Abstract: A differential assembly with at least a first gear ratio and a second gear ratio that can be integrated with an automatic transmission system thereby increasing the total number of available gear ratios is presented. A method of shifting to improve engine efficiency is also provided.

Abstract: An integrated electronic drive unit constructed in accordance to one example of the present disclosure includes a differential, a first axle, a second axle and a secondary power system. The differential includes a ring gear fixed for concurrent rotation with a differential case. The differential has a plurality of pinion gears rotatably mounted to the differential case and meshed with first and second side gears. The first axle is coupled to the first side gear. The second axle is coupled to the second side gear. The secondary power system is selectively engageable to at least one of the first and second axles. The integrated electronic drive unit is operable in an open differential mode, a braking mode, an electric vehicle start mode and a torque vectoring mode.

Abstract: A piston system comprises a housing (3) comprising a first recess (6) and a second recess (7). A first piston (1) comprises a first portion embedded in the first recess (6). A second piston (2) comprises a second portion embedded in the second recess (7). An actuator (10) has a first side (20) and a second side (21). The first piston (1) selectively presses against the first side (20) of the actuator, and the second piston (2) selectively presses against the second side (21) of the actuator. The actuator may be a synchronizer of a clutch assembly.

Abstract: A cover for a differential housing is disclosed herein. The cover can include a body, a flange, a fluid reservoir, a first fluid conduit, and second fluid conduit. The body can have an inwardly-facing surface and outwardly-facing surface opposite the inwardly-facing surface. The flange can extend about at least a portion of a perimeter of the body. The fluid reservoir can be defined within the body and have a reservoir outlet and a return port. The first fluid conduit can be defined within the body. The first fluid conduit can be spaced from the fluid reservoir and extend between a first inlet and a first outlet. The second fluid conduit can be defined within the body and extend between the first fluid conduit and the return port of the fluid reservoir.

Abstract: A limited slip differential assembly includes a planetary gear assembly, a differential case, a differential gear assembly and a hydraulic clutch assembly. The differential case is coupled for rotation with a portion of the planetary gear assembly. The differential gear assembly is arranged within the differential case and includes a first side gear and a second side gear for coupling with first and second drive wheels of a vehicle, respectively. The hydraulic clutch assembly includes a clutch pack and a clutch actuator. Pressurized hydraulic fluid from a transmission pump is selectively provided to the clutch pack to actuate the clutch pack between an open configuration, in which the side gears rotate independently, and a fully closed configuration, in which the side gears rotate together such that the first and second drive wheels rotate at a same speed.

Abstract: A piston system comprises a housing (3) comprising a first recess (6) and a second recess (7). A first piston (1) comprises a first portion embedded in the first recess (6). A second piston (2) comprises a second portion embedded in the second recess (7). An actuator (10) has a first side (20) and a second side (21). The first piston (1) selectively presses against the first side (20) of the actuator, and the second piston (2) selectively presses against the second side (21) of the actuator. The actuator may be a synchronizer of a clutch assembly.

Abstract: The present disclosure provides a differential assembly with at least a first gear ratio and a second gear ratio. The differential assembly of the present disclosure can be integrated with an automatic transmission system thereby increasing the number of available gear ratios. A method of shifting to improve engine efficiency is also provided.

Abstract: A differential gear mechanism constructed in accordance to one example of the present disclosure can include a planetary gear assembly having a plurality of planetary gears rotatably mounted on a corresponding plurality of planetary gear shafts. A first differential case portion can have a plurality of first planetary gear shaft mounting surfaces. A second differential case portion, separately formed from the first differential case portion can have a plurality of second planetary gear shaft mounting surfaces. A differential gear assembly can be arranged in at least one of the first and second differential case portions. The first and second plurality of gear shaft mounting surfaces can cooperate to mount the corresponding plurality of planetary gear shafts in an assembled position.

Abstract: A limited slip differential assembly includes a planetary gear assembly, a differential case, a differential gear assembly and a hydraulic clutch assembly. The differential case is coupled for rotation with a portion of the planetary gear assembly. The differential gear assembly is arranged within the differential case and includes a first side gear and a second side gear for coupling with first and second drive wheels of a vehicle, respectively. The hydraulic clutch assembly includes a clutch pack and a clutch actuator. Pressurized hydraulic fluid from a transmission pump is selectively provided to the clutch pack to actuate the clutch pack between an open configuration, in which the side gears rotate independently, and a fully closed configuration, in which the side gears rotate together such that the first and second drive wheels rotate at a same speed.

Abstract: A differential gear mechanism can include a differential casing, a piston and an externally mounted plenum assembly. The differential casing can have a differential gear set configured to selectively rotate a first axle shaft and a second axle shaft. The piston can be slidably disposed in the differential casing and configured to actuate a clutch assembly. The externally mounted plenum assembly can include a plenum assembly housing, a hydraulic coupling and a motor mounted on the plenum assembly housing. The plenum assembly housing can define an axle opening configured to receive one of the first and second axle shafts therethrough. The hydraulic coupling can be arranged on the plenum assembly housing at the axle opening. The motor can be configured to pump hydraulic fluid from the externally mounted plenum assembly, through the hydraulic coupling and into the differential casing to act onto the piston.

Abstract: A differential gear mechanism constructed in accordance to one example of the present disclosure can include a differential case, a clutch pack and a plurality of lock pins. The differential case can include a first differential case portion that defines a first output shaft opening and includes a plurality of clutch ear guides and a plurality of lock pin engaging surfaces. The clutch pack can include a plurality of annular plates that are interleaved between a plurality of annular friction disks. At least one of the annular plates and annular friction disks can include a plurality of radially extending plate ears that are received by the corresponding plurality of clutch ear guides. The plurality of lock pins can be received by the plurality of first lock pin engaging surfaces of the first differential case at locations in-line with the clutch ear guides.

Abstract: A differential comprises a differential case and electrical generator. The electrical generator comprises a first portion that is supported by the differential case and a second portion that is disposed in the differential case. The electrical generator is responsive to rotation of the differential case for generating electrical power. In another embodiment, the differential may further comprise a differential gear set, and the electrical generator comprises a first portion that is supported by the differential gear set and a second portion that is disposed in the differential case in accordance with an embodiment of the invention. The electrical generator is responsive to movement of the differential gear set for generating electrical power. In another embodiment, an axle assembly includes a differential case and axle housing that together function as an electrical generator. The rotation of the differential case generates electrical power.

Abstract: An improved differential gear mechanism is characterized by a lockout mechanism (129) operably associated with a latch member (119) that cooperates with a flyweight mechanism (53) to retard differentiating action in the differential gear mechanism. The lockout mechanism (129) includes a lockout member (131) positionable, in response to an input signal, in a normal condition and a lockout condition. In the normal condition, the lockout member (131) permits the latch member (119) to move freely between a locking position and an unlocking position. In the lockout condition, the lockout member (131) prevents the latch member (119) from moving into the locking position.

Abstract: An improved differential gear mechanism is characterized by a lockout mechanism (63) operably associated with a flyweight mechanism (53) and including a lockout member (65, 101) positionable, in response to an input signal, in a normal condition and a lockout condition. In the normal condition, the lockout member (65, 101) permits a flyweight stop surface (57) to move from the retracted position to the extended position. In the lockout condition, the lockout member (65, 101) prevents the flyweight stop surface (57) from moving from the retracted position to the extended position.

Abstract: A differential having means (35) operable to limit rotation of an output gear (23) relative to a gear case (11), and actuation means (55) for actuating the rotation limiting means, from an unactuated (FIG. 1) to an actuated condition (FIG. 4). The rotation limiting means includes a member (47), toward one axial end of the gear case and moveable between a first position, the unactuated condition of said rotation limiting means, and a second position, the actuated condition. A sensor assembly is adjacent the one axial end of the gear case and includes a sensor element (71) and a wall-like member between the rotation limiting means and the actuation means. The wall-like member includes a non-ferromagnetic portion (73) between the sensor and the moveable member. Movement between the first and second positions results in a corresponding change in the electromagnetic flux (F) coupling the sensor element and the moveable member.