Abstract: A power-transmitting device (10) and a method of assembling a power-transmitting device (10) secures and releases driving continuity between driving and driven parts (22, 62) through at least one clutch assembly (26, 66). The power-transmitting device (10) includes an apply plate (36) axially moveable with respect to the clutch assembly (26, 66) for engaging and disengaging the clutch assembly (26, 66). A return spring (34) acting on the apply plate (36) and an apply spring (32) having a higher compression force than the return spring (34) can be located between the apply plate (36) and the clutch assembly (26, 66). A ball (38) can be engageable with a portion of the apply plate (36) for locking the apply plate (36) in engagement with the clutch assembly (26, 66) during a steady state condition and a piston (40) can drive the ball (38) into engagement with the apply plate (36) in response to application of fluid under pressure.

Abstract: A power-transmitting device (10) and a method of assembling a power-transmitting device (10) secures and releases driving continuity between driving and driven parts (22, 62) through at least one clutch assembly (26, 66). The power-transmitting device (10) includes an apply plate (36) axially moveable with respect to the clutch assembly (26, 66) for engaging and disengaging the clutch assembly (26, 66). A return spring (34) acting on the apply plate (36) and an apply spring (32) having a higher compression force than the return spring (34) can be located between the apply plate (36) and the clutch assembly (26, 66). A ball (38) can be engageable with a portion of the apply plate (36) for locking the apply plate (36) in engagement with the clutch assembly (26, 66) during a steady state condition and a piston (40) can drive the ball (38) into engagement with the apply plate (36) in response to application of fluid under pressure.

Abstract: An automotive accessory drive system for a motor vehicle connects to an internal combustion engine crankshaft during at least one mode of operation. The system includes an accessory drive pulley, a starter motor/generator, and an endless loop power transmission member connecting at least the starter motor/generator and the accessory drive pulley. A planetary gear set includes a sun gear, a ring gear integrally associated with the accessory drive pulley, and a planetary carrier connected to the engine crankshaft. First and second one way clutches connect the engine crankshaft to the ring gear, and the sun gear to a grounding member, respectively, to define a normal drive mode and an engine start mode, respectively. An electromagnetic disconnect includes a normally closed friction clutch connecting the grounding member to ground to define a third mode of operation corresponding to a free wheel function with the grounding member disengaged from connection to ground.

Abstract: An automotive accessory drive system for a motor vehicle connects to an internal combustion engine crankshaft during at least one mode of operation. The system includes an accessory drive pulley, a starter motor/generator, and an endless loop power transmission member connecting at least the starter motor/generator and the accessory drive pulley. A planetary gear set includes a sun gear, a ring gear integrally associated with the accessory drive pulley, and a planetary carrier connected to the engine crankshaft. First and second one way clutches connect the engine crankshaft to the ring gear, and the sun gear to a grounding member, respectively, to define a normal drive mode and an engine start mode, respectively. An electromagnetic disconnect includes a normally closed friction clutch connecting the grounding member to ground to define a third mode of operation corresponding to a free wheel function with the grounding member disengaged from connection to ground.

Abstract: A rear axle assembly for a motor vehicle which includes two clutch packs to deliver torque to the right and left hand driven axle shafts of a motor vehicle. The axle assembly clutch packs are efficiently packaged within the axle housing within the inside the diameter of the axle ring gear. A single hydraulic actuator is used to apply hydraulic pressure through a closed circuit to pistons associated with each of the clutch packs to apply compressive force to the clutch packs to energize them. In this manner, the single actuator allows the axle to transfer torque between the ring gear to both the left and right hand axles.

Abstract: A shift assembly for a transfer cases, manual and semi-automatic transmissions comprises a drive motor having a worm gear output which engages and drives a gear having an eccentric drive pin disposed parallel to and offset from the axis of a rotation of the gear. The drive pin engages a slot in a shift fork which extends normal to the axis of movement of the shift fork and associated speed change or gear shift mechanism. The shift fork is disposed upon and supported by a shift rail. Uni-directional or bi-directional rotation of the drive motor rotates the gear and sequentially moves the eccentric pin, shift fork and shift mechanism between first and second terminal positions and, typically, a center or intermediate, neutral position.

Abstract: An electromagnetic clutch assembly having a ball ramp operator provides enhanced torque throughput capability. The electromagnetic clutch assembly includes a primary or pilot friction clutch pack and a secondary or main friction clutch pack. A ball ramp operator which is actuated by the primary or pilot friction clutch pack includes a plastic washer or annulus adjacent one of the operator members. The plastic washer provides feedback which enhances the operation of the primary friction clutch pack, augments the compressive force applied to the secondary or main clutch pack and thus increases the torque throughput capability of the electromagnetic clutch assembly.

Abstract: A shift assembly for a two-speed transfer case utilizes a single actuator to drive both the speed range selection mechanism and a modulating friction clutch pack which selectively transfers drive torque from a primary output to a secondary output. The shift assembly includes an actuator which rotates a shift rail and cam having an intermediate helical track and a dwell region at each end. A lost motion assembly operating in conjunction with the helical cam selectively engages and disengages the clutch when the cam follower is in one of the two dwell regions. Thus, the shift assembly provides sequential operation from full clutch engagement in a first speed range, clutch disengagement in the first speed range, de-selection of the first speed range, selection, and de-selection of neutral, selection of a second speed range and, up to full engagement of the clutch in the second speed range.

Abstract: A shift assembly for a two-speed transfer case utilizes a single actuator to drive both the gear or speed range selection mechanism and a modulating friction clutch pack which selectively transfers drive torque from a primary transfer case output to a secondary transfer case output. The shift assembly includes an actuator which rotates a shift rail and cam having an intermediate helical track and a dwell region at each end. A lost motion assembly operating in conjunction with the helical cam selectively engages and disengages the friction clutch pack when the cam follower is in one of the two dwell regions. Thus, the shift assembly provides sequential operation from full clutch engagement in a first speed range through clutch disengagement in the first speed range, de-selection of the first speed range and selection of neutral, de-selection of neutral and selection of the second speed range and thence increasing engagement, up to full engagement, of the friction clutch pack in the second speed range.

Abstract: A shift assembly for a transfer cases, manual and semi-automatic transmissions comprises a drive motor having a worm gear output which engages and drives a gear having an eccentric drive pin disposed parallel to and offset from the axis of a rotation of the gear. The drive pin engages a slot in a shift fork which extends normal to the axis of movement of the shift fork and associated speed change or gear shift mechanism. The shift fork is disposed upon and supported by a shift rail. Uni-directional or bi-directional rotation of the drive motor rotates the gear and sequentially moves the eccentric pin, shift fork and shift mechanism between first and second terminal positions and, typically, a center or intermediate, neutral position.

Abstract: A preferred embodiment compound ball ramp clutch assembly for motor vehicle drive line components includes a force amplifying assembly having two ball ramp operators arranged in tandem. The clutch assembly includes a first ball ramp operator having opposed cam plates with load transferring balls, an electromagnetic coil, a rotor and an armature. When energized, the coil creates drag which causes separation of the plates of the first ball ramp operator which compresses a primary (pilot) clutch pack disposed in mechanical parallel with the cam plates and load transferring balls of a second ball ramp operator. A speed difference and drag across the second ball ramp operator compresses a secondary (main) clutch pack. Significantly increased torque carrying capacity is exhibited by such a compound or a tandem ball ramp clutch assembly.

Abstract: An electromagnetic clutch assembly having a ball ramp operator provides enhanced torque throughput capability. The electromagnetic clutch assembly includes a primary or pilot friction clutch pack and a secondary or main friction clutch pack. A ball ramp operator which is actuated by the primary or pilot friction clutch pack includes a plastic washer or annulus adjacent one of the operator members. The plastic washer provides feedback which enhances the operation of the primary friction clutch pack, augments the compressive force applied to the secondary or main clutch pack and thus increases the torque throughput capability of the electromagnetic clutch assembly.

Abstract: A preferred embodiment compound ball ramp clutch assembly for motor vehicle drive line components includes a force amplifying assembly having two ball ramp operators arranged in tandem. The clutch assembly includes a first ball ramp operator having opposed cam plates with load transferring balls, an electromagnetic coil, a rotor and an armature. When energized, the coil creates drag which causes separation of the plates of the first ball ramp operator which compresses a primary (pilot) clutch pack disposed in mechanical parallel with the cam plates and load transferring balls of a second ball ramp operator. A speed difference and drag across the second ball ramp operator compresses a secondary (main) clutch pack. Significantly increased torque carrying capacity is exhibited by such a compound or a tandem ball ramp clutch assembly.

Abstract: A transfer case (10) having a drive shaft (12) on a bearing (18) to permit the drive shaft to be rotated with respect to the transfer case, the drive shaft having a free end portion (12a) which is adapted to drive an axle of a vehicle. The drive shaft passes through a sleeve (20), and bearings (22, 24) are provided to permit the sleeve to be rotated with respect to the transfer case. The sleeve has a sprocket (14) affixed to it, and the sprocket is caused to rotate by an endless chain (16). The sleeve is drivingly connected to the drive shaft by a universal joint (26), preferably a cardan joint, which is contained within an enlarged end portion (20a) of the sleeve. The sprocket is positioned between the universal joint and the free end portion of the drive shaft, to maximize the distance therebetween, and thereby minimize the included angle required of the universal joint.

Abstract: A transmission shift control mechanism for facilitating forward upshifting or downshifting and at the same time reducing any tendency to shift accidentally into reverse. The shift end of the shift control cane is chamfered to provide flat surfaces transverse to the axes of the shift rails. These surfaces guide movement of the shift end into the appropriate shift rail gate.

Abstract: Self-energizing anti-rattle apparatus particularly adapted for eliminating gear rattle encountered in modern manual transmissions is characterized by the provision of a device which is activated for imposing a drag on the first ratio output gear when the transmission either is in neutral with the clutch engaged or is in reverse. The device includes a lost motion mechanism to prevent imposition of the drag while the first ratio output gear is being engaged, thereby eliminating any tendency to bind during engagement.