Shift on the fly transmission

Abstract

A shift on the fly transmission is provided. The shift on the fly transmission includes a continuously variable transmission portion, a discrete transmission portion, at least one input shaft and a disconnect clutch. The continuously variable transmission portion is operationally coupled to receive torque from an engine. The discrete transmission portion includes a gear assembly. The at least one input shaft is operationally coupled to an output of the continuously variable transmission portion. The disconnect clutch operationally couples the at least one input shaft to the discrete transmission portion. The disconnect clutch is further configured to selectively decouple torque from the at least one input shaft to the discrete transmission portion during a range ratio shift of the discrete transmission portion.

The invention claimed is: 
     
       1. A shift on the fly transmission comprising:
 a continuously variable transmission portion operationally coupled to receive torque from an engine; 
 a discrete transmission portion having a gear assembly; 
 at least one input shaft operationally coupled to an output of the continuously variable transmission portion; 
 a disconnect clutch operationally coupling the at least one input shaft to the discrete transmission portion, the disconnect clutch configured to selectively decouple torque from the at least one input shaft to the discrete transmission portion during a range ratio shift of the discrete transmission portion; 
 a shift drum having a disconnect track; and 
 a disengagement fork operationally engaged with the disconnect track of the shift drum, the disengagement fork further configured to activate the disconnect clutch. 
 
     
     
       2. The shift on the fly transmission of  claim 1 , wherein the at least one input shaft further comprises:
 a first input shaft operationally coupled to an output of the continuously variable transmission portion; 
 a second input shaft operationally coupled to the discrete transmission portion; and 
 the disconnect clutch operationally coupling the at least one input shaft to the second input shaft. 
 
     
     
       3. The shift on the fly transmission of  claim 2 , wherein the first input shaft is an inner input shaft and the second input shaft is an outer input shaft, the inner input shaft received within the outer input shaft. 
     
     
       4. The shift on the fly transmission of  claim 1 , wherein the disconnect clutch includes a clutch pack. 
     
     
       5. The shift on the fly transmission of  claim 1 , further comprising:
 the disengagement fork pivotally coupled to the at least one input shaft. 
 
     
     
       6. The shift on the fly transmission of  claim 1 , wherein the continuously variable transmission portion further comprises:
 a drive clutch operationally coupled to receive the torque from the engine in the form of a rotational input; 
 a driven clutch, the at least one input shaft operationally coupled to the driven clutch; and 
 a belt engaged between the drive clutch and the driven clutch to rotationally couple the drive clutch to the driven clutch. 
 
     
     
       7. The shift on the fly transmission of  claim 1 , wherein the gear assembly of the discrete transmission portion further comprises:
 an input shaft high gear assembly; and 
 an input shaft low gear assembly. 
 
     
     
       8. The shift on the fly transmission of  claim 7 , further comprising:
 the input shaft high gear assembly including,
 an input shaft high gear, 
 a reverse shaft high gear, and 
 an engagement dog; and 
 
 the input shaft low gear assembly including:
 an input shaft low gear, 
 reverse shaft low gear, and 
 engagement dog; and: 
 
 a reverse shaft operationally coupled between the gear assembly and the final drive. 
 
     
     
       9. A shift on the fly transmission comprising:
 a drive clutch operationally coupled to receive torque from an engine in the form of a rotational input; 
 a driven clutch; 
 a belt engaged between the drive clutch and the driven clutch to rotationally couple the drive clutch to the driven clutch; 
 an inner input shaft operationally coupled to the driven clutch; 
 a discrete transmission portion having a gear assembly; 
 an outer input shaft operationally coupled to the discrete transmission; 
 a disconnect clutch operationally coupling the inner input shaft to the outer input shaft, the disconnect clutch configured to selectively decouple torque from the inner input shaft to the outer input shaft during a range ratio shift of the discrete transmission portion; and 
 the discrete transmission portion including,
 a shift drum having a disconnect track, 
 a disconnect shift collar operationally engaged in the disconnect track of the shift drum, 
 a push rod operationally coupled to the disconnect shift collar, and 
 a disengagement fork operationally engaged with the push rod, the disengagement fork further configured and arranged to activate the disconnect clutch. 
 
 
     
     
       10. The shift on the fly transmission of  claim 9 , wherein the disconnect clutch further comprises:
 an inner ring clutch basket operationally coupled to the outer input shaft; 
 an outer clutch basket operationally coupled to the inner input shaft; and 
 a clutch pack including a plurality sandwiched clutch plates and friction plates, the clutch plates engaged with the inner ring basket and the friction plates engaged with the outer clutch basket, wherein activation of the disconnect clutch reduces friction between the sandwiched clutch plates and friction plates. 
 
     
     
       11. The shift on the fly transmission of  claim 10 , further comprising:
 at least one pressure plate configured and arranged to operationally engage the clutch pack; and 
 a plurality of compression springs operationally engaged with the at least one pressure plate to compress the sandwiched clutch plates and friction plates of the clutch pack, the disengagement fork configured to selectively compress the plurality of springs to disengage the disconnect clutch. 
 
     
     
       12. A vehicle having a shift on the fly transmission system, the vehicle comprising:
 an engine to provide torque; 
 a continuously variable transmission portion operationally coupled to the engine to receive the torque; 
 a discrete transmission portion having a gear assembly; 
 at least one input shaft operationally coupled to the continuously variable transmission portion; 
 a disconnect clutch operationally coupling the at least one input shaft to the discrete transmission portion, the disconnect clutch further configured and arranged to selectively decouple torque from the at least one input shaft to the discrete transmission portion; 
 a final drive assembly operationally coupled to an output of the discrete transmission; 
 at least one vehicle wheel operationally coupled to the final drive assembly; 
 a shift drum having a disconnect track; 
 a disconnect shift collar operationally engaged in the disconnect track of the shift drum; 
 a push rod operationally coupled to the disconnect shift collar; and 
 a disengagement fork operationally engaged with the push rod, the disengagement fork further configured and arranged to activate the disconnect clutch. 
 
     
     
       13. The vehicle of  claim 12 , wherein the at least one input shaft further comprises:
 a first input shaft operationally coupled to an output of the continuously variable transmission portion; 
 a second input shaft operationally coupled to the discrete transmission portion; and 
 the disconnect clutch operationally coupling the at least one input shaft to the second input shaft. 
 
     
     
       14. The vehicle of  claim 12 , wherein the first input shaft is an inner input shaft and the second input shaft is an outer input shaft, the inner input shaft received within the outer input shaft. 
     
     
       15. The vehicle of  claim 12 , wherein the continuously variable transmission further comprises:
 a drive clutch operationally coupled to receive the torque of the engine in the form of a rotational input; 
 a driven clutch, the at least one input shaft operationally coupled to the driven clutch; and 
 a belt engaged between the drive clutch and the driven clutch to rotationally couple the drive clutch to the driven clutch. 
 
     
     
       16. The vehicle of  claim 12 , wherein the gear assembly further comprises:
 an input shaft high gear assembly; and 
 an input shaft low gear assembly. 
 
     
     
       17. The vehicle of  claim 12 , further comprising:
 the input shaft high gear assembly including,
 an input shaft high gear, 
 a reverse shaft high gear, and 
 at least one of a high engagement dog and a high synchronizer; 
 
 the input shaft low gear assembly including:
 an input shaft low gear, 
 reverse shaft low gear, and 
 at least one of a low engagement dog and a low synchronizer; and 
 
 a reverse shaft operationally coupled between the gear assembly and the final drive.