Ford Global Technolgoies, LLC

Jeffrey Edward Maurer

Gregory Daniel Goleski

David Allen Janson

Steven Gerald Thomas

Steven Anatole Frait

Laurence Andrew Deutsch

Yuji Fujii

Gregory Michael Pietron

John Edward Brevick

Joseph F Kucharski

Nimrod Kapas

Andreas Evangelos Perakes

Matthew David Hammond

Bruce Granstrom

Keith A Devereaux

David Gon Oh

Michael Tekletsion Berhan

Nicholas Edward McCubbin

Steven Adam Hermann

Steve G Thomas

Shaun Gordon Knowles

Julie Anne Sunstein

Chip Hartinger

Larry A Deutsch

Steven Isaac Klurfeld

Mark Edward Urbaniak

Monica R DeGraffenreid

A hybrid transaxle permits location of a traction motor in a more favorable location, decreasing the risk of occupant injury in a vehicle collision. Axis transfer gearing moves the generator off the engine axis, which permits placing the traction motor further forward without interference with the generator. The gearing is confined to two gear planes, reducing the transaxle width.

Hybrid transaxle

In a pump system for a hybrid electric transmission, the pump is alternately driven by the input shaft and the output shaft, whichever is rotating faster. The input shaft and output shaft are co-axial. Sprockets and a chain transmit power from axis of the input and output shafts to the axis of the pump. The driven sprocket is selectively coupled to the input shaft by a first one-way-clutch and selectively coupled to the output shaft by a second one-way-clutch. Two alternative one-way-clutch and bearing arrangement are disclosed.

Hybrid transmission with dual-drive pump

A transmission includes a simple planetary gear set and several clutches. A first clutch selectively couples the carrier of the planetary gear set to a first shell. The housing of the first clutch is integrated with the planetary carrier. A piston return spring extends axially to occupy space between the planet gears. A second and third clutch share a common housing that is fixedly coupled to the ring gear. The second clutch selectively couples the ring gear to the sun gear. The third clutch selectively couples the ring gear to a second shell. The planetary gear set is axially located between the two clutch housings.

Transmission with integrated clutch and gear set

The output gear of a transmission is externally supported from an interior support by two ball bearings. The output gear is fixed to a shell. A carrier of a simple planetary gear set and a ring gear of a stepped pinion planetary gear set are splined to the shell. A brake includes a piston supported by the bell housing and clutch plates splined to the interior support.

Transmission assembly

A power split hybrid transaxle includes an axis transfer chain and a final drive planetary gear set. The components are arranged such that the power split planetary gear set is opposite the final drive planetary gear set with both located at the front of the transmission. This minimized the axial length of the transaxle by limiting the number of components that must be staggered axially. Furthermore, this permits use of electric machines with a large diameter and short axial length which also reduces the total axial length of the transaxle.

A transmission includes a case, a torque sensor, and a two-piece output shaft. The torque sensor is attached to the case and defines an inner diameter. The two-piece output shaft assembly is partially disposed within the case and includes a planet carrier operably coupled to a shaft extending through the inner diameter. The carrier and the shaft are separate components that are directly connected together and the carrier defines a park gear.

Transmission output shaft

A transmission utilizes a three clutch module. The clutch module may be pre-assembled before it is assembled into the transmission. All three clutch packs are splined to a common shell at their outer diameter. One of the clutch pistons passes through openings in the clutch pack of one of the other clutches. The common shell is fixedly coupled to a hollow shaft through which the transmission input shaft protrudes. Pressurized fluid to engage the three clutches is routed through axial passageways in the input shaft.

Clutch assembly and transmission

A torque converter utilizes four distinct fluid passageways. The torque converter hydrodynamic chamber is supplied with fluid via a passageway that includes a gap between a stator shaft insert and a turbine shaft. Fluid returns from the hydrodynamic chamber via a passageway that is formed between a hollow stator shaft and the stator shaft insert. The torque converter includes a bypass clutch with an apply chamber and a return chamber. Fluid is routed to the apply chamber via a passageway that includes a gap between a hollow portion of the turbine shaft and a turbine shaft insert. Fluid is routed between the balance chamber and an elevated exhaust via a passageway that runs through the turbine shaft insert.

Four pass torque converter

A transmission includes a main housing having a rear wall and at least one sidewall extending from the rear wall. The rear wall has an outer side and has an inner side that cooperates with the at least one sidewall to define an interior. A planetary gearset is disposed within the interior. An output shaft is coupled to the gearset and extends through a hole defined in the rear wall. An extension housing is connected to a rear portion of the main housing such that the outer side and the extension housing cooperate to define a torque-sensor cavity. The output shaft extends through the cavity. A torque sensor is disposed within the cavity adjacent to the output shaft and has an electrical connector disposed in a wall of the extension housing.

Torque sensor packaging for automatic transmissions

A transmission includes an input shaft, and a primary drive gear fixed to the input shaft. The primary gear has a first set of gear teeth. An idler gear is disposed in the transmission and has a second set of gear teeth in meshing engagement with the first set of gear teeth. The transmission also includes a transmission-pump drive gear having a third set of gear teeth in meshing engagement with the second set of gear teeth. The transmission-pump drive gear is configured to transmit power from the input shaft to a transmission pump. A power take-off unit is mounted to a case of the transmission and includes a first unit drive gear having a fourth set of gear teeth in meshing engagement with the second set of teeth. The a first unit drive gear is configured to transmit power from the idler gear to the power take-off.

Transmission having power take-off

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

Various packaging designs for placement of a magnetic torque sensor at the output shaft of a front wheel drive transmission are provided. One design provides for mounting a sensor on a chain drive sprocket or integrating a sensor into a modified sprocket bearing mount. Another design provides for mounting a sensor at the grounded ring gear of a final planetary drive. Another design provides for mounting a sensor at the differential housing. Another design provides for mounting a sensor at the output planetary carrier hub/park gear. Another design provides for mounting a sensor at a multi-piece transfer gear face.

Sensor packaging at output side of front wheel drive (FWD) transmissions

Two brakes of a transmission utilize the transmission front support as a clutch housing. One brake, which selectively holds a sun gear against rotation, is located on the inside of a cylindrical wall of the front support. A second brake, which selectively holds a ring gear against rotation, is located on the outside of the cylindrical wall. The clutch pack of the inner brake is splined to the inner surface of the cylindrical wall. The reaction plate of the first clutch pack includes radial fingers that extend between axial fingers of the cylindrical wall. The portion of the reaction plate that extends to the outer side of the cylindrical wall provides a reaction for a return spring of the outer brake.

A powertrain incorporates a link shaft between the transmission output shaft and downstream components in order to facilitate use of a torque sensor. The link shaft includes an inner section splined to the output shaft and an outer section treated to produce a magnetic field that varies based on transmitted torque. The inner section and outer section are separated by a circumferential gap that directs the torque past the treated surface. Use of the link shaft eliminates the need to directly treat the transmission output shaft. Separating the spline and the treated surface radially reduces the axial length required for torque sensing and allows commonality among variants with and without torque sensors and between two wheel drive and four wheel drive variants.

Transmission and transfer case with torque sensing

An assembly includes a one-way transmission control element including first and second races, first discs secured to the first race, and second discs interleaved with the first discs and secured to the second race.

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Commerce, MI, United States of America

Jeffrey Edward Maurer