Magna Powertrain Usa, Inc.

New Venture Gear, Inc.

Magna Powertrain Inc

Magnadrivetrain of America, Inc.

Harrier Technologies, Inc.

Richard Mizon

Sankar K Mohan

James S Brissenden

John D Zalewski

Eric A Bansbach

Thomas Christopher Bowen

Aaron Ronk

Malcolm E Kirkwood

Joseph G Mueller

Dale L Pennycuff

James L Lanzon

Khazaee Mozaffar

Brian Vaughn

Randolph C Williams

Carl David Schleuder

David E Young

Timothy W Breen

Burke Smith

John Desilvia

Brian Ide

Michael Sullivan

Timothy Breen

A gear set for a transmission for use in limited space and capable of transmitting relatively large amounts of power with a small diameter of the gear sets, comprising a series of helical gear elements having stub shafts extending laterally from either side thereof, each of the stub shafts having teeth formed at the remote ends thereof and a central axial bore extending through each gear element and a coupler adapted to engage the teeth on adjacent gear elements join gear elements in driving contact. The gear set having a relatively large effective diameter, and a tension rail extending through the axial bore in the gear elements with retainers at either end of the tension rail so as to effectively permit limited axial movement along the tension rail while preventing inadvertent disengagement.

Helical gear sets

A transfer case is provided with a range unit, an interaxle differential, a clutch assembly and a power-operated actuation mechanism. The range unit includes a planetary gearset driven by an input shaft, and a synchronized dog clutch assembly for releasably coupling one of the input shaft or an output component of the planetary gearset to an input member of the interaxle differential. The interaxle differential further includes a first output member driving a first output shaft, a second output member operably driving a second output shaft. The clutch assembly is a multi-plate friction clutch operably disposed between the first and second output shafts. The power-operated actuation mechanism includes a range actuator assembly, a clutch actuator assembly and a motor assembly operable to control coordinated actuation of the range actuator assembly and the clutch actuator assembly.

Two-speed transfer case with ballramp clutch actuator

A power transmission device for a motor vehicle includes a clutch for transferring torque between first and second shafts. A clutch actuation system includes a drive member and a cam member in cooperation with one another. The drive member is driven by an electric motor and includes first and second rollers rotatably mounted thereon. The cam member includes first and second circumferentially extending channels, each having a continually reducing radius. The first and second channels are separate from and overlap one another. The first roller is positioned within the first channel to engage the drive member and the cam member. The second roller is positioned within the second channel to engage the drive member and the cam member such that relative rotation between the drive member and the cam member translates the cam member along an axis of relative rotation to vary the force applied to the clutch.

Spiral cam clutch actuation system

A transfer case for a motor vehicle having an input shaft, a first output shaft, a second output shaft, a clutch, a transfer mechanism, a sensor portion and a magnetoelastic torque sensor. The clutch has a clutch pack and a thrust mechanism that is configured to exert an engagement force on the clutch pack. The clutch pack has a first portion, which is rotatably driven by either or both of the input shaft and the first output shaft, and a second portion that is supported for rotation relative to the first portion. The transfer mechanism couples the second portion of the clutch pack to the second output shaft. The sensor portion is coupled to the first or second output shaft and is at least partially formed of a magnetoelastic material. The magnetoelastic torque sensor is disposed about and radially in-line with the sensor portion.

Power transfer assembly with torque sensors and torque control system

A transfer case includes a two-speed range unit, a friction clutch, an actuation mechanism and a control system. The actuation mechanism includes an electric motor, a geartrain driven by the motor, a range actuator assembly and a mode actuator assembly. The range actuator assembly includes a driveshaft driven by the geartrain, a cam driven by the driveshaft and a shift fork having a follower retained in a groove formed in the cam and a fork engaging a shift collar associated with the range unit. The mode actuator assembly has a face cam with spiral cam surfaces and a control gear with radially-moveable rollers engaging the cam surfaces. The control gear is rotatively driven by the geartrain. The face cam is axially moveable for controlling engagement of the friction clutch. An anti-rotation mechanism limits rotation of the face cam in response to continued rotation of the control gear.

Sprial cam clutch actuation system for two-speed transfer case

Dynamic traction control system

A full-time power take-off unit is equipped with a dual-mode bi-directional overrunning clutch and a shift mechanism to establish all-wheel drive and part-time four-wheel drive modes. Further, the power take-off unit includes a disconnect clutch that is controlled by the mode shift mechanism to establish a full-time four-wheel drive mode.

Power take-off unit for four-wheel drive vehicle

An on-demand power take-off unit is equipped with a dual-mode bi-directional overrunning clutch and a shift mechanism to establish on-demand and part-time four-wheel drive modes. Further, the power take-off unit includes a disconnect clutch that is controlled by the mode shift mechanism to establish a two-wheel drive mode in addition to the four-wheel drive modes.

On-demand power take-off unit for four-wheel drive vehicle

A power transfer system is provided and equipped with a torque transfer coupling which includes a clutch and a ball-screw actuator. The ball-screw actuator functions to axially translate an apply plate via a closed hydraulic system to operatively engage the clutch and vary the frictional engagement thereof.

Power transfer device with hydraulic clutch actuation

Torque transfer clutch with linear piston hydraulic clutch actuator

An electric drive axle for use in hybrid vehicles has an electric motor driving a compact gearbox. The gearbox includes a planetary reduction unit and a differential assembly. The planetary reduction unit has a sun gear driven by the electric motor, and compound planet gears supported from a planet carrier which have a first gear segment meshed with a fixed first ring gear and a second gear segment meshed with a second ring gear. The sun gear is also meshed with one of the first and second gear segments of the compound planet gears. The second ring gear drives the differential which transfer motive power to a pair of output shafts adapted for connection to one set of wheels. When used with a conventional engine-based powertrain for the other set of wheels, the electric drive axle establishes a four-wheel drive powertrain for the hybrid vehicle. The electric motor and gearbox are mounted in a common housing assembly to provide a compact drive axle assembly.

Drive axle for hybrid vehicle

A split planetary gear assembly is provided having a pair of helical gearsets implemented in a vehicle transmission. The first helical gearset includes a first sun gear, a first ring gear, and a set of first planet gears meshed with the first sun gear and the first ring gear. The second helical gearset includes a second sun gear, a second ring gear, and a set of second planet gears meshed with the second sun gear and the second ring gear. The components of the second helical gearset have the same number of teeth, helix angle, and tooth pitch as the components of the first helical gearset with the exceptions that their angular helix orientation (i.e., left-hand/right-hand) is reversed and they are circumferentially indexed by one-half tooth pitch. In addition, the first and second planet gears are arranged in paired sets and supported on a common pinion shaft which, in turn, is fixed to a planet carrier. The second sun gear is splined for rotation with and limited axial movement relative to the first sun gear. A plurality of split planetary gear assemblies are interconnected and components of each assembly are selectively braked or clutched for establishing numerous forward drive ratios and a reverse ratio.

Compact multi-speed automatic transmission with load sharing and anti-phase gear assembly

A power transfer device for a motor vehicle having a modular housing assembly which supports a geartrain. A first embodiment of the modular housing assembly includes a case having unitary sidewall with terminal edges defining two opposed openings. The sidewall also defines an interior chamber and the openings are enclosed by a pair of cover plates. Pillow blocks are used to support the drive components of the geartrain within the chamber and are secured to shelves which extend from the sidewall. Loads created during operation are transmitted from the geartrain to the sidewall. The cover plates are secured to the terminal edges of the sidewall using a plurality of U-shaped spring clamps. A second embodiment of the modular housing assembly includes a box-like case having one open side. A cover plate is used to enclose the geartrain and lubrication fluid within the interior volume of the box-like case. A continuous support shelf is formed from the base of the box-like case and allows loads to be transmitted directly to the box-like case. A third embodiment of the modular housing assembly includes a box-like case having one open side, a cover plate used to enclose the geartrain and a continuous support shelf. Rotary and non-rotary components of the geartrain are entirely contained within the box-like case. Pillow blocks are used to support the drive components of the geartrain.

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Fayetteville, NY, United States of America

Richard Mizon