Wedge fork clutch actuator for driveline clutches

A power transmission device comprising:

• a rotary input member adapted to receive drive torque from a power source;
• a rotary output member adapted to provide drive torque to an output device;
• a torque transfer mechanism operable for transferring drive torque from said input member to said output member, said torque transfer mechanism including a transfer clutch operably disposed between said input member and said output member and a clutch actuator for applying a clutch engagement force to said transfer clutch, said clutch actuator including a drive member having a tapered drive surface, a reaction member having a tapered reaction surface engaging said tapered drive surface and an apply surface engageable with said transfer clutch, an electric motor having a rotary output, and a conversion mechanism for converting rotary motion of said motor output into translational motion of said drive member;
• and
• a control system for controlling the direction and amount of rotation of said motor output for controlling the direction and amount of translational movement of said drive member, wherein translational movement of said drive member causes said tapered drive surface to slide relative to said reaction surface on said reaction member for forcibly moving said reaction member relative to said transfer clutch so as to vary the clutch engagement force exerted by said apply surface on said transfer clutch.

A power transfer assembly for use in a four-wheel drive vehicle having a powertrain and first and second drivelines, comprising:

• a first shaft driven by the powertrain and adapted for connection to the first driveline;
• a second shaft adapted for connection to the second driveline;
• a transfer clutch operably disposed between said first shaft and said second shaft;
• a clutch operator for generating and applying a clutch engagement force to said transfer clutch, said clutch operator including a drive member having a tapered drive surface, a reaction member having a tapered reaction surface engaging said tapered drive surface and an apply surface engaging said transfer clutch;
• and
• an electric motor for causing linear non-rotary translation of said drive member between a retracted position and an extended position, said drive member is operable in its retracted position to locate said reaction member in a released position relative to said transfer clutch and is further operable in its extended position to locate said reaction member in a locked position relative to said transfer clutch.

A power transmission device comprising:

• an input member adapted to received drive torque from a power source;
• an output member adapted to transmit drive torque to an output device;
• a transfer clutch operably disposed between said input member and said output member;
• a clutch actuator operable for engaging said transfer clutch to transfer drive torque from said input member to said output member, said clutch actuator including a drive member with a tapered drive surface, a reaction member having a tapered reaction surface, rollers disposed between said tapered drive surface and said tapered reaction surface, and an electric motor for causing translational movement of said drive member;
• and
• a control system for controlling activation of said electric motor, wherein translational movement of said drive member results in corresponding movement of said reaction member relative to said transfer clutch so as to vary the clutch engagement force exerted on said transfer clutch.

A motor vehicle comprising:

• a powertrain operable to generate drive torque;
• a first driveline driven by said powertrain;
• a second driveline;
• a power transmission device having a transfer clutch and a clutch actuator, said transfer clutch is operably disposed between said first and second drivelines, said clutch actuator is operable to engage said transfer clutch for transferring drive torque from one of said powertrain and said first driveline to said second driveline, said clutch actuator including a drive member with a ramped drive surface, a reaction member with a ramped reaction surface, and an electric motor for causing translational movement of said drive member;
• and
• a control system for controlling actuation of said motor so as to control translational movement of said drive member relative to said reaction member, said reaction member being slidably moveable in response to movement of said drive member so as to vary the magnitude of a clutch engagement force exerted on said transfer clutch.