Method of determining and predicting a ball loss in a ball and ramp assembly

1. A method of detecting a ball loss condition, comprising:

providing a drive unit assembly, wherein said drive unit assembly comprises one or more clutch pack assemblies, one or more ball and ramp assemblies and one or more motors with a motor output shaft drivingly connected to at least a portion of said one or more ball and ramp assemblies;

running one or more actuation profiles with said one or more motors;

measuring an amount of motor current used by said one or more motors during said one or more actuation profiles ran;

measuring a position of said motor output shaft of said one or more motors during said one or more actuation profiles ran;

generating one or more motor current versus motor output shaft position plots having one or more characteristic curves based on said amount of motor current measured and said position of said motor output shaft measured during said one or more actuation profiles ran;

comparing said amount of motor current measured and said motor output shaft position measured for one or more of said one or more actuation profiles ran to said one or more characteristic curves generated; and

identifying an occurrence of a ball loss condition within said one or more ball and ramp assemblies of said drive unit assembly based on said comparison of said amount of motor current measured and said motor output shaft position measured for one or more of said one or more actuation profiles ran to said one or more characteristic curves generated.

2. The method of detecting a ball loss condition of claim 1 , wherein said one or more motors is one or more electric motors, one or more actuators, one or more linear actuators, one or more pneumatic actuators, one or more hydraulic actuators, one or more electro-mechanical actuators and/or one or more electro-magnetic actuators.

3. The method of detecting a ball loss condition of claim 1 , further comprising the step of:

providing one or more first sensors, wherein said one or more first sensors are disposed radially outboard from said motor output shaft and are operably configured to measure said position of said motor output shaft.

4. The method of detecting a ball loss condition of claim 3 , wherein said one or more first sensors are one or more Hall Effect sensors, one or more Hall sensors, one or more rotary encoders, one or more proximity sensors and/or one or more capacitive displacement sensors.

5. The method of detecting a ball loss condition of claim 1 , further comprising the step of:

providing one or more second sensors, wherein said one or more second sensors are operably configured to measure said amount of motor current used by said one or more motors.

6. The method of detecting a ball loss condition of claim 5 , wherein said one or more second sensors are one or more Hall Effect current sensors, one or more Hall current sensors and/or one or more resistors.

7. The method of detecting a ball loss condition of claim 1 , further comprising the step of:

averaging said amount of motor current measured and said motor output shaft position measured during said one or more actuation profiles ran.

8. The method of detecting a ball loss condition of claim 1 , further comprising the step of:

performing a timing error check, wherein said timing error check is performed if said amount of motor current measured for one or more of said one or more actuation profiles ran is less than said characteristic amount of current determined for that motor output shaft position of said one or more characteristic curves, wherein said timing error check monitors and/or compares said amount of motor current measured for a pre-determined amount of time to eliminate false positive ball loss condition identifications.

9. The method of detecting a ball loss condition of claim 1 , further comprising the step of:

running one or more ball recapture procedures, wherein during said one or more ball recapture procedures ran includes aligning a home position of a first plate of said one or more ball and ramp assemblies with a home position of a second plate of said one or more ball and ramp assemblies.

10. The method of detecting a ball loss condition of claim 1 , further comprising the step of:

determining an amount of force applied by said one or more ball and ramp assemblies onto said one or more clutch pack assemblies of said drive unit assembly during said one or more actuation profiles ran.

11. The method of detecting a ball loss condition of claim 10 , further comprising the step of:

checking for a ball loss condition based on an amount of force and position requests compared to a pre-determined threshold.

12. The method of detecting a ball loss condition of claim 1 , further comprising the steps of:

sending out a flag to indicate a potential ball loss condition within said one or more ball and ramp assemblies;

monitoring an amount of time said flag has been sent out to indicate a potential ball loss condition; and

monitoring a number of times a potential ball loss condition flag has been sent out within a pre-determined amount of time in order to eliminate false positive ball loss condition identifications.

13. The method of detecting a ball loss condition of claim 1 , further comprising the steps of:

providing one or more control units having one or more data processors and one or more second sensors, wherein said one or more second sensors are operably configured to measure said amount of motor current used by said one or more motors during said one or more actuation profiles ran;

providing one or more first sensors, wherein said one or more first sensors are disposed radially outboard from said motor output shaft, and are operably configured to measure said position of said motor output shaft;

sending said an amount of current used by said one or more motors during said one or more actuation profiles ran and measured by said one or more second sensors to said one or more data processors of said one or more control units; and

sending said motor output shaft position measured during said one or more motor actuation profiles ran by said one or more first sensors to said one or more data processors of said one or more control units.

14. The method of detecting a ball loss condition of claim 13 , wherein said ball loss condition is identified by said one or more data processors of said one or more control units.

15. The method of detecting a ball loss condition of claim 1 , further comprising the steps of:

providing one or more control units having one or more second sensors, wherein said one or more second sensors are operably configured to measure said amount of motor current used by said one or more motors;

providing a vehicle bus having one or more data processors;

sending said motor output shaft position measured during said one or more motor actuation profiles ran by said one or more first sensors to said one or more data processors of said vehicle bus; and

sending said an amount of current used by said one or more motors during said one or more actuation profiles ran and measured by said one or more second sensors to said one or more data processors of said vehicle bus.

16. The method of detecting a ball loss condition of claim 15 , wherein said ball loss condition is identified by said one or more data processors of said vehicle bus.