Ford Global Technolgoies, LLC

Andreas Evangelos Perakes

Nicholas Edward McCubbin

Steven Anatole Frait

Peter John Grutter

Ashok E Rodrigues

Matthew David Hammond

Laurence Andrew Deutsch

Jeffrey Edward Maurer

Samuel Ellis

Gregory Daniel Goleski

Robert Scott Lippert

Paul M Moubarak

David Allen Janson

Dale Scott Crombez

John Edward Brevick

Steven Gerald Thomas

Michael Benjamin Levin

Furqan Zafar Shaikh

Scott J Lauffer

Danrich Henry Demitroff

Jacob Martin Povirk

Jason C Marcath

Filip Tomik

W Cary Cole

Paul John Bojanowski

Lawrence Marshall

Vladimir Ivanovic

Michael Paul Lindlbauer

Richard David Bruns

Mathew John Fast

Mark E Briscoe

Charles Krysztof

Shaun Gordon Knowles

Wayne Uhrick

Abhinav Kumar

Chip Hartinger

Derek Kempton Ward

Kevin M Sullivan

Monica R DeGraffenreid

Charles G Hartinger

Thomas E Gochenour

Thomas Gerard Neumann

Kevin Kootsillas

Dan Fratila

Jim Koppenol

A vehicle includes a power source configured to provide drive torque, a front axle, a rear axle, and a transfer case configured to distribute drive torque from the power source between the front axle and the rear axle. The vehicle additionally includes a clutch arranged between the front axle and the transfer case. The clutch has a disengaged state and an engaged state drivingly coupling the transfer case and the front axle. The vehicle also includes a regenerative braking system configured to, in response to a braking request, provide regenerative braking torque to the rear axle. The vehicle further includes a controller. The controller is configured to, in response to a braking request and the clutch being in the disengaged state, control the clutch to shift into the engaged state to couple the regenerative braking system to the front axle and provide regenerative braking torque to the front axle.

System and method for increasing regenerative braking in a rear-wheel-drive-based platform with four-wheel-drive capability

A method for manufacturing a case-hardened ring gear/differential case assembly includes attaching a ring gear to a differential case. The case-hardened ring gear and the differential case are fabricated of materials each having differing properties of at least carbon content and melting temperature. The attaching includes placing a flange of the case-hardened ring gear in intimate contact with a flange of the differential case whereby a predetermined gap is defined between a remainder of the ring gear and a remainder of the differential case. The ring gear flange is attached to the differential case flange by a friction welding process. The predetermined gap defines an outflow channel that receives a carburized portion of the case-hardened ring gear as overflow material created by an upset forging step of the friction welding process. Differential assemblies and vehicles including such are described.

Precisely aligned, friction welded spiral bevel or hypoid ring gear and differential case assembly

A vehicle includes a first axle, second axle, first clutch, second clutch, and controller. The first and second axles are coupled by a driveshaft. The first and second clutches are configured to isolate the driveshaft from loads transferred through the first and second axles, respectively, when open. The controller is programmed to, in response to a difference between output speeds of the first and second axles exceeding a first threshold, close the second clutch, reduce the difference such that it is below a second threshold, and close the first clutch.

Vehicle traction and all-wheel drive control system

A method for controlling a vehicle driveline uses sensors to estimate a need for powering secondary wheels for each of a plurality of conditions. The estimates are scaled and the scaled estimates summed. Only primary wheels are powered when the summed estimates are less than a reference value. Both the primary and secondary wheels are powered when the summed estimates exceed the reference value.

Automatic control of driveline states

A vehicle includes a driveshaft, first axle, second axle, first clutch, second clutch, and controller. The driveshaft is selectively coupled to outputs of the first and second axles by the first and second clutches, respectively. The controller is programmed to, in response to a command to reconnect the driveshaft to the outputs of the first and second axles, close the second clutch to transfer loads from the second axle to the driveshaft, adjust the slip speed of the first clutch to within a target range, and close the first clutch.

Vehicle all-wheel drive control system

A transfer case and transmission are designed to permit the transmission hydraulic control system to control a range selection coupler and a torque on demand clutch in the transfer case. Two pressure circuits are transmitted from the transmission to the transfer case: a high range circuit and a low range circuit. The low range circuit is pressurized to engage low range while the range circuit is pressurized to engage high range. The torque on demand clutch is controlled by whichever of these circuits has the higher pressure. Lubrication is provided to a front section of the transfer case via the transmission output shaft, with the fluid returning to the transmission sump through a drainback passageway. The rear portion of the transfer case has a segregated sump. A control strategy is employed to partially fill front section of the transfer case with fluid in preparation for vehicle towing.

Transmission and integrated transfer case

A front wheel drive transmission is adapted for all-wheel drive by the addition of a selectively engageable power take-off shaft. When a disconnect clutch is engaged, power may be transferred to rear wheels via a power take-off unit and a rear drive unit to improve vehicle mobility. When the disconnect clutch is disengaged, various components of the all-wheel drive system do not rotate, reducing parasitic losses and improving fuel economy. To provide packaging space for the disconnect clutch, the differential is moved to the left (driver side) of the driven transfer gear. A planetary differential, such as a double pinion planetary differential, is suitable for this location.

Transmission having selectable power transfer shaft

A vehicle includes axle housing, a differential and a ring gear, a scraper port, and a reservoir. The housing has a cover forming a heat exchanger having a coolant side and a lubricant side. The differential and ring gear are configured to pump a lubricating fluid. The scraper port is disposed at a bottom of the heat exchanger adjacent to the ring gear and is configured to direct the lubricating fluid through the lubricant side of the heat exchanger. The reservoir is disposed at a top of the heat exchanger and is configured to receive and store the lubricating fluid from the lubricant side of the heat exchanger.

Driveline thermal and lubricant flow management

A vehicle powertrain includes a transaxle configured to drive front wheels and a power take-off unit configured to drive rear wheels through a driveshaft. The power take-off unit includes a disconnect clutch such that the power flow path to the rear wheels can be disconnected to reduce fuel consumption and reconnected when needed for traction enhancement. Although the disconnect clutch is physically located within the power take-off unit, it is actuated by fluid from the transaxle valve body. The disconnect clutch actuator includes a piston that slides within a chamber in a housing and a solenoid controlled valve that fluidly connects the chamber either to a pressure source or to the transaxle sump.

A drive system includes a differential for transmitting power between a power source and first axles; a clutch including a first member driveably connected to the power source and a second member secured to a power transfer shaft; and a servo including a cylinder connected to a pressure source, a piston displaceable in the cylinder for mutually disconnecting the first and second members and allowing mutual engagement of the first and second members.

Mechanism for actuating a power transfer unit

A system and a method for controlling a hybrid vehicle powertrain during a change from a two-wheel drive mode to a four-wheel drive mode is provided. In response to a request to couple the second pair of wheels to the powertrain, a driveline controller commands an increased torque from the electric motor to be applied to the first pair of wheels The increased torque from the electric motor is based on an AWD engagement torque of the second pair of wheels to counteract an engagement torque of a second pair of drive wheels before changing from the two-wheel drive mode to the four-wheel drive mode.

System and method for controlling a driveline in a hybrid vehicle

A system for lubricating a differential mechanism includes a housing containing a ring gear, a pinion meshing with the ring gear, a sump containing fluid, and a reservoir that receives fluid flung from the ring gear as the ring gear rotates through the sump fluid, and an orifice restricting the flow rate of fluid from the reservoir.

Variable lubricant level in a differential sump

A vehicle driveline includes a power source, a transmission connected to the power source and including an output driveably connected to primary road wheels, a driveshaft, a synchronizer that opens and closes a drive connection between the output and the driveshaft, and a clutch that alternately opens and closes a drive connection between the driveshaft and secondary road wheels. A control executes synchronization and connection strategies using one of singular, overlapping and sequential activation of the driveline components that produce all-wheel-drive on-demand.

All wheel drive speed synchronization and connection

A motor vehicle powertrain includes a multiple speed transmission including a first lube circuit that supplies hydraulic lubricant to components of the transmission, a first oil sump, and a first pump driveably connected to an engine for supplying oil at a first pressure to the lube circuit, a transfer case including a first output, a second oil sump located in the transfer case, a second pump located in the transfer case and driveably connected to the first output, and a check valve for alternately opening and closing a connection between the first pump and the lube circuit and for opening and closing a connection between the second pump and the lube circuit in response to differential pressure between an outlet of the first pump and an outlet of the second pump.

Transfer case for a motor vehicle powertrain

A method for controlling a vehicle drivetrain includes de-energizing a clutch that connects a differential output to a wheel, rotating said component through a sump by pulsing the clutch when a speed of a differential component is less than a reference speed, and cyclically pulsing the clutch while a speed of said component exceeds the reference speed and a count of a timer, started when the clutch is de-energized, exceeds a reference count.

All-wheel-drive disconnect clutch control

Growing community of inventors

Canton, MI, United States of America

Andreas Evangelos Perakes