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    © All Rights Reserved
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    5 views21 pages

    LSD 1

    Uploaded by

    Dejan Zdravkovski

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
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    of 21
    ay United States Patent 1US010288160B2 a0) Patent No: US 10,288,160 B2 Guarino et al. (4s) Date of Patent: May 14, 2019 (64) DRIVE UNIT WITH LIMITED SLIP.AND. 6) References Cited DRIVELINE DISCONNECT CAPABILITY US. PATENT DOCUMENTS (7) Appian: Ford Gioal echnologes, LLC, aman bt A202 Varo Dearbom, MI US) Sass Bt, 330m) Gana cat stack BB+ aot Thckeeheate Book 17356 (72) Inventors: Wiliam David Guarino, Dearborn, Ml waste (US) Paul Moubarak, Redon Twp, sassy a Demi MIS) Boast BI Down ESR3Y BL Rounot cal (03). Assignce: Rord Gaba Technologies, LLC Semon Rae 32014 Schmit Hep 2800 Dearbom, MI (US) SA7LI29 82 72014 Bead Moons FISD ws (#) Notice: Subject to any disclaimer, the term of this 9.199.640 B2 122015 Weston et al. poten is extended or ast under 35. 2017084 AL “63017 Cooper Fiep 212 USC. 154°) by 295 doy. Soles Ale 201% Modal) Heb 3312 (21) Appl Now 15792,569 FOREIGN PATENT DOCUMENTS oa L207» 079 (22) Fils: Ost 13,2016 By MBM 4, !O4oTa ) Prior Pubcation Data * ct by examine US 20180106883 A1_Ape 19,2018 Primary Examiner — Derk D Kaight (hy mech (74) dormer, gent, oF Frm —Dasid Kelley: Brooks Fiat 48220601) Kushian, PC nook 176 (200601) ‘hook 2405 (200601) on ABSTRACT Prot 808 (200601) a A chtch assembly inches fst hutch assembly having 16m 4422 (201301), BOK 17720 ies cluch plates ratbly xe Io fst ssa ik Corson: Baan 2004 C1801. BoMK’ cae paies rab fie oa ciatch sk. The hth 2023/043 (2013.01); BOOY 2400/424 Iudes a second clutch assembly having (2013.01); B6OY 2400804 (2013.01); FI6It rotatably fixed to a second shaft and Catt eon) rota xe th cle basket. The Gye cee fist and second chich assembles rotate about common cc UsPe See application file for Complete search history FI6D 21/06; FLSD 13/385 192/38.1, 48.91 eee S ya Se Y iZ ne Ll central axis and are actuated by a common actuator. 18 Claims, 13 Drawing Sheets LE U.S. Patent May 14, 2019 Sheet 1 of 13 US 10,288,160 B2 10 oN‘ of) 2 12~ 16 Engine PTU 13 Transaxle 1 FIG. 1 30 U.S. Patent May 14, 2019 Sheet 2 of 13 US 10,288,160 B2 74 76 \ | FIG. 3 U.S. Patent May 14, 2019 Sheet 3 of 13 US 10,288,160 B2 > ->| __ & 7 | - eA >| > a 72 68 FIG. 5 U.S. Patent May 14, 2019 Sheet 4 of 13 US 10,288,160 B2 FIG. 6 U.S. Patent May 14, 2019 Sheet 5 of 13 US 10,288,160 B2 Ball Ramp Actuator Drive Torque: Torque Motor Postion FIG. 7A Ball Ramp Actuator Drive Torque Torque Motor Position FIG. 7B Ss U.S. Patent May 14, 2019 Sheet 6 of 13 US 10,288,160 B2 U.S. Patent May 14, 2019 Sheet 7 of 13 US 10,288,160 B2 8 eS FIG. 12 FIG. 11 ® Patent May 14, 2019 Sheet 8 of 13 US 10,288,160 B2 x g & e = 5 2 A : TMT Tim sn ] Gg “0 US 10,288,160 B2 Sheet 9 of 13 May 14, 2019 U.S. Patent Bury souuy dst ‘Si ast Ol Buyout ast ‘OW OST "SIA VST ‘DL U.S. Patent May 14, 2019 Sheet 10 of 13 US 10,288,160 B2 100: ™ “ N10 FIG. 16 ie Inner Ring = 85 = = = 54 2 B 455 eo 4 Outer Ring * 354 3A 0.05 oA 0.15 02 Time (sec) FIG. 17 US 10,288,160 B2 Sheet 11 of 13 May 14, 2019 U.S. Patent st‘Sld \ 004 US 10,288,160 B2 Sheet 12 of 13 May 14, 2019 U.S. Patent U.S. Patent May 14, 2019 Sheet 13 of 13 US 10,288,160 B2 Double Ball Ramp Actuator Torque Motor Position FIG. 20A Double Ball Ramp Actuator Torque Motor Position FIG. 20B US 10,288,160 B2 1 DRIVE. UNIT WITH LIMITED SLIP AND DRIVELINE DISCONNECT CAPABILITY ‘TECHNICAL FIELD This disclosure relates 10 a clutch assembly and more particularly wo a secondary axle clutch assembly having ‘orque transfer capabilites and limited slip differential capa bilities actuated by a single actuator BACKGROUND A motor vehicle may be provided with an alwheel-drive (AWD) powertrain capable of tansmitting power 1 the ‘hes ofa primary axle and to the wheels ofa secondary txle. Power is provided tothe secondary axle through a rear ‘drive unit having a dlferatal assembly, Various dileential ssscmblies may be utilized, inching open, limited slip, and focking diferenials. Open differentials havea gear tra that allows the output shafts of the differentia o spin at different spscds while maintaining the sum of their speeds propor onal © the input of the diferental, but the amount of torque transfered to the inner and outer wheels must be qual, A Timited sip diferental allows diferent amounts of torque to be transferred to the inner-whes! compared to the fteswheel daring tor, ‘AWD systems tend to degrade vehicle fuel economy due to increased driveline parasitic losses even wihen AWD is aot sctivated. These parasitic losses oceur, in part, because the Secondary drive wheels snd their rotation cause drag 5 Torgve 10 be exerted on the driving element, An AWD ‘vehicle may be provided with w driveline disconnect system that improves fuel economy by disconnecting pars of the driveline when AWD isnot activated, In many’ aspects, his js accomplished witha side mounted catch on rear drive ‘nit that functions as a forge tansferldisconnectdeviee. In ‘many instances, inelusion of & driveline disconnect system in a side cluch rear drive unit prechudes the wse of ‘mechanical limited slip diferental inthe rear dive unit, SUMMARY ‘This disclosure eates to a clutch assembly having tongue transfer capabilities and limite sip differential capabilities actuated by'a single acwator. In some approaches a sc ondary axle clu assembly includes a differential carrier having a diferenal shaft rotatable about a eontal axis of rotation. A plurality of limited slip differential (LSD) clutch plates are rotatably fixed to the diferential shat and are fxilly movable relative tothe diferental shaft. An intr: shaft extends couially with the difleratial shat fn is rotatable about the central axis of rotation. A plurality ff tarque clutch pats are rotatably fixed to the intermediate shaft and are axially movable relative to the intermediate Shaft. clutch basket extends over the torque clutch plates ‘nd the LSD elute plates and is rotatable about the central ‘xis of rotation, The lutch basket inl fist plurality ‘of carr plates disposed adjacent tothe tongue cltch plates fad a second plurality of carrer pltes disposed adjacent to the LSD clutch plates. An aewator is adapted to apply an axial force tothe torgue clutch plates and the LSD itch plates 10 engage the torque clutch plates with the frst phiality of carier plates, and to engage the LSD clutch plates withthe second plurality of cartier plates. In some approaches, a cluch assembly includes 2 first luc assembly having fist clutch plates rotatably fixed to ‘first shal and first carer plates rotatably fined 4 eltch 2 basket. The clutch assembly fuer includes a second clutch assembly having second clutch plates rotatably fixed 0 sccond shaft und second earrier plates rotatably fixed to the cles basket, The fist and second clutch assemblies rotate bout a common central axis and are actuated by a common sctuator In sill other approaches, a method of actuating multiple lich assemblies includes axially displacing using a com: ‘mon actuntor, a fist plurality of clutch plates rotationally fixed to a fist shall. The method further inckudes axially displacing, wsing the common actuator a second pl clutch plates rotationally fixed to @ second sha Saft i comxial with the second shaft and extends at last partially within the second shaf. DRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is «schematic diagram showing s vehicle pow- FIG. 2 is schematic diagram showing a rear drive uni. FIG. 3 is a schematie diagram showing a rear drive unit ina first stage. FIG. 4s a schematic diagram showing the rear deve unit of FIG. 3 in a second stage, FIG. $isaschematie diagram showing the rear deve uit of FIG. 3 ina thin sage. IG. 6 is cross-sectional view ofa rar drive unit having ball mmp actuator FIGS. Ta and 7h are example clutch engagement profiles for ball ramp actuator, FIG. Bisa schematic diagram showing. double ball ramp FIG, 9 is a perspective view of « double ball ramp FIG, 10 is a perspective view of double ball ramp sctuator having cages. FIG, 11 Font elevational view ofa double ball amp sctuator FIG, 12 side elevational view of a double ball ramp setuator FIG, 13 isa side elevational view of a double ball ramp sctuator having a pressure plate with projections. IG. If is font elevational view ofa double ball ramp setuator having a pressure plate with projections FIGS. 180-F8e are example ramp profile fra double ball amp aetuator. FIG. 16 is schematic diagram showing a double ball famp gets ving rings axially movable in opposite IG. 17 isa chart showing example axial displacements of inner and outer rings. FIG. 18 isan exploded side elevational view of rear rive unit having double ball ramp actator FIG, 19 is side elevational view ofthe rear drive unit of FIG. 18 FIGS, 20 and 205 are example clutch engagement pro- files for a double ball ramp actuator p lL ED DESCRIPTION As require, detailed emboxtiments of the present inven tion are disclosed herein; however, tis o be understood that the dlselosed embostiments are merely exemplary of the Jnvention tat may be embodied in various and alternative orm, The figures are not necessarily to scale; some features may be exeggersted or minimized to show details of par- ticular components. Therefore, speife structural and une US 10,288,160 B2 3 ional deals disclosed herein are not w be intepeeted a8 limiting, but merely as a representative basis for teaching fone skilled in the art to variously employ the present Refering t0 FIGS. 1 and 2, the powertain of # motor vehicle 10 includes ‘an engine 12, such as an internal combustion engine: a tansaxle 13 for producing multiple Tew drive spe ratios and reverse dive, halshats 14, 16 for transiting rotating power between the tansaxle’s ‘ouput and the font driven wheels 18,20; gear drive unit (RDU) 22; a driveshaft 24; a power transfer unit (PTU) 26 or transmitting rotating. power between the transxle’s output and the driveshaft, and a clutch assembly 28 for providing limited stip capabilities and for connecting and Uisconnecting the output of the RDU and the rear driven wheels 30, 32 ‘As shown in FIG, 2, the RDU 22 includes diflerentil cater 34, Inside the differential carrier 34 area differential side pear 36, which is connected by a sbat 40 10 whee! 30, 3 and difeental side gear 38, which is connected by a shaft 42 to wheel 32. The dffecontil assembly ofthe RDU 22 is, Fo example, almited slp diferential (LSD), and preferably an electronic Fimited slip differential (@LSD). Where an LSD is utlized, the eLSD is controlled by at least one controller 44 (shown in FIG. 1), compute, or other such network of interconnected controllers in control system. ‘The eLSD controls the amount of clamping force applied i 1 clutch pack, as described in greater detail clawhere herein, This provides a computerized control of the chch pressure in order to selectively deliver various amounts of Tonge to the wheels 30,32. Aliuough deseribed herein in conjunetion with a rear drive unit, it is expressly contemplated that the cltch ‘ssembly andor the elute actuator may be incorporated in a front drive unit, along the driveshaft, or in any ether suitable region ofa vehicle Refering 0 1G. 3, a ring gear 46 secured to the ilfereatal carrier 34 receives tore input from an input pinion 4, The input pinion 48 js connected te eompsinion ange (not shown), which in tra is connected to a drive: shaft @qg, devesbaft 24 in FIG, 1) that taasmits ouput torque from a power transfer unit (e.. PTU 26 in FIG. 1), teansmisson, or transfer case to the RDU 22. Difleental Pinion gears 50, 52 are deveably connceted tothe diere ial eariee 34 by a pin $4 and are in continuous meshing engagement with the differential side pears 36, 38, “The differential carrier 34 includes & differential shat $6 thatextends into clutch basket $8, An intermediate shaft 60 extends from the diferential side gear 38 into the cltch busket 88. The intermediate shaft 60 extends coolly with the differential shaft $6, and both are rotatable about the contal axis of rotation 62. Ina prefered approach, shown in FIG. 3, the intermediate shaft 60 hasan outer diameter less than an inner diameter of the diflerential shat $6, aad st least a portion ofthe intermestiae shal 60 s disposed within and extends through atleast a portion of the differential shaft 6. Other stale configurations ofthe intemediate shat 60 relative tothe diferntial shaft S6 are possible. “The clutch assembly 28 includes cltch basket 58 that houses a tongue transfer clutch assembly 64 and an LSD clueh assembly 66, The torque transfer cluteh assembly 64 and the [SD elute assembly 66 are coaxial and tate about ‘common central axis 62, In some approaches, the torque transfer clutch assembly 64 and the LSD clutch assembly 66 are immediately adjacent In other approaches, the torque transfer clutch assembly 64 and the LSD clutch assembly 66 4 are adjacent and separated by a separator plate 76. Other ‘coaxial anrangements are expressly contemplated The torgue tausfer clu assembly 68 includes torque transfer clutch plates 68 that are coupled o differential side ear (eg differential side gear 38) through the intermediate Shaft 60. The forgue transfer clatch plates 68 are preferably Iietion plates, but may also be steel plates (e.g, pressure ates) or combinations thereof, and may be formed of any Suitable material. The torque tansfer chtch plates 68 are rotatably fixed to the intermediate shaft 60 such that rotation ofthe intermediate shaft 60 cates corresponding rotation of | the torque transfer clutch plates 68. The lone transler Jutch plates 68 are also axially movable relative to the lntemmatiate shaft 60. In © preferred approach, the torque teansfer clutch plates 68 ae internally splined to the inter mediate shaft 60. For example, a series of protrusions and recesses disposed at an interior diameter of the torque Twansfer clutch plates 68 may mesh with a corresponding ‘ries of proiusions and recesses disposed at an exterior diameter of the intermediate shat 60. In tis way the tongue transfer clutch plates 68 and the iatermesite shaft 60 may be in continuous meshed engagement The torque transfer clutch assembly 64 also inchades torque transfer carrier plates 70 tht are coupled othe clutch busket 88, The torque traser carer plates 70 are prefer ably sel plates (ex, pressize plates), but may also be {ition plates or combinations thereo!, and may be formed ofany suitable material, The torque tansfer earrer plates 70 fre rotatably fixed othe clutch hasket 88 such that tation Of the tongue transfer carer plates 70 causes comespanding rotation ofthe clutch basket $8. The torque transfer carer plates 70 are also axially movable relative to the clutch basket $8. Ina preferred approach, the torque transfer carrier plates 70 are extemlly splined to the clutch basket $8. For example, series of protrusions and recess disposed at an exterior diameter ofthe tue transfer carrier plates 70 may mesh witha corresponding series of protrusions and recess disposed at an interior surface ofthe clutch basket 58. In ‘another exannple, the torgue transfer earier plates 70 include ‘one or more peoirsions ad the eluich basket 88 includes lone or more recesses or apertures adapted to receive the one or more protsioas. ‘Thus, when the torque transfercltch plats 68 engage the torgue transfer carrer plates 70, torgue is transferred from the intermediate shaft 60 tothe clutch basket 8 though the engaged torque transfer clutch plates 68 and torque transfer rir plates 70, As the clutch basket 58 srtatably coupled to the output shalt 42, torque is also directly transfered 19 the rear wheel 32, When the torque transfer etch plates 68 disengage from the torque wansfer carier plates 70, the dliferentialcarior M4 is disconnected and the rar whee! 32 js therefore disconnected fm the powertmin ofthe vehicle 410. As such, the torgue tansfer cltch assembly 64 is espable of providing “disconnect” capabilites. The LSD clutch assembly 66 inches LSD clutch plates 72 that are coupled tothe differential eaeriee 34 though the Aitfercatal shall $6, The LSD clutch petes 72 ae preferably fiction plates, but may also be steel plates (eg, pressure Plates) of combinations dherof, and may be formed of any Suitable material. The LSD clutch plates 72 ace rotatably fixed to the differential shaft 86 such that rotation of the ditferental shaft $6 causes corresponding rotation of the LSD elutch plates 72, The LSD clutch plates 72 are also axially movable relative to the differential shaft 86. Ina prefered approach, the LSD clutch plates 72 are intemal Eplined to the dilferntal shat $6, For example, a scres of protrusions and recesses disposed at an interior diameter of | US 10,288,160 B2 5 the LSD clutch plates 72 may mesh with a comesponding series of protrasions and recesses disposed at an exterior ‘diameter of the dfereatal shaft $6, In this wa, the LSD clutch plates 72 and the differential shaft $6 may be in ‘continuous meshed engagement, The LSD clutch assembly 66 also includes LSD carrer plates 74 that are coupled to the clutch baskot §8. The [SD carrier plates 74 are preferably steel plates (et, pressure plates), but may also be friction plates o¢ combinations thereof, and may be formed of any suitable material. The LLSD carrier plates 74 are rately fixed to the clutch basket 58 sich that rlation of the LSD carer plates 74 causes corresponding rotation of the clutch basket S¥. The LSD carrie plates 74 are also axially movable relative to the clutch basket $8. Ina prefered approach, the LSD carer plates 74 are extomally splined tothe elutch basket 88. For ‘example, a series of protrusions and recesses disposed tat texterior diameter of the LSD cami plates 74 may mesh ‘with a comesponding series of protmisions and recesses disposed at an interior of the clutch hasket 88, In another example, the LSD carrier plates 74 include one er more protrusions, and the clutch basket 58 includes one or more fevesses oF apertures adapted to recive the one OF more protrusions “Thus, when the LSD clutch plates 72 engage the LSD. carrier plates 74, torque is transfered from the differential shaft $6 tothe clutch basket 88 though dhe engaged LSD ‘luc plates 72 and LSD earier plates 74. As the clutch busket Sf is rotatably coupled to the output shaft 42, the tore is such, the LSD clutch assembly 66 is capable of providing “Tlmited slip" capabilites, As willbe appreciated, the torque provided by the LSD clutch assembly 66 may bein addition ‘o, orn place of, the torque applied by the torque transler clu assembly 64, The tongue transfer clutch assembly 64 and the LSD lich assombly 66 may be separately activated by one or ‘ore actuators. FIG. 3 shows a clutch assembly 28 in which neither the togue transfer clutch assembly 64 nor the LSD. lich assembly 66 are activated, In this sate, the RDU 22 ‘doesnot apply torque to the eur wheels 30, 32 ofthe vehicle 10. FIG. 4 shows a clutch assembly 28 in which the tongue transfer clutch assembly 64 has buen activated (eg, by the controller 44 moving & motor toa fist motor position) But the LSD cluteh assembly 66 has not been activated. In this sate the tore tansfer clutch plates 68 and the torgue Transfer carrier plates 70 are axially moves int engagement, and the RDU 22 applies torqe to the rear wheels of the vehicle, However, Because the LSD clutch assembly 66 has fot been activate, the LSD clutch plates 72 and the LSD cari plates 74 are not engaged, and the differentia assem by does not provide limited slip capabilities. Rather, the

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