TECHNICAL FIELD

[0001] The present invention relates to a six-speed front wheel drive (FWD) automatic transmission having a selectable one-way clutch that is selectively engaged in one or more predetermined operating modes.

BACKGROUND OF THE INVENTION

[0002] In certain front wheel drive (FWD) vehicle transmissions, such as in a six- speed FWD automatic transmission of the type known in the art having three gear sets and five torque transmitting elements or clutches, one of the five clutches can be applied in engine braking first gear, manual low, and reverse transmission operating modes. Therefore, such a clutch referred to functionally as a "low and reverse clutch", and is selectively engaged or disengaged to enable the operating modes listed above. The input member of the low and reverse clutch can also be selectively connected to a conventional one-way clutch in order to selectively prevent relative rotation of members of two of the gearsets of the transmission when engaged.

[0003] In all other forward gears, i.e., in second-through-sixth gear in the conventional six-speed FWD automatic transmission mentioned above, reaction torque does not act on the one-way clutch due to the application or engagement of one or more of the four other clutches in the transmission. Consequently, the one-way clutch rotates freely or "freewheels", that is, with relative motion being present between the input and output members of the low and reverse clutch. Moreover, the relative speed of such rotation tends to increase with each successive gear change.

[0004] As is known in the art, a disengaged multi-plate clutch can produce drag or spin losses whenever relative motion is present between the input and output members of the multi-plate clutch. The spin losses can in turn reduce fuel economy. As the low and reverse clutch is disengaged in all of the forward gears of the FWD transmission described above, except for engine braking first gear and manual low, and as most of the time such a transmission operates in one of these forward gear ratios, a modest but measurable amount of the spin loss occurs when the low and reverse clutch is disengaged.

SUMMARY OF THE INVENTION

[0005] Accordingly, a front-wheel drive (FWD) vehicle having a six-speed FWD automatic transmission is provided. The transmission includes five torque -transmitting mechanisms or clutches and three gear sets. The transmission includes a valve body assembly (VBA) and a two-mode selectable one-way clutch (SOWC) as one of the five clutches. Within the scope of the invention, the SOWC replaces the low and reverse clutch and the conventional one-way clutch described above, while a conventional VBA is modified to include a SOWC control mechanism adapted to select between the two modes of the SOWC, forward and reverse, in the engine braking first gear, reverse, and in a manual low transmission gear speeds.

[0006] When a transmission control algorithm commands or signals a mode change or shift to one of the engine braking first gear, reverse, or manual low gears, pressurized fluid enters the piston bore. The piston moves from the top of the piston bore to the bottom of the piston bore, thus compressing the return spring and simultaneously moving the actuator mechanism to the second position. When the transmission algorithm commands or signals a mode change or shift to one of the second-through-sixth gears, and first gear other than manual low and engine braking, pressurized fluid exits the piston bore, and the return spring moves the piston to the top of the piston bore. [0007] The VBA is located to the side of the rotating torque elements of the transmission, and is aligned with and secured to a lateral or side surface of the transmission case. The control mechanism portion of the VBA includes a bore housing on or within a side surface the VBA, with the bore housing defining a piston bore as well as a spring bore. The piston bore contains a hydraulically-actuated piston, the movement of which ultimately moves an interconnected actuator mechanism or linkage which controls the rotational movement of a selector plate within SOWC. The centerline of the piston bore is perpendicular to the axis of rotation of the transmission, and is ideally located in the same plane as the rotational arc of the selector plate of the SOWC, although other planar configurations are also usable within the scope of the invention. [0008] The piston is in continuous contact with or connected to the actuator linkage, which can be configured as a plate, a rod, or any other suitable linkage. The actuator linkage engages the selector plate of the SOWC by retaining or engaging a shift lever that is attached to the selector plate, or that is an appendage thereof. An energy storage device, such as a compression spring or other style of return spring, exerts a return/biasing force on the piston to bias the piston in a first position, with fluid pressure to the VBA moving the piston to a second position. The first position corresponds to a first angular position of the selector plate of the SOWC, which is maintained only during one or more predetermined forward operating modes, i.e., the first-through-sixth gears, other than engine braking first gear and manual low. The second corresponds to a second angular position of the selector plate, which is maintained only during one or more other operating modes, i.e., the engine braking first gear speed, the reverse gear speed, and the manual low gear speed.

[0009] A method for reducing spin losses in a six-speed FWD automatic transmission is also provided. The transmission has a SOWC that is controlled via a selection mechanism integrated into the VBA, with the SOWC replacing the conventional low and reverse clutch assembly and one-way clutch. The method includes detecting, sensing, or otherwise determining a shift command signaling a requested shift of the transmission to a reverse, engine braking, or manual low speeds, and admitting pressurized fluid into the VBA described above in response to the shift command. Pressurized fluid moves the piston in one direction, and thus moves the shift lever of the SOWC to lock a driving member of the transmission to a stationary member. In this manner, spin losses in the transmission are reduced.

[0010] The above features and advantages, and other features and advantages of the present invention are readily apparent from the following detailed description of the best modes for carrying out the invention when taken in connection with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] FIGURE 1 is schematic illustration of a vehicle in accordance with the invention;

[0012] FIGURE 2 is partial cutaway view of a six-speed FWD automatic transmission in accordance with the invention;

[0013] FIGURE 3 is an schematic exploded perspective view of the transmission of Figure 2;

[0014] FIGURE 4 is a cutaway view of a portion of the transmission of Figures 2 and 3; and

[0015] FIGURE 5 is a schematic perspective view of a control mechanism usable with the transmission of Figures 2-4.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0016] With reference to the Figures, wherein like reference numerals refer to like or similar components throughout the several figures, and beginning with Figure 1, a vehicle 10 includes an engine (E) 12, such as a gasoline, diesel, or alternative fuel internal combustion engine, although other power sources may be used within the scope of the invention. For example, the engine 12 could be also or alternatively configured as a fuel cell or battery powered electric motor, or another alternative power source to the conventional internal combustion engine. The engine 12 is connected to an automatic transmission (T) 14 via an input member or shaft 11. The transmission 14 transmits a rotational force or torque to an output member or shaft 13 , which ultimately propels the vehicle 10 via a set of road wheels 17.

[0017] Referring to Figure 2, the transmission 14 has three gear sets, which are labeled Gl, G2, and G3 is Figure 2 for clarity. The transmission 14 also has five clutches, four of which are labeled C1-C4 for clarity, with the fifth clutch being configured as a two-mode selectable one-way clutch (SOWC) 16. The gear sets Gl, G2, and G3 respectively are an output gear set, an input gear set, and reaction gear set. The gears sets G1-G3, the clutches Cl-4, and the SOWC 16 can be selectively engaged and disengaged alone or in various combinations to provide a six-speed front-wheel drive (FWD) functionality, as will be understood by those of ordinary skill in the art. [0018] The transmission 14 includes an outer housing or case 20, as well as a valve body assembly (VBA) 22 having an integrated SOWC control mechanism 24, as described in detail below with reference to Figures 4 and 5. As used herein, the term "integrated" refers to the relative configuration of the SOWC control mechanism 24 and the VBA 22, with the control mechanism 24 being a portion or integral part of the VBA 22. The control mechanism 24 selectively controls or actuates the SOWC 16 based on one or more predetermined operating modes of the transmission 14, as described below. [0019] As will be understood by those of ordinary skill in the art, a SOWC is similar to a conventional one-way clutch in basic operation. However, depending on the details of the design, a SOWC is also capable of producing a mechanical connection between a given "driving" member, such as an input race or a first coupling plate, to a second independent "driven" member, such as an output race or second coupling plate in one or both rotational directions. Also depending on the design, a SOWC can overrun in one or both directions of rotation. Typically, a SOWC contains a selector ring or plate that when moved to a second or a third position, controls or selects the various operating modes of the SOWC.

[0020] The mechanical means used to lock a SOWC such as the SOWC 16 of

Figure 1 are varied and well known. For example, a SOWC may use rollers, sprags, rockers, struts, or another suitable torque -transmitting element, a plurality of which are positioned between the input and output races or members of the SOWC 16. Depending on the particular type or style of SOWC used and the required direction of rotation, each race of the SOWC may contain unique surface features, such as windows or strut wells, each being suitable for engaging one or more of the torque-transmitting elements positioned therein in order to selectively enable various clutch operating modes. [0021] In the transmission 14 of Figure 2 in particular, the SOWC 16 has an input race or driving member 26 and an output race or driven member 28. The driven member 28 is affixed or grounded to the case 20, such as by using a plurality of splines 33 with mating splines 37 in the case 20. The driving member 26 is connected to the reaction gear set G3, such as but not limited to a carrier member of a planetary gear set. The SOWC 16 can selectively transmit torque between the driving member 26 and the driven member 28 in one rotational direction. Reversing the direction of rotation of the driving member 26 in turn enables the driving member 26 to freewheel with respect to the driven member 28.

[0022] The VBA 22 is positioned adjacently to and laterally with, i.e., next to, the axis or centerline 27 of the SOWC 16, as best shown in Figure 2, such that fluid pressure admitted to the VBA 22 moves the shift lever 40 of the SOWC 16 in one direction, ultimately engaging the SOWC 16 in a reverse mode of the two-mode SOWC 16. Discharge of the fluid pressure from the VBA 22 moves the shift lever 40 in another direction, ultimately disengaging the SOWC 16 to enable a forward operating mode, usable with the first-through-sixth gears of the transmission 14, other than manual low and engine braking first gear speeds. Thus, the SOWC 16 can be engaged in three transmission operating modes: reverse gear speed, manual low gear speed, i.e., when an operator moves a shift lever to the "L" position, and engine braking first gear speed, i.e., which occurs for short time when the shift lever is in the "D" position and the transmission 14 is launching the vehicle 10 of Figure 1 from a standstill in first gear up to approximately 5 miles per hour.

[0023] Referring to Figure 3, an exploded view of a portion of the transmission

14 of Figure 2 shows the general orientation of the VBA 22, the case 20, and the SOWC 16. The VBA 22 with its control mechanism 24 are positioned adjacently to a lateral side 31 of the case 20 (see Figure 2), which can include a cavity defined by the case 20 in order to minimize packaging space. The case 20 includes a center or main bore 23 having a centerline or axis 27, which is the axis of rotation of the transmission 14, with the SOWC 16 being positioned at least partially within the main bore 23. The driven member 28 is grounded or connected to the case 20, such as by engaging the various splines 33 of the driven member 28 with a plurality of mating splines 37 of the case 20 within the main bore 23.

[0024] An extension, arm, or shift lever 40 of the SOWC 16, which is integrally formed with or operatively connected to a selector ring or plate (not shown) of the type known in the art, extends radially-outward through a slot 41 in the case 20. The shift lever 40 can be configured with a shaped end 44 as described below, with the shaped end being shaped, sized, or otherwise configured so as to engage an actuator linkage 50, such as a rod, plate, or other suitable linkage of the control mechanism 24. While in Figures 3 and 4 a plate embodiment is shown, Figure 5 shows an alternate rod configuration, each being usable within the scope of the invention depending on the available packaging limitations. The SOWC 16 may include a retaining ring 48 for securing the SOWC 16 within the case 20 within a desired tolerance.

[0025] Referring to Figure 4, the VBA 22 is shown in a partial cutaway perspective view to show internal detail of the control mechanism 24 portion thereof. As described above, the control mechanism 24 is an integral portion of the VBA 22, and includes a bore housing 56. The bore housing 56 is formed integrally with, or is otherwise connected to, a side or lateral surface 57 of the VBA 22, with the VBA 22 having a spring end 62 and a piston end 64 generally describing the separate functional portions or ends of the VBA 22. At the piston end 64 is a piston bore 58 containing an apply piston 66, and at the spring end 62 is a spring bore 59 containing a return spring 76. [0026] The piston bore 58 is machined to receive the apply piston 66 in a close- fitting but freely movable manner. The piston 66 is selectively actuated in the direction of arrow A by an inlet of pressured fluid, represented in Figure 4 by the arrow I, through an inlet port 68. Likewise, an exhaust port 74 is provided in the lower end 78 of the piston bore 58 to allow any trapped fluid to escape, as indicated by the arrow O, thereby preventing the piston 66 from becoming hydraulically locked. A stop feature 70, such as but not limited to a bumper or stop pin, prevents the piston 66 from blocking the flow of hydraulic fluid into the inlet port 68. Within the scope of the invention, a similar feature could also be incorporated into a piston bore plug 72 instead of the piston 66. [0027] The piston 66 is in direct continuous contact with and/or operatively connected to the actuator mechanism 50, which is itself connected to the shift lever 40, and ultimately to the SOWC 16, as best shown in Figure 5 and described below. Due to packaging limitations, the actuator linkage 50, the piston 66, and a return spring 76 can be positioned in different planes as shown in Figure 4, or alternately can be coplanar as shown in Figure 5. However configured, movement of the piston 66 in the direction of arrow A pushes or moves the actuator linkage 50 in the same direction. When the inlet fluid pressure is discontinued, the return spring 76 within the spring bore 59 pushes or moves the piston 66 in the direction of arrow B, a movement that exhausts or discharges fluid back through the inlet port 68.

[0028] The stroke length of the piston 66 is preferably slightly shorter than the chordal length of the total rotational angle of the shift lever 40 (see Figure 5) at a centerline 87 of the spring bore 59. If the piston stroke is greater than the chordal length, certain components in the SOWC 16 such as the selector plate (not shown) would become the reaction members for the apply force in the direction of arrow A from the piston 66, as well as the return force in the direction of arrow B from the return spring 76. By minimizing the reaction forces transmitted to the SOWC 16, wear is reduced, which potentially prolongs the life of the SOWC 16. Conversely, if the piston stroke was much less than the aforementioned chordal length, the mode changes in the SOWC 16 may not be fully or optimally implemented.

[0029] Still referring to Figure 4, the actuator linkage 50 is shown in an exemplary configuration as a flat bar or plate, and is slidingly supported on one end 91 A by a guide pin 72 disposed within the piston bore 58. The actuator linkage 50 is also slidingly supported at another end 9 IB by a spring seat 79 provided in the spring bore 59. A slot, hole, or other suitable retention feature 32 defined by the actuator linkage 50 engages the shaped end 44 of the shift lever 40 of Figures 2 and 5 such that any movement of the piston 66 in the direction of arrow A moves the actuator linkage 50 in the same direction. This motion ultimately moves the shift lever 40, thereby actuating or shifting the SOWC 16 (see Figures 2 and 5).

[0030] The return spring 76, which can be configured as a helical compression spring or other suitable return mechanism, is radially-restrained within the spring bore 59. A retaining collar 80, a portion of which is shown in Figure 4, and one or more fasteners 35 can be used to secure the spring support housing 52. The spring support housing 52 is suitably configured, such as by using a flange 29, to prevent the spring support housing 52 from being displaced by the reaction force from the return spring 76. [0031] The return spring 76 is in contact with the spring seat 79 on the actuator linkage 50, and with a bottom 45 of the spring bore 59. The spring force from the return spring 76 urges the actuator linkage 50 into contact with the piston 66. The piston 66 moves within the piston bore 58 until a stop feature 70 on the piston 66, such as a bumper or pin, contacts a piston bore plug 72. The bore plug 72 closes one end of the piston bore 58, and is secured in place by a plug retaining ring 90. The piston bore plug 72 also acts as a hard stop to limit piston travel in the upward direction, i.e., the direction of arrow B. The plug retaining ring 90 can also provide the second reaction member for the spring force of the return spring 76.

[0032] Referring to Figures 4 and 5 together, when a mode change is required of the SOWC 16, and in particular when the SOWC 16 is to be applied or engaged, pressurized fluid from a transmission pump (not shown) or a dedicated pump is directed into the fluid control channel 88, and then enters the piston bore 58 through the port 68. As any hydraulic force acting in the direction of arrow A on the piston 66 exceeds a return force provided in the direction of arrow B by the return spring 76, the piston 66 and the actuator linkage 50 move together towards the spring end 62 of the VBA 22 until the piston 66 contacts the wall 82 at the bottom of the piston bore 58. Because the shaped end 44 of the shift lever 40 is engaged with or retained in the retention feature 32, the shift lever 40 and the selector plate (not shown) of the SOWC 16 each rotate around the rotational axis 27 of the SOWC 16 (see Figure 5) to a second angular position 96, thereby affecting the required mode change or shift in the SOWC 16. Once positioned at the second angular position 96, the SOWC 16 is set or engaged in a reverse/forward low mode, wherein no relative motion is possible between the driving member 26 and the driven member 28 (see Figures 2, 3, and 5) in either rotational direction. [0033] To return the SOWC 16 to its other mode, i.e., the forward mode, pressurized fluid is exhausted from the fluid control channel 88. As the return force provided by the return spring 76 exceeds that of the exhausting fluid, the piston 66 and the actuator linkage 50 move in the direction of arrow B toward the piston end 64 of the VBA 22. [0034] Referring to Figure 5, the bore housing 56 has a centerline 89 in the same plane as the rotational arc of the selector plate (not shown) of the SOWC 16. The first and second angular positions 94 and 96 of the selector plate (not shown) of the SOWC are substantially equidistant from the horizontal centerline or axis 85 of the SOWC 16. To facilitate assembly into the case 20 (see Figure 2), the shift lever 40 and/or the shaped end 44 thereof can be configured so as to be removable from the selector plate (not shown) and the SOWC 16. For example, the shift lever 40 can be inserted into a groove or slot in the selector plate, with the shift lever 40 prevented from moving once secured or retained to the actuator mechanism 50.

[0035] In this manner, spin losses are reduced in the transmission in the first- through-sixth gear transmission operating modes. Also, the weight and packaging space of the transmission is reduced, as all of the conventional low and reverse clutch components are eliminated, such as a clutch plate assembly, a clutch apply piston and a clutch return spring. The reverse mode of the SOWC 16 replaces the functionality of the low and reverse clutch, while the forward mode of the SOWC 16 behaves in the same manner as the one-way clutch it replaces.

[0036] While the best modes for carrying out the invention have been described in detail, those familiar with the art to which this invention relates will recognize various alternative designs and embodiments for practicing the invention within the scope of the appended claims.