Adaptive vehicle drive system for extreme operating conditioning

• US 5,704,444 A
• Filed: 12/11/1995
• Issued: 01/06/1998
• Est. Priority Date: 12/11/1995
• Status: Expired due to Term

• Current Assignee: Borg-Warner Automotive Incorporated (BorgWarner Incorporated)
• Original Assignee: Borg-Warner Automotive Incorporated (BorgWarner Incorporated)
• Inventors: Showalter, Dan J.
• Primary Examiner(s): Hurley, Kevin
• Application Number:
  US08/570,450
• Time in Patent Office: 757 Days
• Field of Search: 180/233, 180/244, 180/247, 180/248, 180/249, 180/250, 180/197, 364/424.08, 364/424.094, 364/424.098, 364/424.096, 477/176, 477/180
• US Class Current: 180/247
• CPC Class Codes: B60K 17/344 having a transfer gear
• CPC Class Codes: B60K 17/35 including arrangements for suppressing or influencing the power transfer, e.g. viscous clutches differential gearing with locking devices F16H48/20
• CPC Class Codes: B60K 23/08 for changing number of driven wheels , for switching from driving one axle to driving two or more axles B60K17/3515 takes precedence
• CPC Class Codes: B60K 23/0808 for varying torque distribution between driven axles, e.g. by transfer clutch
• CPC Class Codes: F16D 27/004 with permanent magnets combined with electromagnets
• CPC Class Codes: F16D 27/115 with more than two discs, e.g. multiple lamellae
• CPC Class Codes: F16H 2063/3056 using cam or crank gearing
• CPC Class Codes: F16H 63/304 the final output mechanisms comprising elements moved by electrical or magnetic force band brake actuating mechanisms F16H63/3003

Abstract

An adaptive torque control and distribution system for a motor vehicle having a transfer case, primary driveline and drive wheels and secondary driveline and drive wheels for operation in extreme off road conditions such as sand. The transfer case includes a modulating clutch and a lockup clutch disposed in parallel between its primary (rear) output and secondary (front) output. The system detects abnormally high magnitude and rapidly repeating wheel spin transients which are characteristic of operation in sand or similar highly randomly variable tractive conditions and overrides the on demand torque distribution program for a predetermined time interval. During this predetermined time interval, the transfer case lockup clutch is activated thereby coupling the primary and secondary drivelines and achieving a fifty-fifty torque split therebetween while the modulating clutch is inactive. The system and this operating mode reduces clutch and clutch operator cycling thereby reducing heat generation within the transfer case and increasing clutch and transfer case longevity.

Claims

1. An adaptive vehicle drive system comprising, in combination,

a first driveline having a first speed sensor,

a second driveline having a second speed sensor,

a transfer case for driving said first driveline and said second driveline a modulating clutch operably disposed between said first driveline and said second driveline, and a lockup clutch operably disposed between said first driveline and said second driveline,

a microcontroller for receiving signals from said first and said second speed sensors and

determining the average and instantaneous speed differences between said first driveline and said second driveline over a predetermined time period,

determining the speed of the slower of said first and said second drivelines,

comparing said average and instantaneous speed differences to said speed of said slower of said drivelines,

providing signals sequentially to said modulating clutch and said lockup clutch to operably couple said first and said second drivelines in response to both said average speed difference and said instantaneous speed difference exceeding respective predetermined values relating to said speed of said slower of said drivelines.

2. The adaptive vehicle drive system of claim 1 wherein said sensors are Hall effect sensors.

3. The adaptive vehicle drive system of claim 1 wherein said first driveline is located toward the rear of a vehicle.

4. The adaptive vehicle drive system of claim 1 wherein said microcontroller includes a timer for maintaining lockup clutch engagement to between 2.5 and 7.5 minutes.

5. The adaptive vehicle drive system of claim 1 wherein said modulated clutch includes an electromagnetic coil and a pair of circular members having opposed recesses and balls disposed in said recesses.

6. The adaptive vehicle drive system of claim 1 wherein said signal to said modulating clutch ceases after said lockup clutch is activated and said lockup clutch signal ceases after a second predetermined time period.

7. The adaptive vehicle drive system of claim 1 wherein said lockup clutch includes at least a pair of collars acted upon by a shift fork and a spring disposed between said pair of collars.

8. An adaptive vehicle drive system for extreme off road conditions comprising, in combination,

a first driveline having a first drive shaft, first differential and first set of wheels,

a second driveline having a second drive shaft, second differential and second set of wheels,

a transfer case having a first output coupled to said first driveline, a second output coupled to said second driveline, a modulating clutch operably disposed between said first output and said second output and a lockup clutch operably disposed between said first driveline and said second driveline,

a first sensor for sensing the speed of said first driveline,

a second sensor for sensing a speed of said second driveline,

a microcontroller for receiving signals from said first and said second sensors and determining an average speed difference between said first driveline and said second driveline over a first predetermined time period,

determining a maximum instantaneous speed difference between said first driveline and said second driveline over said predetermined time period,

determining the speed of the slower of said first and said second drivelines,

sequentially activating said modulating clutch to operatively couple said first and said second drivelines in response to both said average speed difference and said maximum instantaneous speed difference exceeding said speed of said slower of said drivelines by respective predetermined values,

activating said lockup clutch to directly couple said first driveline and said second driveline.

9. The adaptive torque distribution system of claim 8 wherein said microcontroller includes a timer for maintaining activation of said lockup clutch for a second predetermined time period.

10. The adaptive torque distribution system of claim 8 wherein said first predetermined time period is three seconds.

11. The adaptive torque distribution system of claim 8 wherein said second predetermined time period is 5 minutes.

12. The adaptive torque distribution system of claim 8 wherein said transfer case further includes a planetary gear assembly for providing direct and reduced speed drive to said first output.

13. The adaptive torque distribution system of claim 8 wherein said lockup clutch includes a spring biased clutch collar for coupling said first and said second outputs.

14. The adaptive torque distribution system of claim 8 wherein said transfer case includes a chain drive sprocket disposed about said first output and said modulating clutch is disposed on one side of said modulating clutch and said lockup clutch is disposed on the other side of said modulating clutch.

15. The adaptive torque distribution system of claim 8 wherein said average speed difference is between 5% and 15% of said speed of said slower driveline and said maximum instantaneous speed difference is between 15% and 45% of said speed of said slower driveline.

16. A control system for an on demand vehicle drive system comprising, in combination,

a first sensor for sensing the speed of a first vehicle driveline,

a second sensor for sensing the speed of a second vehicle driveline,

microcontroller means for receiving signals from said first and said second sensors and

determining the instantaneous speed difference between said first driveline and said second driveline,

determining the average speed difference between said first driveline and said second driveline over a predetermined time period,

determining the speed of the slower of said first and second drivelines,

determining a threshold average speed which is greater than said slower shaft speed,

comparing said average speed to said threshold speed,

determining the maximum instantaneous speed difference during said predetermined time period,

determining a threshold maximum speed difference which is greater than said slower shaft speed,

providing a signal to engage a clutch to operatively couple said first and said second drivelines in response to both said average speed difference and said maximum instantaneous speed difference exceeding said threshold average and maximum speeds, respectively.

17. The control system of claim 16 wherein said time period is between 1.5 and 4.5 seconds.

18. The control system of claim 16 wherein said threshold average speed difference is between 5% and 15% of said speed of said slower driveline.

19. The control system of claim 16 wherein said maximum instantaneous speed difference is between 15% and 45% of said speed of said slower driveline.

20. The control system of claim 16 wherein said clutch is disengaged after a period of approximately five minutes.