Abstract: A disconnect system for selectively engaging and disengaging one or more shafts of a power train unit. The disconnect system includes a plurality of cam members and an electromagnetic coil. At least one cam member rotates at the same speed as an input shaft. At least one cam member rotates at variable speeds. In operation, the electromagnetic coil is energized by rotation of the input shaft for selectively activating a clutch to engage one or more of the cams to connect and disconnect one or more output shafts.

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: A rear drive module for an all-wheel drive motor vehicle includes a differential assembly having an outer differential housing and an inner differential housing, the inner differential housing being fixed for rotation with an output shaft of the differential assembly; a ring gear assembly having a ring gear mounted to and fixed for rotation with the outer differential housing; and a disconnect and synch-lock mechanism: operable to synchronize and lock the inner differential housing and the outer differential housing, and to disconnect the inner differential housing and the outer differential housing to prevent rotation of the outer differential housing and the ring gear. The disconnect and synch-lock mechanism may include a synchronizer clutch and a clutch actuator. The clutch actuator may be a ball-ramp or face cam mechanism which is configured to control the operation of the synchronizer clutch and locking between the inner and outer differential housings.

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 disconnect system for selectively engaging and disengaging one or more shafts of a power train unit. The disconnect system includes a plurality of cam members and an electromagnetic coil. At least one cam member rotates at the same speed as an input shaft. At least one cam member rotates at variable speeds. In operation, the electromagnetic coil is energized by rotation of the input shaft for selectively activating a clutch to engage one or more of the cams to connect and disconnect one or more output shafts.

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.

Abstract: A rear drive module for an all-wheel drive motor vehicle includes a differential assembly having an outer differential housing and an inner differential housing, the inner differential housing being fixed for rotation with an output shaft of the differential assembly; a ring gear assembly having a ring gear mounted to and fixed for rotation with the outer differential housing; and a disconnect and synch-lock mechanism: operable to synchronize and lock the inner differential housing and the outer differential housing, and to disconnect the inner differential housing and the outer differential housing to prevent rotation of the outer differential housing and the ring gear. The disconnect and synch-lock mechanism may include a synchronizer clutch and a clutch actuator. The clutch actuator may be a ball-ramp or face cam mechanism which is configured to control the operation of the synchronizer clutch and locking between the inner and outer differential housings.

Abstract: A drive axle system and a method of control. The drive axle system may include a first drive axle assembly and a second drive axle assembly that may be operatively coupled via a slip clutch.

Abstract: An axle assembly that may have a housing and a carrier housing. The axle assembly may include one or more quiet lubricant reservoirs that may not receive rotating components of the axle assembly. A seal may be provided in a channel that may be disposed between the housing and the carrier housing.

Abstract: A transfer case having a shift mechanism. The shift mechanism may include a shift rail, a range shift assembly, a mode shift assembly, and a sector cam. The sector cam may control movement of the range shift assembly and the mode shift assembly when the sector cam is rotated.

Abstract: A drive axle system and a method of control. The drive axle system may include a first drive axle assembly and a second drive axle assembly that may be operatively coupled via a slip clutch.

Abstract: A drive axle system and a method of control. The drive axle system may include a first drive axle assembly and a second drive axle assembly that may be operatively coupled via a slip clutch.

Abstract: An axle assembly that may have a housing and a carrier housing. The axle assembly may include one or more quiet lubricant reservoirs that may not receive rotating components of the axle assembly. A seal may be provided in a channel that may be disposed between the housing and the carrier housing.

Abstract: A drive axle system and a method of control. The drive axle system may include a first drive axle assembly and a second drive axle assembly that may be operatively coupled via a slip clutch.

Abstract: A multi-wheel drive system for a vehicle and a method of control. The system may include first and second inlet valves that may control the flow of fluid to a gerotor pump that may actuate a clutch to provide torque to a wheel set.

Abstract: A transfer case having a shift mechanism. The shift mechanism may include a shift rail, a range shift assembly, a mode shift assembly, and a sector cam. The sector cam may control movement of the range shift assembly and the mode shift assembly when the sector cam is rotated.

Abstract: A differential assembly having a clutch collar actuator mechanism. The clutch collar actuator mechanism includes an actuator and a fork that may pivot about a pivot axis to actuate a clutch collar.