Abstract: A rotary sensor (10) includes a rotating portion (12) having an outside surface (28) and a magnetic pattern (16) magnetically printed on the rotating portion (12). One or more hall-effect switches (32) are located adjacent to the magnetic pattern (16) and a magnetic field of at least a portion of the magnetic pattern actuates the switches (32). Rotation of a driveshaft (18) controls electric signals conducted through the switches (32) indicating the angular position of the driveshaft (18).

Abstract: A electromagnetic clutch assembly for use in a vehicle is presented. More specifically, the clutch assembly comprises an input member; an output member; a friction clutch pack having a first plurality of clutch plates coupled for rotation with said input member and a second plurality of clutch plates interleaved with said first plurality of clutch plates and coupled for rotation with said output member; a solenoid coil; an actuator hub having an armature plate; and a cam lever assembly having a first end engaging said actuator hub and a second end engaging said friction clutch pack. When electrical current is applied to the solenoid coil, the armature plate moves the actuator hub, the actuator hub engages the cam lever and causes said cam lever to compress the interleaved first and second plurality of clutch plates, thereby, resulting in the coupling of the input and output members.

Abstract: A method of estimating force output of a solenoid assembly including a solenoid coil and a corresponding armature upon which the solenoid coil exerts a magnetic solenoid force is provided. The method includes a step of measuring a plurality of data points of current being drawn by the solenoid coil resulting in a plurality of measured current values, a step of measuring a plurality of data points of voltage being supplied to the solenoid coil resulting in a plurality of measured voltage values, and a step of estimating the magnetic solenoid force exerted upon the corresponding armature based on the pluralities of measured voltage and current values, resulting in an estimated force value.

Abstract: A electromagnetic clutch assembly for use in a vehicle is presented. More specifically, the clutch assembly comprises an input member; an output member; a friction clutch pack having a first plurality of clutch plates coupled for rotation with said input member and a second plurality of clutch plates interleaved with said first plurality of clutch plates and coupled for rotation with said output member; a solenoid coil; an actuator hub having an armature plate; and a cam lever assembly having a first end engaging said actuator hub and a second end engaging said friction clutch pack. When electrical current is applied to the solenoid coil, the armature plate moves the actuator hub, the actuator hub engages the cam lever and causes said cam lever to compress the interleaved first and second plurality of clutch plates, thereby, resulting in the coupling of the input and output members.

Abstract: A method of estimating force output of a solenoid assembly including a solenoid coil and a corresponding armature upon which the solenoid coil exerts a magnetic solenoid force is provided. The method includes a step of measuring a plurality of data points of current being drawn by the solenoid coil resulting in a plurality of measured current values, a step of measuring a plurality of data points of voltage being supplied to the solenoid coil resulting in a plurality of measured voltage values, and a step of estimating the magnetic solenoid force exerted upon the corresponding armature based on the pluralities of measured voltage and current values, resulting in an estimated force value.

Abstract: A two-speed transfer case includes a planetary gear assembly, and a shift sleeve that is used for selecting either the reduced speed gear ratio, in which the torque from the input is transferred though the planetary gears, or the direct drive speed ratio, in which the input and output shafts are coupled directly together. The carrier of the planetary gear assembly is equipped with a surface that is capable of receiving a band brake that is disposed thereabout. A lever composed to two pieces, a brake apply arm and a cam follower, applies the brake band, and in doing so controls retardation of the planet carrier, controlling the speed of the carrier, and thus, controlling the output of the planetary gear assembly.

Abstract: A two-speed transfer case includes a planetary gear assembly, and a shift sleeve that is used for selecting either the reduced speed gear ratio, in which the torque from the input is transferred though the planetary gears, or the direct drive speed ratio, in which the input and output shafts are coupled directly together. The carrier of the planetary gear assembly is equipped with a surface that is capable of receiving a band brake that is disposed thereabout. A lever composed to two pieces, a brake apply arm and a cam follower, applies the brake band, and in doing so controls retardation of the planet carrier, controlling the speed of the carrier, and thus, controlling the output of the planetary gear assembly.

Abstract: A clutch having a multiple pole electromagnetic actuator is useful in motor vehicle powertrain components such as transaxles, transfer cases, transmissions, differentials and the like. The electromagnetic actuator includes a stationary coil, a rotating, multiple pole stator and a rotating, multiple pole armature which is linked to the stator. Both the stator and the armature include multiple coils which are electrically connected in pairs. A cam or ball ramp assembly is disposed between the armature and a friction clutch pack. Energization of the stationary coil induces current in the coils of the stator and the respective coils of the armature. The magnetic flux and force generated rotates the armature relative to the stator, thereby actuating the cam or ball ramp assembly, which in turn, compresses the friction clutch pack.