Patents by Inventor John D. Zalewski

John D. Zalewski has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).

  • Patent number: 10525829
    Abstract: An AWD drivetrain is configured to primarily direct drive torque from a transversely-aligned powertrain assembly through an auxiliary power transfer unit to a rear driveline and selectively transmit drive torque to a front driveline via actuation of at least one power-operated clutch. The auxiliary power transfer unit includes an input component drivingly connected to the powertrain assembly, and an output component connected to the input component by a hypoid gearset The output component is operatively connected to the rear driveline and is configured to normally transfer the drive torque to the rear driveline.
    Type: Grant
    Filed: September 11, 2015
    Date of Patent: January 7, 2020
    Assignee: MAGNA POWERTRAIN OF AMERICA, INC.
    Inventors: Matthew G. Girlando, John D. Zalewski
  • Publication number: 20170246953
    Abstract: An AWD drivetrain is configured to primarily direct drive torque from a transversely-aligned powertrain assembly through an auxiliary power transfer unit to a rear driveline and selectively transmit drive torque to a front driveline via actuation of at least one power-operated clutch. The auxiliary power transfer unit includes an input component drivingly connected to the powertrain assembly, and an output component connected to the input component by a hypoid gearset The output component is operatively connected to the rear driveline and is configured to normally transfer the drive torque to the rear driveline.
    Type: Application
    Filed: September 11, 2015
    Publication date: August 31, 2017
    Inventors: Matthew G. GIRLANDO, John D. ZALEWSKI
  • Publication number: 20160356372
    Abstract: A differential assembly is provided to include a two-piece differential case, a differential gearset disposed in a gearset chamber formed in the differential case, and a ring gear. An interlocking feature mechanically interconnects the first and second case members of the two-piece differential case and define a continuous differential case weldment surface. The ring gear is mounted on the differential case such that its ring gear weldment surface is aligned with the differential case weldment surface. A welded joint along the aligned weldment surfaces creates a weldment junction connecting the case members and the ring gear to each other.
    Type: Application
    Filed: June 8, 2015
    Publication date: December 8, 2016
    Inventor: John D. Zalewski
  • Publication number: 20140174430
    Abstract: A method of calibrating a mirror orientation system of a heliostat includes mounting an artificial light source to a heliostat mirror, providing an array of light sensors on a solar thermal tower and positioning the heliostat mirror at a first orientation. A control module is provided a signal indicative of a mirror drive mechanism position at the first mirror orientation. The control module correlates the signal indicative of the mechanism position with an energy distribution across the sensor array as the artificial light source is energized when the mirror is at the first orientation. The drive mechanism moves the mirror to a second orientation and directs artificial light on the sensor array. The drive mechanism position signal is correlated with an energy distribution across the sensor array based on the second mirror orientation. The heliostat is calibrated based on the energy distributions and the drive mechanism position signals.
    Type: Application
    Filed: November 6, 2013
    Publication date: June 26, 2014
    Inventors: Brian M. Fitzgerald, John D. Zalewski, Peter M. Jacobsen, Franz Faschinger, Richard A. Bakowski, Philipp Ebner, David W. Wenthen, Burke Smith
  • Publication number: 20140174499
    Abstract: A heliostat for reflecting sunlight toward a target includes a first structure supporting a mirror including inner and outer tubes being rotatable relative to one another. A first actuator includes an electric motor driving a reduction gearset to rotate one of the first tubes and rotate the mirror about a first axis. A second structure also includes inner and outer rotatable tubes. A second actuator includes a second electric motor driving a reduction gearset to rotate the mirror about a second axis.
    Type: Application
    Filed: October 23, 2013
    Publication date: June 26, 2014
    Inventors: Brian M. Fitzgerald, John D. Zalewski, Franz Faschinger, Richard A. Bakowski, Philipp Ebner, David W. Wenthen, Burke Smith, Peter M. Jacobsen
  • Patent number: 8316738
    Abstract: A power transmission device for a four-wheel drive vehicle having a power source and first and second drivelines includes an input shaft adapted to be driven by the power source. A first output shaft is rotatable about a first axis and adapted to transmit torque to the first driveline. A second output shaft is adapted to transmit torque to the second driveline and is rotatable about a second axis. The first and second axes do not extend parallel to each other. A transfer unit includes a first cylindrically-shaped gear rotatably supported on the first output shaft and a second conically-shaped gear fixed for rotation with the second output shaft. The first and second gears are in constant meshed engagement with each other.
    Type: Grant
    Filed: June 10, 2009
    Date of Patent: November 27, 2012
    Assignee: Magna Powertrain of America, Inc.
    Inventors: William A. Hellinger, John D. Zalewski, David W. Wenthen, Brian M. Fitzgerald
  • Patent number: 8165767
    Abstract: A method controls a powertrain that directs power from an engine and a transmission to all four wheels or to just front wheels or to just rear wheels. The method includes monitoring information transmitted over a communications network. The method determines whether one or more components of the powertrain are in an active condition or in an inactive condition. The one or more components of the powertrain are in the inactive condition when not connected to the transmission and not connected to the front wheels or the rear wheels. The one or more components of the powertrain are in the active condition when connected to the transmission and connected to the front wheels and the rear wheels. The method switches the one or more components of the powertrain between the inactive condition and the active condition based only on the information from the communications network and without intervention from a user.
    Type: Grant
    Filed: August 17, 2007
    Date of Patent: April 24, 2012
    Assignee: MAGNA Powertrain USA, Inc.
    Inventors: John D. Zalewski, Charles Fairbanks, Gunter Niederbacher
  • Patent number: 8079928
    Abstract: A transfer case includes an input shaft and first and second output shafts. An overdrive unit is driven at an increased speed relative to the input shaft. A clutch is operable in a first position to establish a drive connection between the input shaft and the first output shaft. The clutch is further operable in a second position to establish a drive connection between the overdrive unit and the first output shaft. An actuator is driven by a motor for moving the clutch between its first and second positions. The actuator includes an axially movable fixed disk fixed for rotation with an output member of the overdrive unit. The shift engages an axially movable sleeve of the clutch.
    Type: Grant
    Filed: February 25, 2008
    Date of Patent: December 20, 2011
    Assignee: MAGNA Powertrain USA, Inc.
    Inventors: Aaron Ronk, Matt Phalen, Christopher J. Decker, Nancy Mintonye, John D. Zalewski
  • Patent number: 7895913
    Abstract: A power transmission device for a motor vehicle includes a clutch for transferring torque between first and second shafts. A clutch actuation system includes a drive member and a cam member in cooperation with one another. The drive member is driven by an electric motor and includes first and second rollers rotatably mounted thereon. The cam member includes first and second circumferentially extending channels, each having a continually reducing radius. The first and second channels are separate from and overlap one another. The first roller is positioned within the first channel to engage the drive member and the cam member. The second roller is positioned within the second channel to engage the drive member and the cam member such that relative rotation between the drive member and the cam member translates the cam member along an axis of relative rotation to vary the force applied to the clutch.
    Type: Grant
    Filed: January 25, 2010
    Date of Patent: March 1, 2011
    Assignee: MAGNA Powertrain USA, Inc.
    Inventors: Richard Mizon, John D. Zalewski
  • Publication number: 20100313706
    Abstract: A power transmission device for a four-wheel drive vehicle having a power source and first and second drivelines includes an input shaft adapted to be driven by the power source. A first output shaft is rotatable about a first axis and adapted to transmit torque to the first driveline. A second output shaft is adapted to transmit torque to the second driveline and is rotatable about a second axis. The first and second axes do not extend parallel to each other. A transfer unit includes a first cylindrically-shaped gear rotatably supported on the first output shaft and a second conically-shaped gear fixed for rotation with the second output shaft. The first and second gears are in constant meshed engagement with each other.
    Type: Application
    Filed: June 10, 2009
    Publication date: December 16, 2010
    Inventors: William A. Hellinger, John D. Zalewski, David W. Wenthen, Brian M. Fitzgerald
  • Publication number: 20100122884
    Abstract: A power transmission device for a motor vehicle includes a clutch for transferring torque between first and second shafts. A clutch actuation system includes a drive member and a cam member in cooperation with one another. The drive member is driven by an electric motor and includes first and second rollers rotatably mounted thereon. The cam member includes first and second circumferentially extending channels, each having a continually reducing radius. The first and second channels are separate from and overlap one another. The first roller is positioned within the first channel to engage the drive member and the cam member. The second roller is positioned within the second channel to engage the drive member and the cam member such that relative rotation between the drive member and the cam member translates the cam member along an axis of relative rotation to vary the force applied to the clutch.
    Type: Application
    Filed: January 25, 2010
    Publication date: May 20, 2010
    Inventors: Richard MIZON, John D. Zalewski
  • Patent number: 7650808
    Abstract: A transfer case includes a two-speed range unit, a friction clutch, an actuation mechanism and a control system. The actuation mechanism includes an electric motor, a geartrain driven by the motor, a range actuator assembly and a mode actuator assembly. The range actuator assembly includes a driveshaft driven by the geartrain, a cam driven by the driveshaft and a shift fork having a follower retained in a groove formed in the cam and a fork engaging a shift collar associated with the range unit. The mode actuator assembly has a face cam with spiral cam surfaces and a control gear with radially-moveable rollers engaging the cam surfaces. The control gear is rotatively driven by the geartrain. The face cam is axially moveable for controlling engagement of the friction clutch. An anti-rotation mechanism limits rotation of the face cam in response to continued rotation of the control gear.
    Type: Grant
    Filed: January 24, 2007
    Date of Patent: January 26, 2010
    Assignee: Magna Powertrain USA, Inc.
    Inventors: Richard Mizon, John D. Zalewski
  • Publication number: 20100017083
    Abstract: A method controls a powertrain that directs power from an engine and a transmission to all four wheels or to just front wheels or to just rear wheels. The method includes monitoring information transmitted over a communications network. The method determines whether one or more components of the powertrain are in an active condition or in an inactive condition. The one or more components of the powertrain are in the inactive condition when not connected to the transmission and not connected to the front wheels or the rear wheels. The one or more components of the powertrain are in the active condition when connected to the transmission and connected to the front wheels and the rear wheels. The method switches the one or more components of the powertrain between the inactive condition and the active condition based only on the information from the communications network and without intervention from a user.
    Type: Application
    Filed: August 17, 2007
    Publication date: January 21, 2010
    Inventors: John D. Zalewski, Charles Fairbanks, Gunter Niederbacher
  • Patent number: 7588133
    Abstract: A power transmission device includes a rotary input member receiving drive torque from a source of torque, a rotary output member for providing drive torque to an output device and a torque transfer mechanism for transferring drive torque between the input member and the output member. The torque transfer mechanism includes a friction clutch assembly operably disposed between the input member and the output member and a hydraulic clutch actuation system operable for applying a clutch engagement force to the friction clutch assembly. The hydraulic clutch actuation system includes an electromagnet and a piston operable to supply pressurized fluid and provide the clutch engagement force.
    Type: Grant
    Filed: August 21, 2006
    Date of Patent: September 15, 2009
    Assignee: Magna Powertrain USA, Inc.
    Inventors: Aaron Ronk, John D. Zalewski, James S. Brissenden
  • Patent number: 7506740
    Abstract: A power transmission device includes a rotary input member receiving drive torque from a source of torque, a rotary output member for providing drive torque to an output device and a torque transfer mechanism for transferring drive torque between the input member and the output member. The torque transfer mechanism includes a friction clutch assembly operably disposed between the input member and the output member and a hydraulic clutch actuation system operable for applying a clutch engagement force to the friction clutch assembly. The hydraulic clutch actuation system includes an electromagnet and a piston operable to supply pressurized fluid and provide the clutch engagement force.
    Type: Grant
    Filed: June 28, 2006
    Date of Patent: March 24, 2009
    Assignee: Magna Powertrain USA, Inc.
    Inventors: Aaron Ronk, John D. Zalewski, James S. Brissenden
  • Patent number: 7445100
    Abstract: A power transmission device includes a rotary input member adapted to receive drive torque from a source of torque, a rotary output member adapted to provide drive torque to an output device and a torque transfer mechanism operable to transferring drive torque from the input member to the output member. The torque transfer mechanism includes a friction clutch assembly operably disposed between the input member and the output member and a hydraulic clutch actuation system operable for applying a clutch engagement force to the friction clutch assembly. The hydraulic clutch actuation system includes an electric motor drivingly coupled to a first piston. The first piston is slidably positioned within the housing for supplying pressurized fluid to an accumulator. The pressurized fluid within the accumulator is in communication with a second piston to provide the clutch engagement force.
    Type: Grant
    Filed: January 12, 2007
    Date of Patent: November 4, 2008
    Assignee: Magna Powertrain USA, Inc.
    Inventors: Aaron Ronk, John D. Zalewski, James S. Brissenden
  • Publication number: 20080234091
    Abstract: A transfer case includes an input shaft and first and second output shafts. An overdrive unit is driven at an increased speed relative to the input shaft. A clutch is operable in a first position to establish a drive connection between the input shaft and the first output shaft. The clutch is further operable in a second position to establish a drive connection between the overdrive unit and the first output shaft. An actuator is driven by a motor for moving the clutch between its first and second positions. The actuator includes an axially movable fixed disk fixed for rotation with an output member of the overdrive unit. The shift engages an axially movable sleeve of the clutch.
    Type: Application
    Filed: February 25, 2008
    Publication date: September 25, 2008
    Applicant: Magna Powertrain USA, Inc.
    Inventors: Aaron Ronk, Matt Phalen, Christopher J. Decker, Nancy Mintonye, John D. Zalewski
  • Patent number: 7337887
    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.
    Type: Grant
    Filed: January 16, 2007
    Date of Patent: March 4, 2008
    Assignee: Magna Powertrain USA, Inc.
    Inventors: Aaron Ronk, John D. Zalewski, James S. Brissenden
  • Publication number: 20070180940
    Abstract: A transfer case includes a two-speed range unit, a friction clutch, an actuation mechanism and a control system. The actuation mechanism includes an electric motor, a geartrain driven by the motor, a range actuator assembly and a mode actuator assembly. The range actuator assembly includes a driveshaft driven by the geartrain, a cam driven by the driveshaft and a shift fork having a follower retained in a groove formed in the cam and a fork engaging a shift collar associated with the range unit. The mode actuator assembly has a face cam with spiral cam surfaces and a control gear with radially-moveable rollers engaging the cam surfaces. The control gear is rotatively driven by the geartrain. The face cam is axially moveable for controlling engagement of the friction clutch. An anti-rotation mechanism limits rotation of the face cam in response to continued rotation of the control gear.
    Type: Application
    Filed: January 24, 2007
    Publication date: August 9, 2007
    Applicant: MAGNA POWERTRAIN USA, INC.
    Inventors: Richard Mizon, John D. Zalewski
  • Patent number: 7182194
    Abstract: A power transmission device includes a rotary input member receiving drive torque from a source of torque, a rotary output member for providing drive torque to an output device and a torque transfer mechanism for transferring drive torque between the input member and the output member. The torque transfer mechanism includes a friction clutch assembly operably disposed between the input member and the output member and a hydraulic clutch actuation system operable for applying a clutch engagement force to the friction clutch assembly. The hydraulic clutch actuation system includes an electric motor drivingly coupled to the hydraulic actuator. The hydraulic actuator includes a first piston biasedly engaged by a spring, slidably positioned within a housing and operable to supply pressurized fluid to a second piston. Supply of pressurized fluid to the second piston provides the clutch engagement force.
    Type: Grant
    Filed: September 1, 2004
    Date of Patent: February 27, 2007
    Assignee: Magna Powertrain USA, Inc.
    Inventors: Aaron Ronk, John D. Zalewski, James S. Brissenden