Creating Innovation in Torque Transfer Systems Through Optimization of Powder Metallurgy Components

This paper will describe the BorgWarner Interactive Torque Management (ITM) system for FWD based AWD systems as well as the utilization of P/M technology for critical components within this system. The ITM is an electro-mechanical coupling device. The device consists of an electromagnet, ball ramp and wet clutch system. The system can be mounted anywhere in the drive line as well as integrated into components such as transfer cases and transaxles. The clutch actuation force is dependent on the current applied to the electromagnetic coil, providing a truly variable torque transfer device. The decision to make extensive use of P/M technology in the structural portion of this system was based on the net shape capability and weight reduction combined with the ability to chose from a wide range of engineered materials that resulted in the most economical total system package.