked position, the middle flat portion 210' of the cam lobe 190' engages the cam ramp 218 of the cam ring 176. Because the peak flat portion 214' of the cam lobe 190' is spaced apart from the cam ramp 218, the locker clutch 100' is maintained in the disengaged state when the disconnect clutch 52' is engaged. The profile of the middle flat portion 210' engaging the cam ramp 218 prevents the return spring 58' from back-driving the motor 170 when the motor 170 is deactivated, which allows the actuator 166 to be bistable in the connected unlocked state. As such, the disconnect system / lock 10 ′ remains in the connected unlocked state until the actuator 166 activates the motor 170 to reposition the disconnect system / lock 10 ′ to one of the connected locked state or the disconnected unlocked state.

[0076] When the disconnect system / locker 10' is in the connected unlocked state by engaging the locker clutch 100', the disconnect system / locker 10' is placed in the connected locked state by the actuator 166. Fig.14 To engage the locker clutch 100′, the actuator 166 activates the motor 170, which drives the drive gear 172 in a forward rotational direction 220, causing the sector gear 174 and the attached cam actuator 182′ to rotate in a first rotational direction 222, causing the peak flat portions 214′ of the cam protrusions 190′ to engage with the respective cam ramps 218. The alignment of the peak flat portions 214′ with the respective cam ramps 218 causes the cam ring 176 to axially move in an inward direction (arrow 224), thereby causing the spline ring 46′ to axially move in an inward direction (arrow 224) to the connected locking position ( Fig.14 and Fig.15 ), causing the spline ring 46' to engage the locker clutch 100' between the shift ring 168 and the side gear 38'. The engagement of the disconnect clutch 52' is maintained between the spline ring 46' and the gear pocket 36' while the spline ring 46' is repositioned to engage the locker clutch 100'. When the spline ring 46' is in the connected locking position ( Fig.14 and Fig.15), the spline ring 46' allows torque to travel from the ring gear 16 through the spline ring 46' and through the disconnect clutch 52' to the gear socket 36', while also allowing torque to travel from the ring gear 16, through the spline ring 46', through the locker clutch 100' to the side gear 38'. After the disconnect system / locker 10' is in the connected locked state, the actuator 166 deactivates the motor 170 in a second predetermined rotational position, which maintains the disconnect clutch 52' in the engaged state and maintains the locker clutch 100' in the engaged state. The profile of the peak flat portion 214' engaging the cam ramp 218 prevents the return spring 58' from back-driving the motor 170 when the motor 170 is deactivated, which allows the actuator 166 to be bistable in the connected locked state. As such, the disconnect system / latch 10 ′ remains in the connected locked state until the actuator 166 activates the motor 170 to reposition the disconnect system / latch 10 ′ to one of the connected unlocked state or the disconnected unlocked state.

[0077] refer to Fig.14 and Fig.15 To disengage the locker clutch 100′ while maintaining engagement of the disconnect clutch 52′, the actuator 166 activates the motor 170, which drives the drive gear 172 in a reverse rotational direction 220′ to drive the sector gear 174 and the attached cam actuator 182′ in a second rotational direction 222′. The cam actuator 182′ rotates in the second rotational direction 222′ until the intermediate flat portion 210′ ​​of the cam protrusion 190′ is circumferentially aligned with the respective cam ramps 218 of the cam ring 176. The return spring 58′ causes the cam ring 176, the inner thrust ring 178 and the spline ring 46′ to axially move in an outward direction (arrow 224′) to a connected unlocked position ( Fig.12 and 13 ), causing the spline ring 46' to move to the connected unlocked position, which disengages the locker clutch 100' while the disconnect clutch 52' remains in the engaged state. When the spline ring 46' is in the connected unlocked position, torque is allowed to travel from the ring gear 16, through the spline ring 46', through the disconnect clutch 52' to the gear socket 36', while allowing the side gear 38' to rotate relative to the gear socket 36'. After the disconnect system / locker 10' is in the connected unlocked state, the actuator 166 deactivates the motor 170, maintains the motor 170 in the first predetermined rotational position, maintains the disconnect clutch 52' in the engaged state, and the locker clutch 100' is in the disengaged state. The profile of the intermediate flat portion 210' engaging the cam ramp 218 prevents the return spring 58' from back-driving the motor 170 when the motor 170 is deactivated, which allows the actuator 166 to be bistable in the connected unlocked state.

[0078] Reference Fig.12 and Fig.13, with the locker clutch 100′ disengaged, to disengage the disconnect clutch 52′ between the spline ring 46′ and the gear socket 36′, the actuator 166 activates the motor 170, which drives the drive gear 172 in a reverse rotational direction 220′, causing the sector gear 174 and the attached cam actuator 182′ to rotate in a second rotational direction 222′. The cam actuator 182′ rotates in the second rotational direction 222′ until the base portion 212 of the cam protrusion 190′ is circumferentially aligned with the respective cam ramps 218 of the cam ring 176. In response to the base portion 212 of the cam protrusion 190′ being rotationally repositioned to align with the cam ramps 218, the return spring 58′ causes the cam ring 176, the inner thrust ring 178 and the spline ring 46′ to move axially in an outward direction (arrow 224′) to the disconnect unlocked position ( Figure 7 and Fig.11 ), causing the spline ring 46' to move to the disconnect unlocked position, which disengages the disconnect clutch 52' between the spline ring 46' and the gear socket 36', thereby allowing the gear socket 36' to rotate freely relative to the ring gear 16. After the disconnect system / locker 10' is in the disconnect unlocked state, the actuator 166 deactivates the motor 170, which maintains the disconnect clutch 52' in the disengaged state and the locker clutch 100' in the unlocked state.

[0079] It can be appreciated that the actuator 166 can be configured to be bistable or monostable in the connection unlock state and the connection locked state. For example, by including the middle flat portion 210 ′ and the inclined peak portion 214 as part of the ramp portions 206, 206 ′, the actuator 166 can be configured to be bistable in the connection unlock state and monostable in the connection locked state. In an optional embodiment, by including the inclined middle portion 210 and the peak flat portion 214 ′ as part of the ramp portions 206, 206 ′, the actuator 166 can be configured to be monostable in the connection unlock state and bistable in the connection locked state.

[0080] As discussed above, the differential disconnect system and locker assembly 10, 10' includes a disconnect clutch 52, 52' configured to selectively connect the ring gear 16 with the differential gear socket 36, 36' so that torque can be transferred from the ring gear 16 through the gear socket 36, 36', the pinion gear 32, and then to the side gears 38, 38', thereby driving the shaft 42. Disengagement of the disconnect clutch 52, 52' between the spline ring 46, 46' and the gear socket 36, 36' allows the ring gear 16, the differential case 18, 18', the bearing 26 and the remainder of the gearbox 12, 12' to stop rotating when the wheels of the vehicle are turned. In addition, the differential disconnect system and locker assembly 10, 10' includes a locking clutch 100, 100', which is configured to selectively lock the differential case 18, 18' or the differential cover 20 with one of the side gears 38, 38' to prevent the side gear 38, 38' from rotating relative to the connected differential case 18, 18' or the differential cover 20.

[0081] The invention has been described in an illustrative manner, and it is to be understood that the terms used are descriptive rather than limiting. In light of the above teachings, the invention is susceptible of many modifications and variations. Therefore, it is to be understood that within the scope of the appended claims, the invention may be practiced beyond the specific description.

Claims

1. A differential disconnect system and locker assembly for a vehicle, comprising: Fixed housing; a rotatable ring gear rotatably supported by the stationary housing; a pinion gear assembly including a plurality of pinion gears drivingly connectable to the ring gear; a plurality of side gears rotatably disposed within the stationary housing and meshing with the pinion gears so that the side gears and the pinion gears rotate together; a differential housing and a differential cover rotatably supported on the stationary housing, wherein the ring gear rotates with at least one of the differential housing and the differential cover, wherein disconnection of the ring gear from the pinion gear assembly allows the ring gear, the differential housing, and the differential cover to stop rotating when the side gears rotate; a differential disconnect system assembly operably connected between respective surfaces of the ring gear and the pinion gear assembly to cause the ring gear, the pinion gears and the side gears to rotate together when connected, the differential disconnect system assembly being actuable to operably disconnect the ring gear and the pinion gear assembly to disconnect torque transmission between the ring gear and the pinion gears and prevent rotation of the ring gear driven by the pinion gears during wheel rotation; as well as A differential locker slidably connected to one or more of the differential case and the differential cover and operably connected to one of the plurality of side gears so that the differential case and the differential cover and one of the plurality of side gears rotate together when connected, and the differential locker is actuable to operably disconnect the one or more of the differential case and the differential cover from one of the plurality of side gears, allowing one of the plurality of side gears to rotate relative to one or more of the differential case and the differential cover.

2. The differential disconnect system and locker assembly of claim 1, wherein the differential case and the differential cover are supported on the stationary case by respective bearings, the bearings also allowing the side gears to stop rotating when the side gears rotate.

3. The differential disconnect system and locker assembly of claim 1, wherein: The pinion gear assembly includes a gear socket radially and axially supported by the differential housing and the differential cover; The gear socket is able to rotate freely relative to both the differential case and the differential cover; as well as The differential disconnect system assembly connects and disconnects the ring gear with the gear socket to connect and disconnect torque transmission upon activation.

4. The differential disconnect system and locker assembly of claim 3, wherein the differential disconnect system assembly includes a spline ring that enters and exits engagement with one or more of the ring gear and the gear pocket to respectively connect and disconnect torque transmission.

5. The differential disconnect system and locker assembly of claim 4, wherein: The spline ring is slidably engaged with the ring gear and is movable between a connected position and a disconnected position; as well as The spline ring is engaged with the pinion gear assembly in the connected position and is disengaged from the pinion gear assembly in the disconnected position.

6. The differential disconnect system and locker assembly of claim 5 wherein said spline ring is movable by an actuator.

7. The differential disconnect system and locker assembly of claim 6, wherein: The differential disconnect system assembly includes a biasing member to normally bias the spline ring to one of the connected position and the disconnected position; as well as The actuator moves the spline ring to the other of the connected position and the disconnected position.

8. The differential disconnect system and locker assembly of claim 7, wherein the actuator includes a drive unit fixedly supported on the stationary housing and a drive member axially displaceable to move the spline ring.

9. The differential disconnect system and locker assembly of claim 1, wherein the differential locker includes a shift collar slidably coupled to one of the differential case and the differential cover, the shift collar being movably brought into engagement or out of engagement with one of the plurality of side gears to respectively lock or unlock the side gear with one or more of the differential case and the differential cover.

10. The differential disconnect system and locker assembly of claim 9 wherein the shift collar is movable by a locker actuator.

11. The differential disconnect system and locker assembly of claim 10, wherein: The differential locker includes a second biasing member to normally bias the shift collar to one of a locked position and an unlocked position; as well as The lock actuator moves the shift collar to the other of the locked position and the unlocked position.

12. The differential disconnect system and locker assembly of claim 11, wherein the locker actuator includes a second drive unit fixedly supported on the stationary housing and a second drive member axially displaceable to move the shift collar.

13. A differential disconnect system and locker assembly for a vehicle, comprising: Fixed housing; a rotatable ring gear rotatably supported by a stationary housing; a differential housing rotatably supported on a stationary housing, wherein the ring gear rotates with the differential housing; a pinion gear assembly including a plurality of pinion gears drivingly connectable to the ring gear, a gear socket radially and axially supported by the differential housing, the gear socket being freely rotatable relative to the differential housing; a plurality of side gears rotatably disposed within the stationary housing and meshing with the pinion gears so that the side gears and the pinion gears rotate together; a differential disconnect system assembly including a spline ring movably brought into or out of engagement with one or more of the ring gear and the gear socket to allow the ring gear, the pinion gears, and the side gears to rotate together when connected, the differential disconnect system assembly being actuatable to operably disconnect the ring gear from the gear socket to disconnect torque transmission between the ring gear and the pinion gears and to prevent rotation of the ring gear driven by the pinion gears during wheel rotation, wherein disconnection of the ring gear from the pinion gear assembly allows the ring gear and the differential case to stop rotating when the side gears rotate; as well as A shift ring is fixedly coupled to the spline ring, the shift ring being movably brought into or out of engagement with one of the plurality of side gears to respectively lock or unlock the side gear with the gear socket.

14. The differential disconnect system and locker assembly of claim 13, wherein: The shift ring is disengaged from one of the plurality of side gears when the spline ring is in the disengaged position, and the shift ring and one of the plurality of side gears are movable into and out of engagement to respectively lock and unlock the side gear and the gear socket when the spline ring engages the gear socket and the ring gear.

15. The differential disconnect system and locker assembly of claim 14, further comprising an actuator configured to selectively move the spline ring into engagement with one or more of the ring gear and the gear socket.

16. The differential disconnect system and locker assembly of claim 15, wherein said actuator is configured to move a shift ring into engagement with one of said plurality of side gears when said spline ring engages said gear socket and said ring gear.

17. The differential disconnect system and locker assembly of claim 16 wherein said actuator includes a cam ring axially slidable to move said spline ring into and out of engagement with said gear socket and to move said shift ring into and out of engagement with one of said plurality of side gears.

18. The differential disconnect system and locker assembly of claim 17, wherein the actuator comprises a cam actuator, wherein: Rotation of the cam actuator causes the cam ring to slide axially to move the spline ring into and out of engagement with the gear socket and to move the shift ring into and out of engagement with one of the plurality of side gears based on the rotational position of the cam actuator.

19. The differential disconnect system and locker assembly of claim 18, wherein: The actuator includes a sector gear fixedly connected to the cam actuator and a drive gear meshingly engaged with the sector gear, so that rotation of the drive gear rotates the sector gear, causing the cam actuator to rotate, and rotation of the cam actuator causes the cam ring to move axially, causing the spline ring to move axially.

20. The differential disconnect system and locker assembly of claim 19, wherein: The actuator includes a motor fixedly coupled to the stationary housing and operably coupled to the drive gear to cause the drive gear to rotate.

21. The differential disconnect system and locker assembly of claim 20, wherein: The cam actuator includes a cam lobe having a ramp portion including an intermediate portion spaced between a base portion and a peak portion; The cam ring includes a cam ramp; When the cam actuator is rotated to align and engage the base portion with the cam ramp, the spline ring is disengaged from the gear socket and the shift ring is disengaged from one of the plurality of side gears; When the cam actuator is rotated to align and frictionally engage the intermediate portion with the cam ramp, the spline ring engages the gear socket and the shift ring disengages from one of the plurality of side gears; as well as When the cam actuator is rotated to align and frictionally engage the peak portion with the cam ramp, the spline ring engages with the gear socket and the shift ring engages with one of the plurality of side gears.

22. The differential disconnect system and locker assembly of claim 21 wherein said intermediate portion is a flat portion such that said actuator is bistable when said spline ring is engaged with said gear socket and said shift ring is disengaged from said side gear.

23. The differential disconnect system and locker assembly of claim 21 wherein said intermediate portion is an inclined portion such that the actuator is monostable when said spline ring is engaged with said gear socket and said shift ring is disengaged from said side gear.

24. The differential disconnect system and locker assembly of claim 21 wherein said peak portion is a flat portion such that said actuator is bistable when said spline ring is engaged with said gear socket and said shift ring is engaged with one of said plurality of side gears.

25. The differential disconnect system and locker assembly of claim 21 wherein said peak portion is an inclined portion such that said actuator is monostable when said spline ring is engaged with said gear socket and said shift ring is engaged with said side gear.

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