Borgwarner Inc.

Christopher Kurmaniak

Larry A Pritchard

Joseph D Mastie

David E Young

Donn Niffenegger

Thaddeus R Kopp, Jr

A transfer case () and a method of assembly in an all-wheel drive vehicle can include a range shifting assembly () for shifting between a low-range and high-range drive mode, a normally disengaged clutch assembly () for transferring drive torque to a first and second driveline, a clutch actuator (), and an actuating gear (). The clutch actuator () can be moveable between an expanded position and a contracted position and engageable with the clutch assembly () for engaging the clutch assembly () when in the expanded position. The actuating gear () can be reversibly rotatable through a predetermined angular arc of movement for operating the clutch actuator () between the contracted and expanded position for actuating the clutch assembly () and for shifting the range shifting assembly () between a low-range drive mode and a high-range mode when the clutch assembly () is in the disengaged position.

Motor driven transfer case with modular actuation

A transfer case () and a method of assembly can include an input shaft () and output shafts (), a mode clutch () for shifting between a two-wheel and four-wheel drive mode, a mode shift mechanism (), a planetary gear assembly () for providing a different drive ratio between the input shaft () and the output shaft (), a range shift mechanism (), and a synchronizer () for speed synchronization before shifting between a low-range drive mode and a high-range drive mode. A fixed ring gear () can be connected to the planetary gear assembly () during the high-range and low-range drive mode. The mode shift mechanism () and the range shift mechanism () can be electro-mechanically actuated by a reversible rotatable actuating gear () interposed between an expandable clutch actuator () and a rotatable barrel cam ().

Electro-mechanical transfer case with range shift on the move

A electromagnetic clutch assembly for use in a vehicle is presented. More specifically, the clutch assembly comprises an input member; an output member; a friction clutch pack having a first plurality of clutch plates coupled for rotation with said input member and a second plurality of clutch plates interleaved with said first plurality of clutch plates and coupled for rotation with said output member; a solenoid coil; an actuator hub having an armature plate; and a cam lever assembly having a first end engaging said actuator hub and a second end engaging said friction clutch pack. When electrical current is applied to the solenoid coil, the armature plate moves the actuator hub, the actuator hub engages the cam lever and causes said cam lever to compress the interleaved first and second plurality of clutch plates, thereby, resulting in the coupling of the input and output members.

Lever applied solenoid clutch actuator

A method of estimating force output of a solenoid assembly including a solenoid coil and a corresponding armature upon which the solenoid coil exerts a magnetic solenoid force is provided. The method includes a step of measuring a plurality of data points of current being drawn by the solenoid coil resulting in a plurality of measured current values, a step of measuring a plurality of data points of voltage being supplied to the solenoid coil resulting in a plurality of measured voltage values, and a step of estimating the magnetic solenoid force exerted upon the corresponding armature based on the pluralities of measured voltage and current values, resulting in an estimated force value.

Estimation of solenoid actuator force performance by analysis of voltage and current signals

A two-speed transfer case includes a planetary gear assembly, and a shift sleeve that is used for selecting either the reduced speed gear ratio, in which the torque from the input is transferred though the planetary gears, or the direct drive speed ratio, in which the input and output shafts are coupled directly together. The carrier of the planetary gear assembly is equipped with a surface that is capable of receiving a band brake that is disposed thereabout. A lever composed to two pieces, a brake apply arm and a cam follower, applies the brake band, and in doing so controls retardation of the planet carrier, controlling the speed of the carrier, and thus, controlling the output of the planetary gear assembly.

Transfer case input shaft brake system

A clutch having a multiple pole electromagnetic actuator is useful in motor vehicle powertrain components such as transaxles, transfer cases, transmissions, differentials and the like. The electromagnetic actuator includes a stationary coil, a rotating, multiple pole stator and a rotating, multiple pole armature which is linked to the stator. Both the stator and the armature include multiple coils which are electrically connected in pairs. A cam or ball ramp assembly is disposed between the armature and a friction clutch pack. Energization of the stationary coil induces current in the coils of the stator and the respective coils of the armature. The magnetic flux and force generated rotates the armature relative to the stator, thereby actuating the cam or ball ramp assembly, which in turn, compresses the friction clutch pack.

Growing community of inventors

Clarkston, MI, United States of America

Christopher Kurmaniak