Abstract: An improved twin clutch, two-speed disconnect secondary drive unit, which may be configured as a rear drive unit (RDU) for an all wheel drive vehicle is provided. The RDU is driven through an input shaft, which is connected to a vehicle drive source such as a motor, and includes a twin clutch assembly, which is connected to the drive shaft and is selectively actuated to drive left and right main shafts, which drive respective wheels of the vehicle. The RDU further includes a modular a shift assembly mountable to one or both of said main shafts to drive output shafts, wherein each shift assembly is selectively operable between the hi-range and lo-range modes to shift driving operation of the output shafts between hi-speed and lo-speed operation. The shift assembly may be controlled by improved mono-stable or bi-stable actuators.

Abstract: A locking differential assembly includes a differential case, a first output shaft and a second output shaft. A first side gear is non-rotatably coupled to the first output shaft and a second side gear is non-rotatably coupled to the second output shaft. A differential pin is also included, the differential pin having differential gears. The differential gears are rotatably supported by the differential case and drivingly engaged with the first and second side gears to allow differential rotation thereof. A lock mechanism is actuated when a first torque force is applied to a drive cam and a driven cam. Finally, an electromagnetic coil actuates a brake plate, wherein the brake plate comes into frictional with a brake disc. Furthermore, the electromagnetic coil is discontinuous around the circumference of the brake disc.

Abstract: A secondary drive unit (SDU) for the secondary axis of an all wheel drive vehicle consists of an SDU housing defining a first section for receiving a main shaft which is connected to a drive source and a second section for enclosing a twin clutch assembly. The twin clutch assembly has a common clutch housing connected to the main shaft, a left clutch for selectively connecting a left output shaft and the clutch housing, a right clutch for selectively connecting a right output shaft and the clutch housing, and a rigid center plate separating the left and right clutches. The twin clutch assembly may be activated by a dual action piston assembly to decrease all wheel drive synchronization and connection response times.

Abstract: Disclosed is a locking differential assembly which includes a differential case, a first output shaft and a second output shaft. Further included is a first side gear non-rotatably coupled to the first output shaft and a second side gear non-rotatably coupled to the second output shaft. A differential pin is also included, the differential pin having differential gears. The differential gears are rotatably supported by the differential case and drivingly engaged with the first and second side gears to allow differential rotation thereof. Also included is a locking mechanism, the locking mechanism being actuated when a first torque force is applied to a drive cam and a driven cam. Finally included is an electromagnetic coil. The electromagnetic coil actuates a brake plate, the brake plate comes into frictional with a brake disc. Furthermore the electromagnetic coil is discontinuous around the circumference of the brake disc.

Abstract: Methods, devices and systems are provided for determining a connection state of an all wheel drive (AWD) assembly in a vehicle. The method includes receiving, by a vehicle, a message indicative of a hazard and a hazard location on the road and determining a distance to the hazard location from the vehicle. In response to the distance to the hazard location being below a first threshold distance, a state for an AWD assembly in the vehicle is set to a connect state. In response to the distance to the hazard location being above the first threshold, the time for the vehicle to reach the hazard location is determined. If the time to the hazard location is below a threshold AWD connection time, the state for the AWD assembly is set to the connect state.

Abstract: A secondary drive unit (SDU) for the secondary axis of an all wheel drive vehicle consists of an SDU housing defining a first section for receiving a main shaft which is connected to a drive source and a second section for enclosing a twin clutch assembly. The twin clutch assembly has a common clutch housing connected to the main shaft, a left clutch for selectively connecting a left output shaft and the clutch housing, a right clutch for selectively connecting a right output shaft and the clutch housing, and a rigid center plate separating the left and right clutches. The twin clutch assembly may be activated by a dual action piston assembly to decrease all wheel drive synchronization and connection response times.

Abstract: Methods, devices and systems are provided for determining a connection state of an all wheel drive (AWD) assembly in a vehicle. The method includes receiving, by a vehicle, a message indicative of a hazard and a hazard location on the road and determining a distance to the hazard location from the vehicle. In response to the distance to the hazard location being below a first threshold distance, a state for an AWD assembly in the vehicle is set to a connect state. In response to the distance to the hazard location being above the first threshold, the time for the vehicle to reach the hazard location is determined. If the time to the hazard location is below a threshold AWD connection time, the state for the AWD assembly is set to the connect state.