Abstract: A method of actuating a clutch in a power transmission device having a first rotary member and a second rotary member includes compressing a spring, releasing the spring to pressurize a fluid, supplying the pressurized fluid to a piston, and applying a force from the piston to the clutch to transfer torque between the first and second rotary members.

Abstract: A torque transfer mechanism and a control system are disclosed for adaptively controlling the transfer of drive torque between first and second rotary members in a power transmission device of the type used in motor vehicle driveline applications. The torque transfer mechanism includes a main clutch assembly operably disposed between the first and second rotary members, a pilot clutch assembly and a clutch operator assembly. The clutch operator assembly includes a rotary cam driven by an electric motor and a pivotal mode fork.

Abstract: A transfer case for a motor vehicle having an input shaft, a first output shaft, a second output shaft, a clutch, a transfer mechanism, a sensor portion and a magnetoelastic torque sensor. The clutch has a clutch pack and a thrust mechanism that is configured to exert an engagement force on the clutch pack. The clutch pack has a first portion, which is rotatably driven by either or both of the input shaft and the first output shaft, and a second portion that is supported for rotation relative to the first portion. The transfer mechanism couples the second portion of the clutch pack to the second output shaft. The sensor portion is coupled to the first or second output shaft and is at least partially formed of a magnetoelastic material. The magnetoelastic torque sensor is disposed about and radially in-line with the sensor portion.

Abstract: A drive axle assembly includes first and second axleshafts connected to a pair of wheels and a drive mechanism operable to selectively couple a driven input shaft to one or both of the axleshafts. The drive mechanism includes a differential, a speed changing unit operably disposed between the differential assembly and the first and second axleshafts, first and second mode clutches and a brake unit. The first mode clutch is operable to increase the rotary speed of the first axleshaft which, in turn, causes a corresponding decrease in the rotary speed of the second axleshaft. The second mode clutch is operable to increase the rotary speed of the second axleshaft so as to cause a decrease in the rotary speed of the first axleshaft. The brake unit is operable to engage the speed changing unit. A control system controls actuation of both mode clutches.

Abstract: An adjustable position sensor is provided suitable for use with a clutch actuation control system. The position sensor includes: a rotatable shaft adapted to engage a control gear of the clutch actuation control system; and an encoder having a position indicator adjustably coupled to the shaft and operable to detect the position of the shaft over a range of motion that is less than the range of movement exhibited by the control gear. The position indicator of the encoder is adjustable in relation to the shaft so that the range of motion detected by the encoder can be correlated to an area of interest within the range of motion exhibited by the control gear.

Abstract: A drive axle assembly includes a pair of axleshafts connected to a pair of wheels, and a drive mechanism for selectively coupling a driven input shaft to one or both of the axleshafts. The drive mechanism includes first and second drive units that can be selectively engaged to control the magnitude of the drive torque transferred and the relative rotary speed between the input shaft and the axleshafts. Each drive unit includes a planetary gearset disposed between the input shaft and its corresponding axleshaft, and a pair of mode clutches that may be activated to cause the planetary gearset to establish different speed ratio drive connections between the input shaft and the axleshaft. A control system including an electronic control unit (ECU) and sensors are provided to control actuation of the clutches so as to control the side-to-side traction characteristics of the drive axle assembly.

Abstract: A hybrid drive system for a four-wheel drive system arranged to supply motive power to a first output shaft of a transfer case from an internal combustion engine and to a second output shaft from an electric motor/generator. The transfer case includes a reduction gearset driven by the electric motor/generator, a power take-off unit driven by the reduction gearset, and a disconnect clutch operable for selectively coupling the reduction gearset to the second output shaft. This hybrid drive arrangement permits installation of a modified transfer case in place of a conventional transfer case for use in a traditional four-wheel drive driveline arrangement.

Abstract: A dual-clutch powershift transmission for use in a motor vehicle having an engine and a driveline includes an output shaft adapted for connection to the driveline, first and second input shafts, a first engine clutch operable for establishing a releasable drive connection between the engine and the first input shaft and a second engine clutch operable for establishing a releasable drive connection between the engine shaft and the second input shaft. A first constant-mesh gearset is driven by the first input shaft. A second constant-mesh gearset is driven by the second input shaft. A first shift clutch releasably engages the first gearset to establish a drive connection between the first input shaft and the output shaft. A second shift clutch releasably engages the second gearset to establish a drive connection between the second input shaft and the output shaft.

Abstract: A drive axle assembly includes first and second axleshafts connected to a pair of wheels and a drive mechanism operable to selectively couple a driven input shaft to one or both of the axleshafts. The drive mechanism includes a differential, a speed changing unit operably disposed between the differential assembly and one of the first and second axleshafts, and first and second mode clutches. The first mode clutch is operable to decrease the rotary speed of the second axleshaft which, in turn, causes a corresponding increase in the rotary speed of the first axleshaft. The second mode clutch is operable to increase the rotary speed of the second axleshaft so as to cause a decrease in the rotary speed of the first axleshaft. A control system controls actuation of both mode clutches.

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 a hydraulic clutch actuation system. The hydraulic clutch actuation system includes a primary fluid circuit coupled to a secondary fluid circuit by a pressure intensifier. The pressure intensifier provides magnified pressure to a piston for actuating the clutch pack.

Abstract: A drive axle assembly includes first and second axleshafts connected to a pair of wheels and a drive mechanism operable to selectively couple a driven input shaft to one or both of the axleshafts. The drive mechanism includes a differential, a speed changing unit operably disposed between the differential assembly and one of the first and second axleshafts, and first and second mode clutches. The first mode clutch is operable to engage the speed changing unit for reducing the rotary speed of the second axleshaft relative to the rotary speed of the first axleshaft. The second mode clutch is operable to engage the speed changing unit for increasing the rotary speed of the second axleshaft relative to the rotary speed of the first axleshaft. A control system controls actuation of both mode clutches.

Abstract: A dual-clutch transmission for use in a motor vehicle having an engine and a driveline includes an output shaft adapted for connection to the driveline and a planetary gearset in constant driving engagement with the output shaft. An input shaft is driven by the engine. A first constant mesh gearset is in selective driving communication with a first member of the planetary gearset. A second constant mesh gearset is in selective driving communication with a second member of the planetary gearset. A first clutch is operable for establishing a releasable drive connection between the input shaft and the first constant mesh gearset. A second clutch is operable for establishing a releasable drive connection between the input shaft and the second constant mesh gearset. A motor is selectively drivingly coupled to a third member of the planetary gearset.

Abstract: A transfer case includes a two-speed range unit, a friction clutch, a power-operated actuation mechanism and a control system. The actuation mechanism includes an electric motor, a geartrain driven by the motor for controlling rotation of an actuator shaft, a range actuator assembly and a mode actuator assembly. The range actuator assembly functions to move a shift collar associated with the range unit in response to rotation of the actuator shaft. The mode actuator assembly includes a mode cam and a ballramp unit. The mode cam is rotatively driven by the actuator shaft for controlling the clutch engagement force exerted on the friction clutch by the ballramp unit.

Abstract: A torque transfer mechanism having a multi-plate friction clutch connecting a pair of rotary members and an electrohydraulic clutch system for controlling engagement of the friction clutch. The electrohydraulic clutch system can include an actuator with first and second components with a plurality of actuation chambers that are employed to control the position of the second component relative to the first component. Relatively high pressure fluid may be directed through or around one or more bypassed portions of the actuation chambers when relatively low compressive clutch engagement forces are to be exerted on the friction clutch. The bypassed portions of the actuation chambers may be sequentially or progressively operated based on a position of the second component relative to the first component to increase an amount of force that is applied by actuator.

Abstract: A drive axle assembly includes first and second axleshafts connected to a pair of wheels and a drive mechanism operable to selectively couple a driven input shaft to one or both of the axleshafts. The drive mechanism includes a differential, first and speed changing units and first and second mode clutches. The first mode clutch is operable in association with the first speed changing unit to increase the rotary speed of the first axleshaft which, in turn, causes a corresponding decrease in the rotary speed of the second axleshaft. The second mode clutch is operable in association with the second speed changing unit to increase the rotary speed of the second axleshaft so as to cause a decrease in the rotary speed of the first axleshaft. A control system controls actuation of both mode clutches.

Abstract: A torque transfer mechanism having a multi-plate friction clutch connecting a pair of rotary members and an electrohydraulic clutch actuator for controlling engagement of the friction clutch. The clutch actuator includes a hydraulic pump, a hydraulically-actuated rotary operator, and a ball ramp mechanism. The hydraulic pump draws low pressure fluid from a sump and delivers high pressure fluid to a series of actuation chambers defined between coaxially aligned first and second components of the rotary operator. The magnitude of the fluid pressure delivered to the actuation chamber controls angular movement of the second component relative to the first component for energizing the ball ramp mechanism. The ball ramp mechanism applies a clutch engagement force on the friction clutch assembly, thereby transferring drive torque from the first rotary member to the second rotary member. A hydraulic control system adaptively regulates the fluid pressure delivered to the actuation chamber.

Abstract: A controllable, multi-mode, bi-directional overrunning mode clutch and a shift system adapted for use in a power transfer assembly for transferring drive torque from a primary driveline to a secondary driveline so as to establish a four-wheel drive mode. The mode clutch 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 between its end segments. A cam member is moveable between positions engaged with and released from one or both end segments of the split first ring. The shift system includes a mode fork which controls movement of the cam member for establishing a two-wheel drive mode in addition to on-demand and locked four-wheel drive modes.

Abstract: An automated dual-clutch multi-speed transmission is adapted to transfer power from an engine to the driveline of a motor vehicle. The transmission includes an output shaft adapted for connection to the driveline, an input shaft continuously driven by the engine and offset from a position substantially parallel to the output shaft. A countershaft is in constant driving engagement with the output shaft and is offset from and positioned substantially parallel to the input and output shafts. A first clutch is operable for establishing a releasable drive connection between the input shaft and a first driven shaft. A second clutch is operable for establishing a releasable drive connection between the input shaft and a second driven shaft. First and second gearset clutches are operable to releasably drivingly couple first and second gearsets to the countershaft.

Abstract: A power transfer unit is provided with a torque limiting coupling that limits the amount of torque that can be transferred to the driveline components when torque peaks occur while torque is transferred to the non-slipping wheels. The torque limiting coupling includes an engagement member disposed between an input from a driving member and an output to a driven member. The engagement member is located radially between and provides a frictional engagement between the input and the output. The engagement member is capable of slipping under heavy torque loads in order to protect the driveline components.

Abstract: An automated triple-clutch multi-speed transmission is adapted to transfer power from the engine to the driveline of a motor vehicle. The transmission includes a first clutch operable for establishing a releasable drive connection between an input shaft and a first shaft, a second clutch operable for establishing a releasable drive connection between the input shaft and a second shaft and a third clutch operable for establishing a releasable drive connection between the input shaft and a third shaft. A first constant mesh gearset is driven by the first shaft. A second constant mesh gearset is driven by the second shaft. A third constant mesh gearset is driven by the third shaft. First, second and third gearset clutches are operable for releasably drivingly coupling the first, second and third gearsets to a countershaft which, in turn, drives an output shaft.