Abstract: A controllable, multi-mode, bi-directional overrunning clutch assembly and a shift system adapted for transferring drive torque from a primary shaft to a secondary shaft. 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 rotary members. The first ring is split to define an actuation channel between its end segments. A first spring-biased pin is moveable between positions engaged with and released from one end segment of the split first ring. A second spring-biased pin is moveable between positions engaged with and released from the opposite end segment of the split first ring. A moveable pin actuator controls movement of the first and second pins for establishing distinct operational modes.

Abstract: A full-time power transfer system is disclosed to include a transfer case having a clutch assembly arranged to control speed differentiation and torque biasing across an interaxle differential, sensors for detecting and generating sensor signals indicative of various dynamic and operational characteristics of the vehicle, and a controller for controlling actuation of the clutch assembly in response to the sensor signals. Upon the occurrence of traction loss, the clutch assembly is automatically actuated for limiting interaxle slip while transferring increased drive torque to the non-slipping driveline. Under a preferred adaptive control scheme, the actuated condition of the clutch assembly is controllably modulated between its non-actuated and fully-actuated limits for automatically varying the magnitude of speed differentiation and torque biasing across the interaxle differential in response to changes in the dynamic and operational characteristics of the vehicle.

Abstract: A hybrid transfer case includes a mainshaft, front and rear output shafts, an electric motor/generator connected to the mainshaft, and an input clutch for selectively coupling the transmission to the mainshaft. The transfer case further includes a planetary gearset having a sun gear driven by the mainshaft, a ring gear, and planet gears supported from a carrier. The carrier drives the rear output shaft and a transfer assembly couple to the front output shaft. A direct clutch is operable to selectively coupled the carrier for rotation with the mainshaft. A low brake is operable to selectively brake rotation of the ring gear. A transfer clutch controls the amount of drive torque delivered through the transfer assembly to the front output shaft. A hybrid control system is provided for controlling actuation of the various clutch and brake assemblies and the electric motor/generator to establish various drive modes.

Abstract: A hydraulic coupling for use in an all wheel drive system, utilized in association with a front wheel drive transaxle, including a multi-plate clutch assembly operably connecting two relatively rotatable members and an actuator assembly for actuating the clutch assembly in response to speed differentiation between the two rotary members. The actuator assembly includes a hydraulic pump, a piston disposed in a piston chamber, and a fluid distribution system including a first flow path for supplying hydraulic fluid from a sump to the hydraulic pump and a second flow path for supplying hydraulic fluid from the hydraulic pump to the piston chamber. Hydraulic pressure in the piston chamber controls the magnitude of the clutch engagement force exerted by the piston on the clutch assembly. A control valve assembly is located in the piston chamber, in close proximity to the clutch pack where a majority of heat is generated.

Abstract: A hybrid drive system for a four-wheel drive system arranged to supply motive power to a transfer case from an internal combustion engine and/or an electric motor/generator. The transfer case is comprised of a planetary gearset having a first input driven by the motor/generator, a second input driven by the engine, and an output directing drive torque to the front and rear drivelines. The output of the planetary gearset drives a rear output shaft connected to the rear driveline and further drives a front output shaft connected to the front driveline. The transfer case further includes a second planetary gearset having an input driven by the motor/generator and an output driving the first input of the first planetary gearset. This hybrid drive arrangement permits use of a modified transfer case in place of a conventional transfer case in a traditional four-wheel drive driveline.

Abstract: A power take-off unit for a transaxle is provided with a unique double enveloping worm/worm gear transmission which has a ratio of the number of gear teeth on the worm gear to the number of threads on the worm which is low. The worm/worm gear transmission is more compact than conventional bevel gear systems which have typically been used in power take-off unit applications. The worm and worm gear transmission of the present invention also is quieter in operation and has a higher torque capacity than standard bevel gears of comparable size.

Abstract: A four-wheel drive transmission is provided which combines a continuously variable transmission unit and a transfer case into a common assembly. The four-wheel drive transmission includes a continuously variable transmission unit, a drive selector unit and a torque transfer unit. Variable speed control of a worm/worm gear transmission drives a component of a differential associated with the continuously variable transmission unit to provide continuous ratio control between an input shaft and an intermediate shaft. The drive selector units establishes forward and reverse drive connections between the intermediate shaft and a first output shaft. Finally, the torque transfer unit controls the selective/automatic transfer of drive torque from the first output shaft to a second output shaft to provide four-wheel drive operation.

Abstract: A full-time all-wheel drive system for a motor vehicle equipped with a transversely mounted engine and transaxle includes a power take-off unit. The power take-off unit includes an interaxle differential which drives a first power path connected to the front wheels and a second power path connected to the rear wheels. The first power path includes a planetary final drive unit which drives a double planetary front differential unit that is interconnected to a pair of front axleshafts. The second power path includes a helical gearset and a bevel gearset which deliver power to a rear propshaft.

Abstract: An automated twin-clutch multi-speed transmission is disclosed which functions to transfer power from the engine to one or more drivelines of a motor vehicle. The transmission includes a first engine clutch operable to establish a releasable drive connection between the engine and a first input shaft, a first motor/generator connected to the first input shaft, a second engine clutch operable to establish a releasable drive connection between the engine and a second input shaft, a second motor/generator connected to the second input shaft, an output shaft adapted to transfer power to the driveline, and a geartrain for selectively establishing a plurality of forward and reverse speed ratio drive connections between the input shafts and the output shaft.

Abstract: An electric drive axle for use in hybrid vehicles has an electric motor driving a compact gearbox. The gearbox includes a planetary reduction unit and a differential assembly. The planetary reduction unit has a sun gear driven by the electric motor, and compound planet gears supported from a planet carrier which have a first gear segment meshed with a fixed first ring gear and a second gear segment meshed with a second ring gear. The sun gear is also meshed with one of the first and second gear segments of the compound planet gears. The second ring gear drives the differential which transfer motive power to a pair of output shafts adapted for connection to one set of wheels. When used with a conventional engine-based powertrain for the other set of wheels, the electric drive axle establishes a four-wheel drive powertrain for the hybrid vehicle. The electric motor and gearbox are mounted in a common housing assembly to provide a compact drive axle assembly.

Abstract: An automated twin-clutch multi-speed transmission is disclosed for use in a four-wheel drive vehicle. The transmission includes a first engine clutch operable to establish a releasable drive connection between the engine and a first input shaft, a first motor/generator connected to the first input shaft, a second engine clutch operable to establish a releasable drive connection between the engine and a second input shaft, a second motor/generator connected to the second input shaft, a mainshaft, and a geartrain for selectively establishing a plurality of forward and reverse speed ratio drive connections between the input shafts and the mainshaft.

Abstract: A drive axle adapted for use in hybrid vehicles and having an electric motor and a gearbox packaged within a common housing assembly. The gearbox includes a differential assembly driven by a planetary-type reduction unit. The reduction unit includes a first planetary gearset having a first sun gear driven by the motor, a first ring gear, and a set of first planet gears meshed with the first sun gear and the first ring gear. A first planet carrier is nonrotatably fixed to a stationary number and rotatably supports the first planet gears. A second planet gearset includes a second sun gear fixed for rotation with the first ring gear, a second ring gear non-rotatably fixed to the stationary member, and a set of second planet gears rotatably supported from a second planet carrier and which mesh with the second sun gear and the second ring gear.

Abstract: The present invention is directed to a power transfer system for a four-wheel drive vehicle equipped with a torque transfer coupling which includes a clutch pack and a ball-screw actuator. The ball-screw actuator functions to axially translates an apply plate to operatively engage the clutch pack and vary the frictional engagement. This arrangement yields numerous operational advantages over the prior art including, but not limited to, establishing a direct drive between the motor output shaft and the apply plate, concentric mounting of the actuator elements with the motor output shaft, and a simplified mechanical arrangement that reduces the number of frictional elements increasing operational efficiency and decreasing motor requirements.

Abstract: An electric drive axle for use in hybrid vehicles has an electric motor driving a compact gearbox. The gearbox includes a planetary reduction unit and a differential assembly. The planetary reduction unit has compound planet gears supported from a planet carrier which mesh with a fixed ring gear and a sun gear driven by the electric motor. The planet carrier drives the differential which transfer motive power to a pair of output shafts adapted for connection to one set of wheels. When used with a conventional engine-based powertrain for the other set of wheels, the electric drive axle establishes a four-wheel drive powertrain for the hybrid vehicle. The electric motor and gearbox are mounted in a common housing assembly to provide a compact drive axle assembly.

Abstract: A transfer case having an input shaft, an output shaft, and a planetary gearset connected therebetween. The planetary gearset includes a first sun gear, a second sun gear, a carrier coupled for rotation with the input shaft, a ring gear coupled for rotation with the output shaft, and meshed pairs of first and second pinions rotatably supported on the carrier with each first pinion meshed with the first sun gear and each second pinion meshed with the second sun gear and the ring gear. The transfer case further includes a powershift clutch assembly comprised of a first range clutch located between the carrier and the ring gear, a second range clutch located between the first sun gear and a stationary member, and a third range clutch located between the second sun gear and the stationary member.

Abstract: A traction drive axle is provided for providing an all-wheel drive operating mode. The traction drive axle includes a unique double enveloping worm/worm gear transmission. A worm is driven by a propshaft which is meshingly engaged with an enveloping worm gear. The enveloping worm gear is selectively coupled via first and second clutches to left and right axle shafts. A control system is provided for controlling actuation of the first and second clutches upon detection of relative rotation between the left and right axle shafts.

Abstract: A hybrid drive system for a four-wheel drive system arranged to supply motive power to a transfer case from an internal combustion engine and/or an electric motor/generator. The transfer case is comprised of a planetary gearset having a first input driven by the motor/generator, a second input driven by the engine, and an output directing drive torque to the front and rear drivelines. The output of the planetary gearset drives a rear output shaft connected to the rear driveline and further drives a front output shaft connected to the front driveline. The transfer case further includes a second planetary gearset having an input driven by the motor/generator and an output driving the first input of the first planetary gearset. This hybrid drive arrangement permits use of a modified transfer case in place of a conventional transfer case in a traditional four-wheel drive driveline.

Abstract: An automated twin-clutch multi-speed transmission includes a first engine clutch operable to establish a releasable drive connection between the engine and a first input shaft, a second engine clutch operable to establish a releasable drive connection between the engine and a second input shaft, an output shaft and a geartrain for selectively establishing a plurality of forward and reverse speed ratio drive connections between the input shafts and the output shaft. The transmission further includes power-operated dog clutches for selectively engaging constant-mesh gearsets associated with the geartrain, and a transmission controller for controlling coordinated actuation of the first and second engine clutches and the power-operated dog clutches. A clutch control system includes a first hydraulic pump driven by the first input shaft, a second hydraulic pump driven by the second input shaft, and flow control valving for controlling fluid flow between the first and second pumps.

Abstract: A power transfer system includes a transfer case having a clutch assembly arranged across an interaxle differential, a hydraulic clutch actuation system operable to control actuation of the clutch assembly, sensors for detecting various dynamic and operational characteristics of the vehicle, and a controller for controlling the hydraulic clutch actuation system in response to the sensor signals. Upon the occurrence of traction loss, the clutch assembly is automatically actuated for limiting interaxle slip while transferring increased drive torque to the non-slipping driveline. The actuated condition of the clutch assembly is modulated between its non-actuated and fully-actuated limits for automatically varying the magnitude of speed differentiation and torque biasing across the interaxle differential in response to changes in the operational characteristics of the motor vehicle.

Abstract: The hydraulic coupling includes a multi-plate clutch assembly operatively connecting a pair of rotary members, an actuator assembly for actuating the clutch assembly, and a fluid control system operable for controlling actuation of the actuator assembly. The actuator assembly includes a hydraulic pump and a piston mounted in a piston chamber for movement relative to the multi-plate clutch assembly. The fluid control system includes an electrically-controlled flow control valve operable for regulating the fluid pressure delivered to the piston chamber. The position of the valve element is controlled by an electronic traction control module that monitors and responds to certain vehicle operating conditions, including a sump fluid temperature, a coupling outlet oil temperature, the four wheel speeds, and the piston chamber pressure.