Abstract: A locking pawl arrangement with a motion compliance mechanism for use with various automotive devices having a rotating hub with a plurality of teeth. There is provided a pawl that is moveable between a disengaged position wherein the pawl is not engaged with the rotating hub, an engaged positioned where the pawl is engaged with the hub and an intermediate position that is between the disengaged position and engaged position. A locking cam is in contact with the pawl and moves between a disengaged position, an engaged position, and an intermediate position against the pawl. There is further provided an actuator that is engageable with the locking cam. The actuator moves between a retracted position and an extended position, thereby causing the locking cam to move the pawl between the intermediate position, disengaged position and engaged position.

Abstract: A press assembly for forming outer helical splines on a blank includes an upper press shoe assembly and a die shoe assembly. The upper press shoe assembly includes an upper rotatable portion rotatable relative to an upper stationary portion. The lower portion includes a lower rotatable portion rotatable relative to a lower stationary portion. The unfinished blank is supported by the lower portion, and the upper portion is moveable into engagement with the blank. The upper rotatable portion joins with the lower rotatable portion for conjoint rotation relative to the upper and lower stationary portions via upper and lower helical meshes defined between the rotatable and stationary portions. The helical meshes convert downward force into rotation and translation of the blank into a spline forming die of the lower stationary portion to create the outer helical splines.

Abstract: A bi-directional clutch assembly equipped with a pair of laterally-spaced, selectable one-way clutches configured in a compact arrangement. The bi-directional clutch assembly establishes a LOCK-LOCK mode when both SOWC's are non-actuated, establishes a FREEWHEEL mode when both SOWC's are actuated, and establishes a pair of LOCK-RATCHET mode when one SOWC is actuated and the other is not actuated. Coils units of the SOWC's are energized to shift an actuator toward active struts of an outer race. The actuator is rotationally fixed to the outer race. The active struts are biased toward the deployed position, and the actuator is biased toward the non-actuated position. The actuator includes a strut engagement feature that contacts the active struts and causes pivotal movement of the active struts to the non-deployed position.

Abstract: A modular clutch assembly with two independent power sources and a connection with an output device. The two independent power sources and the output device can take many different forms. The modular clutch assembly has a housing that connects the two power sources with the output device and controls power transfer using an inner clutch and an upper clutch. There is further provided an output hub connected to the output device, where the output hub extends into the modular clutch assembly for selective rotation. The output device in one exemplary embodiment of the invention is a transmission of a vehicle.

Abstract: A modular clutch assembly with two independent power sources and a connection with an output device. The two independent power sources and the output device can take many different forms. The modular clutch assembly has a housing that connects the two power sources with the output device and controls power transfer using an inner clutch and an upper clutch. There is further provided an output hub connected to the output device, where the output hub extends into the modular clutch assembly for selective rotation. The output device in one exemplary embodiment of the invention is a transmission of a vehicle.

Abstract: A controllable one-way clutch having a clutch module and a power-operated actuator module. The clutch module includes a first clutch component rotatably driven by an input member, a second clutch component rotatably driving an output member, struts disposed on the first clutch component for movement between a deployed position engaging ratchet teeth on the second clutch component and a non-deployed position disengaged from the ratchet teeth, and strut springs for biasing the struts toward their deployed position. The power-operated actuator module includes a coil unit, an armature moveable between an engaged position whereat the armature holds the struts in their non-deployed positions when the coil unit is powered-off and a released position where the armature releases the struts when the coil unit is powered-on, and a ballramp mechanism configured to move the armature along a helical path between its engaged and released positions.

Abstract: A controllable one-way clutch assembly having an actuator module equipped with a solenoid actuator, an active strut moveable in response to energization of the solenoid actuator from a released position to a locked position, a strut spring biasing the active strut toward its released position, and an indirect strut actuation arrangement between the solenoid actuator and the active strut. The indirect strut actuation arrangement includes an intermediate actuation component having a first lug establishing a coupling interface with a translatable plunger of the solenoid actuator and a second lug establishing an engagement interface with the active strut.

Abstract: A bi-directional clutch assembly includes an outer race defining first and second strut pockets, an inner race defining ratchet teeth, a passive one-way clutch including at least two passive struts each supported in a corresponding first strut pocket for pivotal movement relative to the ratchet teeth, passive strut springs for normally biasing the passive struts into engagement with the ratchet teeth on the inner race, and a selectable one-way clutch having at least one active strut supported in the second strut pocket for pivotal movement between a non-deployed position disengaged from the ratchet teeth and a deployed position engaged with the ratchet teeth, and an armature ring fixed for rotation with the outer race and axially moveable between a non-actuated position and an actuated position, in which a strut engagement feature moves the active strut from its non-deployed position to its deployed position.

Abstract: A locking pawl arrangement with a motion compliance mechanism for use with various automotive devices having a rotating hub with a plurality of teeth. There is provided a pawl that is moveable between a disengaged position wherein the pawl is not engaged with the rotating hub, an engaged positioned where the pawl is engaged with the hub and an intermediate position that is between the disengaged position and engaged position. A locking cam is in contact with the pawl and moves between a disengaged position, an engaged position, and an intermediate position against the pawl. There is further provided an actuator that is engageable with the locking cam. The actuator moves between a retracted position and an extended position, thereby causing the locking cam to move the pawl between the intermediate position, disengaged position and engaged position.

Abstract: A controllable one-way clutch assembly having an electromagnetic actuator module equipped with an energizeable coil assembly, a strut moveable in response to energization of the coil assembly from a released position to a locked position, and a latching mechanism operable to releaseably hold the strut in the released position when the coil assembly is not energized.

Abstract: A dual-acting selectable one-way coupling (SOWC) device configured to include a clutch module and an electromagnetic actuator module. The clutch module includes an outer race and an inner race assembly rotatable relative to the outer race. The inner race assembly including a rotatably driven first inner race member, a second inner race member, and compliant connector members drivingly interconnecting the first and second race members. The electromagnetic actuator module includes an electromagnetic actuator operable to releasably engage the second inner race member. An auxiliary locking assembly is operable to independently releasably engage the second inner race member.

Abstract: A controllable one-way clutch assembly having an actuator module with a direct action configuration provided between a linearly-moveable actuation component of a power-operated actuator and a pivotably moveable locking element. In particular, the actuator module is equipped with a solenoid having an energizeable coil assembly, a linearly-moveable plunger having a tip portion, a strut moveable in response to energization of the coil assembly from a released position to a locked position due to engagement with the tip portion of the plunger, and a strut biasing arrangement biasing the strut toward its released position. In addition, various strut/actuator interface arrangements are provided between the tip of the plunger of the solenoid actuator and the strut to control movement of the strut between its released and locked positions.

Abstract: A selectable one-way clutch includes a clutch module and an electromagnetic actuator module. The electromagnetic actuator module includes an electromagnetic actuator and a strut assembly. The electromagnetic actuator having a coil assembly with a magnetic pole piece. The strut assembly having a strut and a magnetic armature mechanically interconnected to the strut for moving the strut between released and deployed positions in response to energization of the coil assembly. A contamination shroud is disposed between the armature and the pole piece to prevent collection of debris therebetween.

Abstract: A method for gas metal arc welding a first component formed of nitrided steel to a second component with reduced porosity in the weld is provided. A welding wire including a core surrounded by a tube is used to weld the components. The material of the core is formed of mild steel including 0.7 to 3.0 wt. % aluminum and 0.7 to 1.5 wt. % titanium. The material of the tube is formed entirely of low carbon steel. During the weld process, the nitrogen from the nitrided steel combines with the aluminum and titanium of the welding wire to form aluminum nitride and titanium nitride, instead of nitrogen bubbles which lead to high porosity. The method can be used to weld components used in automotive applications, for example to weld a ring gear and can of a flexplate, but alternatively could be used for another automotive or non-automotive applications.

Abstract: A controllable one-way clutch assembly having a clutch module and an actuator module mounted to a first clutch member of the clutch module. The actuator module includes an electromagnetic actuator equipped with an energizeable coil assembly, a strut moveable in response to energization of the coil assembly from a released position to a locked position with respect to ratchet teeth formed on a second clutch member of the clutch module, and a strut spring biasing the strut toward its released position. The strut spring is configured to provide an anti-tilting feature.

Abstract: An electro-mechanical clutch apparatus includes a stationary member (22,122) having a center portion extending along an axis A and a stationary coil assembly (34,134) fixed about the center portion. A rotatable member (46,146) extends along the axis A and includes an annular projection (52,152) radially spaced from the coil assembly. A ratchet surface (29,129) presents a plurality of teeth disposed in axially aligned and radially spaced relationship with the annular projection. The rotatable member includes a magnetic pole piece (62,162) disposed in radially spaced and concentrically aligned relationship with said coil assembly.

Abstract: A method for forming a component utilizing ultra-high strength steel and components formed by the method. The method includes the step of providing a flat blank of ultra-high strength 22MnB5 steel. The next step of the method is cold forming the flat blank into an unfinished shape of a component while the blank is in an unhardened state. Then, heating the unfinished shape of the component and generating a spline form thereon. The method proceeds by forming a finished shape of the component using a quenching die resulting in a fine-grained martensitic component material structure and enabling net shape processing to establish final geometric dimensions of the component.

Abstract: A component and method for forming the component utilizing ultra-high strength steel is provided. The method includes the steps of providing a blank of ultra-high strength steel and forming the blank into an unfinished component. Next, heating the unfinished component and moving an inner tooling member and an outer tooling member relative to one another to sandwich the heated component therebetween. Further, moving a punch member from a withdrawn, unactuated position to an extended, actuated position to contact the component while sandwiched between the inner and outer tooling members to form a feature including at least one of a thickened region having an increased thickness relative to an adjacent region, a recessed annular groove, a recessed pocket, a through hole, a flange, a through hole having a tab extending outwardly therefrom, or spline teeth. Then, quenching the feature.

Abstract: A selectable one-way clutch includes a clutch module and at least one electromagnetic actuator module. Each electromagnetic actuator module includes at least one electromagnetic actuator assembly having a coil assembly, a locking strut, and a connection member mechanically interconnected to the locking strut for moving it between released and deployed positions in response to energization of the coil assembly.

Abstract: A flexplate assembly comprising a central plate having a general disc shape disposed about and extending radially from an axis. The central plate has a first radial width. A ring gear is annularly secured about the central plate and presents an outer circumference that defines a plurality of ring teeth extending therefrom. At least one noise plate is disposed adjacent to the central plate and extends circumferentially about the axis for reducing vibrations and noise from the flexplate assembly. The noise plate has a second radial width that is at least one half of the first radial width of the central plate. A method of constructing such a flexplate assembly is also provided.