Actuation system having face cam mechanism operated by a planetary gear set

A torque transfer device configured and dimensioned to transfer torque from a primary output shaft of a vehicle powertrain to a secondary output shaft of the vehicle powertrain, the torque transfer device comprising:

• a housing;
• a torque transfer mechanism positioned within the housing and including a primary gear, a plate clutch rotatably coupling the primary gear to the primary output shaft of the vehicle powertrain, a secondary gear rotatably fixed to the secondary output shaft of the vehicle powertrain, and one of a chain or a transfer gear that extends between the primary gear and the secondary gear to transfer torque therebetween;
• and
• an actuation system comprising:
• an actuator motor including an output gear;
• a ball-ramp mechanism in mechanical cooperation with the actuator motor and including first and second annular members, wherein relative rotation between the first and second annular members causes relative axial displacement between the first and second annular members to actuate the torque transfer mechanism;
• and
• a gear reduction assembly comprising a first planetary gear set that receives and increases torque from the actuator motor by a first ratio to provide a first output torque;
• and a second planetary gear set that receives and increases the first output torque from the first planetary gear set by a second ratio to provide a second output torque;
• and at least one intermediate member having a gear and a barrel cam, the gear and the barrel cam are one-piece, monolithically formed, the at least one intermediate member is in mechanical engagement with the gear reduction assembly and the face cam mechanism for rotational movement such that rotation of the at least one intermediate member causes relative rotation between the first and second annular members of the face cam mechanism to actuate the torque transfer mechanism.

A torque transfer device configured and dimensioned to transfer torque from a primary output shaft of a vehicle powertrain to a secondary output shaft of the vehicle powertrain, the torque transfer device comprising:

• a torque transfer mechanism;
• and
• an actuation system engageable with the torque transfer mechanism, the actuation system comprising:
• an actuator motor;
• a face cam mechanism in mechanical cooperation with the actuator motor, the face cam mechanism including first and second annular members configured and dimensioned for relative rotation to cause relative axial displacement between the first and second annular members and actuation of the torque transfer mechanism;
• a gear reduction assembly comprising:
• a first planetary gear set that receives and increases torque from the actuator motor by a first ratio to provide a first output torque;
• a second planetary gear set that receives and increases the first output torque from the first planetary gear set by a second ratio to provide a second output torque;
• and
• a third planetary gear set that receives and increases the second output torque by a third ratio to provide a third output torque;
• and
• at least one intermediate member having a gear and a barrel cam, the gear and the barrel cam are one-piece, monolithically formed, the at least one intermediate member is in mechanical engagement with the gear reduction assembly and the face cam mechanism for rotation thereof such that torque transferred to the at least one intermediate member causes relative rotation between the first and second annular members.