Abstract: A method for operating an electric vehicle for traversing off-road terrain includes operating the vehicle both in a normal operating mode and an electric low range operating mode. A control unit receives inputs from sensors that determine vehicle operating conditions, such as vehicle speed, grade of terrain, accelerator position, and brake pedal position. The method adjusts motor torque or the maximum allowable motor as a function of the determined vehicle operating conditions, to provide improved electric vehicle operation in a low range mode, including the increasing motor torque at different rates relative to the normal mode, allowing a greater maximum allowable torque, increasing torque to overcome obstacles, and increasing torque to ascend or descend.

Abstract: An electrified transfer case for a vehicle having an engine, a transmission, and front and rear drivelines is provided. The electrified transfer case includes a first output shaft adapted for connection to the rear driveline, a second output shaft adapted for connection to the front driveline, and an input shaft connected to the output of the transmission. The transfer case may further include a gear set engaged to an electric motor for torque multiplication, a multi-position torque transferring mode connection system, and a controllable torque transfer system between the first output shaft and the second output shaft. A synchronizing device is operatively connected between the input and first output shaft, which may utilize a one-way clutch.

Abstract: An electrified transfer case for a vehicle having an engine, a transmission, and front and rear drivelines is provided. The electrified transfer case includes a first output shaft adapted for connection to the rear driveline, a second output shaft adapted for connection to the front driveline, and an input shaft connected to the output of the transmission. The transfer case may further include a gear set engaged to an electric motor for torque multiplication, a multi-position torque transferring mode connection system, and a controllable torque transfer system between the first output shaft and the second output shaft. A synchronizing device is operatively connected between the input and first output shaft, which may utilize a one-way clutch.

Abstract: An electric motor assembly has a motor housing, a stator with end windings, and a rotor. A feed line for cooling fluid is formed in the motor housing and receives cooling fluid from a sump formed in the bottom of the housing cavity. A spray tube is connected to the feed line at an end face of the motor housing, and extends across the top of the end windings. A first spray tube end is secured to the housing via a connector, and a second end is secured to the housing via a tube locator disposed in a pocket of the housing. The tube locator fixes the orientation of the spray tube outlets toward the end windings. The connector may also provide the cooling fluid to a rotor supply tube, which feeds the cooling fluid into the rotor shaft cavity. All of the cooling fluid returns to the sump.

Abstract: An electrified transfer case includes an input shaft, an output shaft, an electric motor, a gear reduction unit, and an axially moveable sleeve that is disposed axially between the input shaft and the output shaft. The sleeve selectively engages the input shaft, output shaft, and gear reduction unit based on the axial positon of the sleeve to selectively transfer power among the input shaft, output shaft, and electric motor. The sleeve is freely rotatable and supported on a support shaft that spans between and is freely rotatable relative to the input shaft and the output shaft. The sleeve includes multiple axially spaced clutch teeth. As the sleeve is controllably axially moved, different clutch teeth will engage with the input shaft, output shaft, and/or gear reduction unit to drivingly connect the components for operating in different modes, including EV, hybrid, conventional, generator, and neutral modes.

Abstract: A method for operating an electric vehicle for traversing off-road terrain includes operating the vehicle both in a normal operating mode and an electric low range operating mode. A control unit receives inputs from sensors that determine vehicle operating conditions, such as vehicle speed, grade of terrain, accelerator position, and brake pedal position. The method adjusts motor torque or the maximum allowable motor as a function of the determined vehicle operating conditions, to provide improved electric vehicle operation in a low range mode, including the increasing motor torque at different rates relative to the normal mode, allowing a greater maximum allowable torque, increasing torque to overcome obstacles, and increasing torque to ascend or descend.