Abstract: A method for operating a transfer case synchronized range shift mechanism. The range shift mechanism can be selectively actuated for establishing a four-wheel high-range drive mode, a neutral mode, and a four-wheel low-range drive mode. The synchronized range shift mechanism is comprised of a first input gear system, a second input gear system, and an output gear system. The output gear system is comprised of a rotary output member that may be selectively engaged with either the first input gear system or the second input gear system, depending on which four-wheel-drive operating mode the vehicle operator selects. The range shift mechanism is further comprised of a synchronizing mechanism. The method for controlling the speed of the range shift as a means for reducing the time it takes to perform the range shift.

Abstract: The present invention discloses a preferred method for operating a adaptive clutch system of the type used in a motor vehicle power transfer assembly by employing a dithered control signal. One aspect of the present invention superimposes a dithering signal onto a control signal by nulling consecutive blocks of control signal pulses. Another aspect of the present invention provides a method for generating a dithered control signal by providing a wave function with which to systematically vary a duty cycle of the dithered control signal. A method for varying the output force of a clutch actuator assembly in response to the dithered control signal is also provided.

Abstract: A controllable, multi-mode, bi-directional overrunning clutch assembly and a shift system are adapted for use in a power transmission device. The clutch assembly includes a first ring journalled on a first rotary member, a second ring fixed to a second rotary member, and a plurality of rollers disposed in opposed cam tracks formed between the first and second rings. The first ring is split to define an actuation channel having a pair of spaced end segments. An actuator ring is moveable between positions engaged with and released from the end segments of the first ring. The shift system includes a moveable clutch actuator which controls movement of the actuator ring for establishing engaged and disengaged clutch modes. An alternate embodiment clutch assembly includes first and second rings non-rotatably coupled to one another. A third ring is selectively engageable with a rotary component to transfer power thereto.

Abstract: A hybrid vehicle system is provided with an internal combustion engine driving one set of wheels and an electric motor connected to the other wheels via an active clutch system. A power take-off unit is provided for selectively providing driving torque from the internal combustion engine to the electric motor to operate the motor in a regenerative operating mode. The active clutch system is selectively engaged and disengaged based upon whether the vehicle is operating in an internal combustion engine operating mode, an electric motor operating mode, a combined electric motor and internal combustion engine operating mode, or a regenerative operating mode.

Abstract: A torque transfer mechanism for controlling the magnitude of a clutch engagement force exerted on a clutch pack that is operably disposed between a first rotary member and a second rotary member includes an actuator having an inner sleeve, an outer sleeve, and a plurality of balls. The inner sleeve is supported for rotation relative to the first rotary member and each of the inner and outer sleeves includes a spiral groove aligned with the other. The balls are positioned within the spiral grooves between the inner and outer sleeves. An electric motor selectively rotates one of the inner and outer sleeves so as to induce axial movement of the other of the inner and outer sleeves to engage the clutch.

Abstract: A power transfer system is provided and equipped with a torque transfer coupling which includes a stage 2 clutch and a clutch actuator. The clutch actuator includes stage 1 and stage 2 ball ramp actuators as well as a stage 1 clutch operably positioned between the ball ramp actuators to operatively engage the stage 2 clutch and vary the frictional engagement thereof.

Abstract: An apparatus is provided for manufacturing a gear component. The apparatus includes a plurality of tooling stocks movable relative to a base. The tooling stocks function to retain a component, as well as operably driving a combination hob/shaver tool and a combination chamfer/debut tool. The apparatus reduces the number of machines required to complete the gear component as well as reducing the cycle time for complete component manufacture. In this way, a more efficient manufacturing system is provided, whereby capital investment and operational costs are reduced.