Abstract: A drive unit includes a housing, a main shaft, an output shaft, an electric motor, a first planetary gear set, and a second planetary gear set. The main shaft is rotatably disposed in the housing, and with the housing cooperatively defines an axis of rotation. The output shaft is disposed at least in part in the housing and is rotatable about the axis. The electric motor is disposed in the housing and has a rotor centered on and rotatable about the axis. The first planetary gear set is centered on the axis and provides a first speed reduction ratio between the rotor and a second planetary gear set. The second planetary gear set provides a second speed reduction ratio between the first planetary gear set and the output shaft.

Abstract: A passive lubrication system, for a gear drive system of a drive system, for powering an electric vehicle, includes an oil network, an oil sump region, an oil paddle, and an oil diverter. The oil network is defined by and disposed within, at least, a fixed annular region of the gear drive system and a planetary gear system. The oil sump region is configured to provide oil for distribution about the oil network. The oil paddle is operatively coupled with the planetary gear system, configured to rotate with a component of the planetary gear system, and during rotation, configured to course oil, from the oil sump region. The oil diverter is positioned concentric with the oil paddle and radially outward of the oil paddle and configured to receive oil from an oil source, upon rotation of the oil paddle, and direct the received oil to the oil network.

Abstract: A drive system for powering the wheels of an electric vehicle is disclosed. The drive system includes an electric motor having a stator and a rotor, and one or more planetary gear sets operably connected to the electric motor and the wheels. The drive system includes one or more configurations that reduce packaging space, reduce the weight of the drive system, and/or provide cooling functions.

Abstract: A lubrication system (400) for a transfer case (200) includes a pump (228) selectively supplying a working fluid to a fluid reservoir of an actuator (226) configured to apply force to a clutch assembly (214) to cause the clutch assembly (214) to move between a disengaged position and an engaged position. The lubrication system also includes a relief valve (302) having a relief valve inlet fluidly coupled to the fluid reservoir of the actuator (226) which opens to receive the working fluid based on a threshold pressure level of the working fluid in the fluid reservoir. The lubrication system also includes a trough (306) fluidly coupled to a relief valve outlet of the relief valve (302). The trough (306) carries the working fluid from the relief valve outlet to a bearing assembly (227) associated with at least one of an input shaft (204) and a primary output shaft (206) of the transfer case (200) when the clutch assembly (214) is in the disengaged position.

Abstract: A transfer case is provided with a primary shaft which is selectively engagable with a secondary shaft via a clutch mechanism. The clutch mechanism is inclusive of a friction pack. A hub of the clutch mechanism is connected on the primary shaft and the clutch housing is torsionally fixed with a primary sprocket rotatively mounted on the primary shaft. A passive or active controlled lubricant collection receptacle is provided which maximize fluid retention in conditions wherein there is not a high demand of torque for the clutch system of the transfer case thereby minimizing fluid that is unnecessarily churned by engagement with the hub connected with the secondary shaft.

Abstract: A transfer case comprises a primary output shaft, and a secondary output shaft selectively coupleable to the primary output shaft with a plate clutch to transfer torque therebetween. The plate clutch includes a housing, a plurality of interleaved plates that are engaged alternatingly with the primary output shaft and the housing to rotate therewith, and an apply plate non-selectively coupled to the primary output shaft to rotate therewith. The apply plate is moveable axially along the primary output shaft into a first configuration in which the apply plate is positively coupled to the housing to rotate therewith, a second configuration in which the apply plate rotates independent of the housing, and a third configuration in which the apply plate compresses the interleaved plates to form a friction coupling between the primary output shaft and the housing.

Abstract: A transfer case includes primary and secondary output shafts, along with a secondary torque transfer mechanism and a locking mechanism, which are configured to selectively couple the primary and secondary output shafts. The secondary torque transfer mechanism comprises a sprocket coupled to the secondary output shaft, and a plate clutch coupled to the sprocket to selectively form a friction coupling with the primary output shaft. The locking mechanism selectively couples the primary output shaft to the sprocket, and includes a locking sleeve and an actuator that moves the locking sleeve between a first position and a second position. In the first position, the locking sleeve forms a first splined connection with the primary output shaft and forms a second splined connection with the sprocket. In the second position, the locking sleeve forms the first splined connection with the primary output shaft and forms a second splined connection with the sprocket.

Abstract: A transfer case for a normally rear wheel drive vehicle having selectively engageable front wheel drive is provided. The transfer case includes a rear housing with a main drive shaft aperture and an aluminum cast front housing threadably connected with the rear housing. The front housing has a main drive shaft aperture axially aligned with the rear housing main drive shaft aperture. The front housing has an integrally formed cylindrical yoke forming an isolation mount for receiving a polymeric isolator allowing for connection of the transfer case with a chassis structure of the vehicle. The cylindrical yoke has a cylindrical preform therein.

Abstract: A transfer case is provided with a primary shaft which is selectively engagable with a secondary shaft via a clutch mechanism. The clutch mechanism is inclusive of a friction pack. A hub of the clutch mechanism is connected on the primary shaft and the clutch housing is torsionally fixed with a primary sprocket rotatively mounted on the primary shaft. A reservoir system is provided for delivering splashed oil axially along the primary shaft overlapping the friction pack. The reservoir system has a collective fluid receptacle that is connected via a stationary passage with a lubrication passage radially inward of the friction pack of the hub.

Abstract: A transfer case for a normally rear wheel drive vehicle having selectively engageable front wheel drive is provided. The transfer case includes a rear housing with a main drive shaft aperture and an aluminum cast front housing threadably connected with the rear housing. The front housing has a main drive shaft aperture axially aligned with the rear housing main drive shaft aperture. The front housing has an integrally formed cylindrical yoke forming an isolation mount for receiving a polymeric isolator allowing for connection of the transfer case with a chassis structure of the vehicle. The cylindrical yoke has a cylindrical preform therein.

Abstract: A transfer case is provided with a primary shaft which is selectively engagable with a secondary shaft via a clutch mechanism. The clutch mechanism is inclusive of a friction pack. A hub of the clutch mechanism is connected on the primary shaft and the clutch housing is torsionally fixed with a primary sprocket rotatively mounted on the primary shaft. A passive or active controlled lubricant collection receptacle is provided which maximize fluid retention in conditions wherein there is not a high demand of torque for the clutch system of the transfer case thereby minimizing fluid that is unnecessarily churned by engagement with the hub connected with the secondary shaft.

Abstract: A transfer case is provided with a primary shaft which is selectively engagable with a secondary shaft via a clutch mechanism. The clutch mechanism is inclusive of a friction pack. A hub of the clutch mechanism is connected on the primary shaft and the clutch housing is torsionally fixed with a primary sprocket rotatively mounted on the primary shaft. A reservoir system is provided for delivering splashed oil axially along the primary shaft overlapping the friction pack. The reservoir system has a collective fluid receptacle that is connected via a stationary passage with a lubrication passage radially inward of the friction pack of the hub.

Abstract: A hydraulic clutch assembly for a motor vehicle driveline is provided. The clutch assembly comprises an input member, and output member and a friction clutch pack operably disposed therebetween for controlling torque transfer. A first fluid circuit contains hydraulic based fluid at a first pressure and is in fluid communication with the friction clutch pack for lubrication thereof. A second fluid circuit is in fluid communication with the first fluid circuit for replenishing the second fluid circuit with the hydraulic based fluid at a second pressure that is less than the first pressure. The clutch assembly further comprises a motor and a gear train. A first piston is in fluid communication with the second fluid circuit for delivering the hydraulic based fluid thereto A second piston is translated by the hydraulic based fluid displaced by the first piston to actuate the friction clutch pack.

Abstract: A hydraulic system having a clutch assembly (30) which is hydraulically actuated, a pressure device (32) in fluid communication with the clutch assembly, and a multi-position actuator device (34) in fluid communication with the pressure device and the clutch assembly. The position of the actuator device includes at least a first position in order for the pressure device to fluidly communicate with the clutch assembly, a second position for maintaining fluid pressure in the clutch assembly, and a third position for bleeding the hydraulic system.

Abstract: A pump system that pressurizes a fluid includes a shaft, a first rotor and a second rotor that is selectively driven by the shaft. Relative rotation between the first rotor and the second rotor generates variable sized pockets therebetween to pressurize the fluid. A clutch regulates a degree of coupling of the rotor to the shaft between a decoupled state and a coupled state to regulate the relative rotation between the first and second rotors.

Abstract: In at least one embodiment, a hydraulic clutch assembly for a motor vehicle driveline is provided. The clutch assembly comprises an input member, and output member and a friction clutch pack operably disposed therebetween for controlling torque transfer. A first fluid circuit contains hydraulic based fluid at a first pressure and is in fluid communication with the friction clutch pack for lubrication thereof. A second fluid circuit is in fluid communication with the first fluid circuit for replenishing the second fluid circuit with the hydraulic based fluid at a second pressure that is less than the first pressure. The clutch assembly further comprises a motor and a gear train. The gear train has an input force driven by the motor and an output force. A first piston is in fluid communication with the second fluid circuit for delivering the hydraulic based fluid thereto and is operatively driven by the output force to displace the hydraulic based fluid.

Abstract: A pump system that pressurizes a fluid includes a shaft, a first rotor and a second rotor that is selectively driven by the shaft. Relative rotation between the first rotor and the second rotor generates variable sized pockets therebetween to pressurize the fluid. A clutch regulates a degree of coupling of the rotor to the shaft between a decoupled state and a coupled state to regulate the relative rotation between the first and second rotors.

Abstract: A hydraulic system having a clutch assembly (30) which is hydraulically actuated, a pressure device (32) in fluid communication with the clutch assembly, and a multi-position actuator device (34) in fluid communication with the pressure device and the clutch assembly. The position of the actuator device includes at least a first position in order for the pressure device to fluidly communicate with the clutch assembly, a second position for maintaining fluid pressure in the clutch assembly, and a third position for bleeding the hydraulic system.

Abstract: A torque coupling having an actuation system operable to control actuation of a transfer clutch in coordination with actuation of a pump clutch. The transfer clutch is disposed between a pair of rotary members to transfer drive torque therebetween. The pump clutch is operable for selectively coupling a fluid pump to the first rotary member when lubricant is required to cool the transfer clutch.

Abstract: A pump system that pressurizes a fluid includes a shaft, a first rotor and a second rotor that is selectively driven by the shaft. Relative rotation between the first rotor and the second rotor generates variable sized pockets therebetween to pressurize the fluid. A clutch regulates a degree of coupling of the rotor to the shaft between a decoupled state and a coupled state to regulate the relative rotation between the first and second rotors.