State of the art

Open Differential with Forged PM Gears

GKN has introduced Forged PM differential bevel gears enabling the highest torque capacity in the smallest package. The count with unmatched strength-to-weight ratio and load carrying capabilities.

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SX8 Facespline (SX8-MTS-AAR)

SX8 sideshaft provides high efficiency, compact packaging and superior noise, vibration and harshness (NVH) properties. The design is suitable for high-powered front-wheel drive vehicles that require lower CO2 emissions and smoother driveability.

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SX8 Ballspline

SX8 sideshaft provides high efficiency, compact packaging and superior noise, vibration and harshness (NVH) properties. The design is suitable for high-powered front-wheel drive vehicles that require lower CO2 emissions and smoother driveability.

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Rear Drive Module (RDM) with ETM

GKN's RDM with Electronic Torque Manager intelligently distributes power to the rear wheels to produce our customers' desired drive performance.

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Power Transfer Unit (PTU)

GKN's range of Power Transfer Units helps direct torque from the engine to the rear drive module in the most effective and efficient way to produce unsurpassed all-wheel drive performance.

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PM Gears for Clutch Driving Actuation/cam actuation within the rear RDM

GKN Powder Metal gears enable perfect performance and longevity for the clutch actuation.

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PM Actuator Cam Discs for PTU

The cam rings are designed with specific high density areas and are formed net-shape. The sinter hardened powder metallurgy material provides high stress resistance.

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High Performance Twinster®

GKN's Twinster system enables instinctive torque vectoring and can be tuned to automakers' specific vehicle requirements, such as great off-road performance, optimum on-road stability or compelling track handling.

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PM Outer Disc Carrier

GKN´s disc carrier system uses high density powder metallurgy (PM) materials enabling an improved accuracy. The lubrication holes of the outer disc carrier are realized net-shape in powder metallurgy technology and support the efficiency of the system.

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PM Inner Disc Carrier

GKN´s disc carrier system uses high density powder metallurgy (PM) materials enabling an improved accuracy. The spline feature of the inner disc carrier is a unique joint systematic realizable net-shape in powder metallurgy only.

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High performance Twinster

High performance Twinster

Via hydraulic Twin clutch technology the GKN TWINSTER® integrates multiple functions in the drivetrain:

  • AWD "Hang-on" functionality
  • Limited slip differential functionality
  • Improved "Torque Vectoring" functionality by gear ratio Offset
  • Outstanding Vehicle Handling Performance
  • Different Modi available e.g: "Drift/Race/Launch"
  • Deep function integration and component modularity
  • Part of GKNs modular building block strategy for various driveline systems and vehicle platforms

PM Gears

GKN produces high-performing gears in PM (powder metal) for PTU and RDM systems which enable for perfect performance for the clutch actuation.
The powder metal manufacturing process with light-weight design guarantees highest performance with tight tolerances and superior quality which results in a longevity of the actuation system.

Benefits:

  • Low friction tooth surfaces
  • Superior strength and torque performance
  • Enables for weight savings and tailor-made designs
  • Tight net-shape tolerances

Cam Ring

Application details
This part is used in an electro-mechanically actuated clutch located in the rear axle of the car, that both biases drive torque and disengages thew all-wheel drive system. GKN is manufacturing the "Driven Cam Ring" (with teeth) and the "Fixed Cam Ring" (without teeth) for this system.

Advantages

  • Improved accuracy
  • Reduced machining by near net shape technology
  • Lower friction through design lubrication slots and PM material
  • Sinter hardening and tempering to avoid external heat treatment.

Customer Concept

  • Clutch Disc Carrier (inner and outer) with lubrications

GKN Design Solution

  • High density materials
  • Spline with lubrications holes
  • All features formed net-shape

Customer Concept

  • Clutch Disc Carrier (inner and outer) with lubrications

GKN Design Solution

  • High density materials
  • Spline with lubrications holes
  • All features formed net-shape

Application Details

At the heart of the differential is a set of four Differential Gears, also known as bevel gears: Two side gears that connect to the left and right axles and two pinions which transmit torque between the side gears. The Forged PM technology enables for smaller, high efficiency differentials with weight savings and superior material performance, especially for eDrive gearboxes and for eDrive AWD power transfer units.

Advantages

  • Highest torque capacity gears
  • Higher strength to weight ratio
  • Higher load carrying capability
  • Net shaped forged PM gear profile, spline and retaining groove

SX8 Ballspline

SX8 Ballspline

Fixed joint countertrackTM

  • countertrackTM principle: combination of "opposed track" concept with specific longitudinal track form to fulfill maximum angle requirements of up to 52o
  • 8 balls for robust steering of the opposed concept in smallest packaging
  • Stepped spline for improved fatigue strength
  • Contributes to vehicle CO2 and fuel consumption

Plunge Unit

  • Extreme plunge capability independent from articulation angle
  • Superior NVH performance independent from articulation angle

Benefits

  • Maximum articulations angle of up to 52o on wheel side
  • Maximum articulation angle of 35o (and more) on differential side
  • Maximum running angle of 10o and more
  • Reduction of losses by 50-60% compared to conventional Rzeppa type joints
  • Plunge capacity of up to 70mm

Power Transfer Unit (PTU)

Power Transfer Unit (PTU)

Front part of an adaptive four-wheel drive system, which disconnects / reconnects the hang-on driveline whenever needed

  • Single or two stage layouts to fit any packaging environment
  • Synchroniser disconnect system actuated by hydraulic (alternatively eMotor)
  • Breaking system to bring the propshaft to a complete stand still
  • Very low driveline drag torque in disconnect mode - PTU <1Nm
  • Fuel Consumption benefit of 0.4I / 100km
  • Deep function integration and component modularity
  • Part of GKNs modular building block strategy for various driveline systems and vehicle platforms

 

Rear Drive Module (RDM) with ETM

Rear Drive Module (RDM) with ETM

Rear part of an adaptive four-wheel-drive system, which disconnects / reconnects the hang-on driveline whenever needed.

  • Side mounted clutch controlled by eMotor ramp actuator [ETM®] (optional: hydraulic)
  • Open Differential
  • DTF (direct torque flow) propshaft interface
  • Low driveline drag torque in disconnect mode (RDU: <2Nm)
  • Fuel consumption benefit of complete AWD disconnect driveline up to 0.3I / 100 km
  • Deep function integration and component modularity
  • Part of GKNs modular building block strategy for various driveline systems and vehicle platforms

SX8 Facespline (SX8-MTS-AAR)

SX8 Facespline (SX8-MTS-AAR)

Design Features - SX8

  • CountertrackTM principle: combination of “opposed track” concept with specific longitudinal track form to fulfill maximum angle requirements of up to 52°
  • 8 balls for robust steering of the opposed concept in smallest packaging

Design Features - MTS

  • Adapted natural bending frequency
  • Adapted torsional stiffness
  • Lowest weight

Design Features - AAR

  • Compact roller design
  • 26° maximum articulation angle
  • 54mm maximum plunging distance

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