Systems and methods for a rotary disconnect

A disconnect system for selectively coupling or disconnecting a drive member and a driven member, the disconnect system comprising:

• a housing;
• a housing cover configured to couple to the housing;
• a clutch ring rotationally coupled to the drive member, the clutch ring defining a rotational axis and including internal teeth, the internal teeth of the clutch ring being engaged with external teeth of the drive member;
• an actuator arranged within the housing;
• a shift fork coupled to the clutch ring and movable by the actuator, such that pivotal movement of the shift fork, relative to the housing, axially translates the clutch ring between a disengaged position and an engaged position in which the internal teeth of the clutch ring are engaged with external teeth of the driven member to rotationally couple the clutch ring and the driven member;
• and
• a first pin coupled to an arm of the shift fork;
• a shift pad positioned between the shift fork and the clutch ring, the shift pad defining a recess configured to receive the first pin and allow pivotal movement between the shift fork and the shift pad;
• and
• a position sensor enclosed by the housing and the housing cover, the position sensor arranged within the housing cover to detect a position of a second pin of the actuator.

A disconnect system for selectively coupling or disconnecting a drive member and a driven member, the disconnect system comprising:

• a housing defining an interior space;
• a housing cover configured to couple to the housing;
• a clutch ring disposed and movable within the interior space of the housing, the clutch ring defining a channel that extends circumferentially around the clutch ring;
• an actuator arranged within the housing and configured to move an actuator pin to actuate the clutch ring;
• a position sensor enclosed by the housing and the housing cover, the position sensor arranged within the housing cover to detect a position of the actuator pin of the actuator;
• a shift fork pivotally coupled to the housing such that pivotal movement of the shift fork, relative to the housing, axially translates the clutch ring between a disengaged position and an engaged position, the shift fork including:
• a body that is pivotally coupled to the actuator pin of the actuator,
• a first arm and a second arm extending from the body, the first arm including a first pin coupled to a distal end of the first arm, the first pin extending radially toward the clutch ring, and the second arm including a second pin coupled to a distal end of the second arm, the second pin extending radially toward the clutch ring,
• a first shift pad defining a first pin recess configured to receive the first pin and allow pivotal movement between the shift fork and the shift pad, the first shift pad being received in the channel of the clutch ring and the first shift pad having an arcuate shape that is complementary to a curvature of the clutch ring, and
• a second shift pad defining a second pin recess configured to receive the second pin and allow pivotal movement between the shift fork and the shift pad, the second shift pad being received in the channel of the clutch ring and the second shift pad having an arcuate shape that is complementary to the curvature of the clutch ring;
• and
• a bumper ring configured to engage with the clutch ring to provide an end stop that prevents overtravel of the clutch ring when the clutch ring is translated between the disengaged position and the engaged position.