Borgwarner Inc.

Thaddeus R Kopp, Jr

Larry A Pritchard

Branden Levi Reeves

Philip John Francis

Joseph D Mastie

David E Young

Christopher Kurmaniak

A transfer case comprises a primary output shaft, and a secondary output shaft selectively coupleable to the primary output shaft with a plate clutch to transfer torque therebetween. The plate clutch includes a housing, a plurality of interleaved plates that are engaged alternatingly with the primary output shaft and the housing to rotate therewith, and an apply plate non-selectively coupled to the primary output shaft to rotate therewith. The apply plate is moveable axially along the primary output shaft into a first configuration in which the apply plate is positively coupled to the housing to rotate therewith, a second configuration in which the apply plate rotates independent of the housing, and a third configuration in which the apply plate compresses the interleaved plates to form a friction coupling between the primary output shaft and the housing.

Locking transfer case

A transfer case includes a primary output shaft, and a secondary output selectively coupleable to the primary output shaft with a secondary torque transfer mechanism. The secondary torque transfer mechanism comprises a plate clutch and a locking sleeve. The plate clutch includes a housing coupled to the secondary output shaft, a plurality of interleaved plates alternatingly coupled to the primary output shaft and the housing, and an apply plate coupled to the primary output shaft and being configured to compress the interleaved plates to selectively form a friction coupling between the primary output shaft and the secondary output shaft. The locking sleeve is non-selectively coupled to one of the housing or the apply plate to rotate therewith, and is selectively coupleable to the other of the housing or the apply plate to form a positive coupling between the primary output shaft and the secondary output shaft.

A number of variations may include a product comprising an electrical machine operatively connected to a driveline module comprising a gear train having a fixed gear ratio, a first planetary gear set having multiple gear ratios operatively connected to the gear train, a second planetary gear set having a fixed gear ratio operatively connected to the first planetary gear set, and a synchronizer, wherein the synchronizer is operatively connected to the first planetary gear set and is positioned between the first and second planetary gear set; a differential operatively connected to the second planetary gear set; wherein the electrical machine selectively transmits power to the differential through the gear train, the first planetary gear set, the synchronizer, and the second planetary gear set, and wherein the synchronizer is constructed and arranged to shift the driveline module into a high range mode, a low range mode, and a neutral mode.

Electric all-wheel drive two speed with split double reduction planetary

A transfer case includes primary and secondary output shafts, along with a secondary torque transfer mechanism and a locking mechanism, which are configured to selectively couple the primary and secondary output shafts. The secondary torque transfer mechanism comprises a sprocket coupled to the secondary output shaft, and a plate clutch coupled to the sprocket to selectively form a friction coupling with the primary output shaft. The locking mechanism selectively couples the primary output shaft to the sprocket, and includes a locking sleeve and an actuator that moves the locking sleeve between a first position and a second position. In the first position, the locking sleeve forms a first splined connection with the primary output shaft and forms a second splined connection with the sprocket. In the second position, the locking sleeve forms the first splined connection with the primary output shaft and forms a second splined connection with the sprocket.

Transfer case with four wheel lock

A number of variations may include a product comprising an electrical machine operatively connected to a driveline module comprising a gear train having a fixed gear ratio, a first planetary gear set having multiple gear ratios operatively connected to the gear train, a second planetary gear set having a fixed gear ratio operatively connected to the first planetary gear set, and a synchronizer operatively connected to the first planetary gear set and which is positioned between the first and second planetary gear set; a differential operatively connected to the second planetary gear set; wherein the electrical machine selectively transmits power to the differential through the gear train, first planetary gear set, synchronizer, and second planetary gear set, and wherein the synchronizer is constructed and arranged to shift the driveline module into a high, low, and a neutral mode through placement of a ring gear of the first planetary gear set.

A number of variations may include a product that may include a power transfer assembly. A gear train may have multiple gears and may provide a first stage gearing that may have a fixed gear ratio. At least one planetary gear set may provide a second stage gearing that may have multiple gear ratios. An electric machine may selectively provide input to the first stage gearing. A differential unit may selectively receive output from the planetary gear set. An engagement mechanism may selectively connect the differential unit with the second stage gearing in each of a high range mode and a low range mode.

Electric all-wheel drive with two-speed double reduction planetary

A number of variation may include a method that may include providing a drive system that may deliver a torque supply to a vehicle. An electric unit may be provided. The torque supply may be reduced. A torque fill may be initiated when the torque supply is reduced. The torque fill may be supplied from the electric unit.

Gear change torque fill strategy

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.

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Oakland Township, MI, United States of America

Thaddeus R Kopp, Jr