Abstract: A range shift arrangement is disclosed for shifting a gear reduction unit between a low-range operating speed and a high-range operating speed, or any speed range in-between. This arrangement is particularly adapted for use in vehicle power transfer devices, such as four-wheel drive transfer cases, for allowing the operator to shift “on-the-move:” between a low-range drive mode and a high-range drive mode, or any range therebetween. In the preferred embodiment, the gear reduction unit includes a first component driven by the input shaft, a second component driving the output shaft, and a third component driven by a worm gearset. The worm gearset includes a worm gear fixed to the third component and a worm meshed with the worm gear. A variable speed motor is operable to drive the worm so as to vary the rotary speed of the third component, thereby varying the speed ratio between the input and output shafts.

Abstract: An automated dual-countershaft twin-clutch multi-speed transmission adapted to transfer power from the engine to a driveline of a motor vehicle. The transmission includes a first master clutch operable to establish a releasable drive connection between the input shaft and a first countershaft, a second master clutch operable to establish a releasable drive connection between the input driveline, and a geartrain for selectively establishing a plurality of forward and reverse speed ratio drive connections between the countershafts and the output shaft. The transmission further includes power-operated shiftable overrunning clutches for selectively engaging constant-mesh gearsets associated with the geartrain, and a transmission controller for controlling coordinated actuation of the first and second master clutches, and the shiftable overrunning clutches to permit non-power interrupted (“powershift”) sequential gear changes automatically without input from the vehicle operator.

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: A split path transmission is provided which is operable by an electric motor/generator and a combustion engine. The transmission is operably attached to both the electric motor/generator and the combustion engine via a planetary splitter and drives a differential. Additionally, the transmission is selectively attached to the output of the combustion engine via a lock-up clutch. The transmission uses multiple gear sets and clutches to achieve six forward speed ratios. First, second and third forward speed ratios are selectively achieved using one of the three drive gear sets while the planetary splitter is in a first mode. With the planetary splitter in a second mode, fourth, fifth and sixth forward speed ratios may be selectively achieved.

Abstract: An automated twin-clutch multi-speed transmission adapted to transfer power from the engine to one or more drivelines of a motor vehicle. The transmission includes a first engine clutch establishing a releasable drive connection between the engine and a first input shaft, a second engine clutch establishing a releasable drive connection between the engine and a second input shaft, an output shaft connected to the driveline, and power-operated dog clutches for selectively engaging constant-mesh gearsets. A transmission controller coordinates actuation of the first and second engine clutches and the power-operated dog clutches to permit non-power interrupted (“powershift”) sequential gear changes automatically without input from the vehicle operator.

Abstract: A compact manual transaxle includes an input shaft having a fixed transfer gear, a reduction shaft having two reduction gears, one of which meshing with the transfer gear, a mainshaft having three input gears and an output shaft supporting three speed gears meshing with the three input gears. The transaxle further includes a pair of synchronizer clutches for establishing a direct and a reduction gearset flow path, and a pair of synchronizer clutches for establishing the forward gear speed ratios by selectively coupling the three speed gears to the output shaft. A reverse gear assembly is provided for establishing a reverse gear. A locking mechanism is provided for selectively inhibiting rotation of a carrier assembly of the reverse gear assembly so as to cause the output to be driven in an opposite direction relative to the input for providing a reverse gear.

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 continuously variable range unit and a torque transfer unit. Variable speed control of a first worm/worm gear transmission drives a component of an epicyclic gearset associated with the continuously variable transmission unit to provide continuous ratio control between an input shaft and an intermediate shaft. Likewise, variable speed control of a second worm/worm gear transmission drives a component of a differential associated with the continuously variable range unit to provide continuous ratio control between the intermediate shaft and a first output shaft. Finally, the torque transfer unit controls the selective/automatic transfer of drive torque from one of the intermediate shaft and the first output shaft to a second output shaft to provide front-wheel drive.

Abstract: A split planetary gear assembly is provided having a pair of helical gearsets implemented in a vehicle transmission. The first helical gearset includes a first sun gear, a first ring gear, and a set of first planet gears meshed with the first sun gear and the first ring gear. The second helical gearset includes a second sun gear, a second ring gear, and a set of second planet gears meshed with the second sun gear and the second ring gear. The components of the second helical gearset have the same number of teeth, helix angle, and tooth pitch as the components of the first helical gearset with the exceptions that their angular helix orientation (i.e., left-hand/right-hand) is reversed and they are circumferentially indexed by one-half tooth pitch. In addition, the first and second planet gears are arranged in paired sets and supported on a common pinion shaft which, in turn, is fixed to a planet carrier. The second sun gear is splined for rotation with and limited axial movement relative to the first sun gear.

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 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: An automated powershift multi-speed transmission adapted to transfer power from the engine to the driveline of a motor vehicle. The transmission includes an engine clutch assembly having a primary clutch operable to establish a releasable drive connection between the engine and a first input shaft, and a secondary clutch operable to establish a releasable drive connection between the engine and a second input shaft. The transmission also includes 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: A compact manual transaxle includes an input shaft having a fixed transfer gear, a reduction shaft having two reduction gears, one of which meshing with the transfer gear, a mainshaft having three input gears and an output shaft supporting three speed gears meshing with the three input gears. The transaxle further includes a pair of synchronizer clutches for establishing a direct and a reduction gearset flow path, and a pair of synchronizer clutches for establishing the forward gear speed ratios by selectively coupling the three speed gears to the output shaft. A reverse gear assembly is provided for establishing a reverse gear. A locking mechanism is provided for selectively inhibiting rotation of a carrier assembly of the reverse gear assembly so as to cause the output to be driven in an opposite direction relative to the input for providing a reverse gear.

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: An electric continuously variable transmission includes first and second planetary splitters each having a corresponding electric motor/generator. Both planetary splitters are integrally linked to an input shaft which transfers torque and rotational motion from a combustion engine. The electric motor/generators switch between driving its corresponding planetary splitter and being driven by its corresponding planetary splitter to generate various ranges, providing variable transmission speed ratios. A lock-up clutch may be selectively engaged producing an overdrive range for cruising speeds. The electric continuously variable transmission drives a first differential which further drives a pair of wheels. A controller and battery are also provided for respectively managing the various electric motor/generators and either storing or providing energy for the system.

Abstract: A power transfer assembly is provided with a coplanar gear assembly. The coplanar gear assembly can be utilized in a differential, a multi-speed transmission, a four-wheel drive transfer case, and a fluid pump.

Abstract: A power transfer system for a motor vehicle is disclosed to include a transfer case having a clutch assembly arranged to control speed differentiation and torque biasing across an interaxle differential, a hydraulic clutch actuation system operable to control actuation of the clutch assembly, sensors for detecting and generating sensor signals indicative of 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.

Abstract: A powertrain assembly includes a first housing defining a first longitudinal axis. The first housing also has an axially extending pilot. The powertrain assembly further includes a second housing defining a second longitudinal axis and an outer wall. The outer wall has a guide face formed on an inner surface. The pilot is disposed within the second housing and engages the guide face to align the first and second longitudinal axes. A fastener interconnects the second housing on the first housing.

Abstract: A gear assembly having a body member with an end wall interconnecting a cylindrical inner wall and a cylindrical outer wall so as to define an annular cavity. The gear assembly also includes a gear ring having a hub segment mounted on and fixed to the outer wall of the body member, and a gear segment having external gear teeth. The gear assembly also includes a clutch ring that is secured to the inner and outer walls of the body member for enclosing the cavity. The clutch ring has clutch teeth adapted for engagement with a shift sleeve associated with a gearshift system.

Abstract: A hydraulic coupling for rotatively coupling a first rotary member and a second rotary member in a motor vehicle is provided. The hydraulic coupling includes a coupling housing that defines an at least partially sealed cavity. A clutch is positioned in the cavity and is operable to selectively couple the first rotary member and the second rotary member. A piston assembly selectively engages the clutch in response to a hydraulic pressure. An internal fluid path extends between a supply chamber, a hydraulic pump, a piston chamber, and back to the supply chamber. An electrically powered mover is then disposed within the sealed cavity in the internal fluid path. The electrically powered mover operates to control fluid flow and, thus, hydraulic pressure through the internal fluid path thereby actuating the piston and the clutch. A flow control module monitors the operating conditions of the motor vehicle and controls the electrically powered mover in response to the operating conditions.