Abstract: A gear box assembly as used in an inverted portal axle or transfer case includes a drive gear and at least one driven gear in meshing engagement with the drive gear at a contact point. A gear housing closely surrounds portions of an outer circumference of the drive and driven gears to form a baffle area. The gear housing includes an discharge orifice that is located near the contact point and a fluid gallery that extends from the discharge orifice to other locations within the gear housing. As the drive gear drives the driven gear, fluid is pumped into the discharge orifice and through the fluid gallery to fluid outlets positioned at desired locations to lubricate other gear box components. Radial inlets with elongated chamfers and stator vanes can be formed within the gear housing to draw air ingested during pumping away from the discharge orifice. Additionally, a bypass loop can be used to scavenge unwanted air ingested into meshing gear teeth.

Abstract: An axle system includes an axle shaft offset located within an axle center beam housing. The axle shaft is located in a recess in a top wall of the axle center beam shaped with slopes to maximize clearance to the bottom of the vehicle floor panels. The pneumatic brake cylinders define a cylinder axis angled within an angular range from a generally vertical orientation for enhanced packaging.

Abstract: A drive unit for a vehicle wheel assembly includes an input gear set driven by an electric motor, a planetary gear set driven by the input gear set, and an output shaft driven by the planetary gear set. An adapter is used to attach a wheel rim and a brake component for rotation with the output shaft, which is rotatably supported by a wheel bearing. The input gear set and the planetary gear set are positioned outboard of the electric motor and inboard of the brake component. The brake component can be easily removed without requiring removal of the planetary gear set or any wheel bearings. Only the wheel rim and the adapter have to be removed in order to remove the brake component.

Abstract: An automotive vehicle drive unit assembly which is located near the sides of a vehicle includes a first driving axle shaft, a second driving axle shaft, a first gear box, a second gear box, a first electric motor, and a second electric motor. The first driving axle shaft drives a first wheel hub of the vehicle and the second driving axle shaft drives a second wheel hub. Together the first and second driving axle shafts define an axis of rotation about which the first and second wheel hubs rotate. The first gear set drives the first wheel and the second gear set drives the second wheel. A first electric motor is mounted in an angular relationship relative to the axis of rotation and drives the first gear set. A second electric motor is mounted in an angular relationship relative to the axis of rotation and drives the second gear set. A plurality of electric motors can be used to drive each wheel hub.

Abstract: A tire inflation system for a portal drive axle assembly includes fluid flow passages that are formed within rotating wheel shafts, which drive a pair of wheel end assemblies. The portal drive axle assembly includes a driving input that drives a pair of axle shafts. A wheel gear assembly operably couples each axle shaft to the respective wheel shaft. The wheel gear assemblies transfer the driving force from the axle shafts to the wheel shafts, which are positioned at different vertical location relative to the axle shafts. A first end of each wheel shaft is in fluid communication with a vehicle air supply and a second end of each wheel shaft is in fluid communication with a tire assembly. Seal assemblies are mounted for rotation with the wheel shaft at the first end of the wheel shafts.

Abstract: An independent suspension undercarriage module includes a first subframe segment and a second subframe segment. The subframe is manufactured of a composite material to provide a truss-like structural unibody which is mounted as a unit to the underside of a low floor vehicle through a plurality of resilient dampers. Passengers are thereby provided with a secondary vibration isolation structure separate from the suspension systems which filter out high frequency content generated by the suspension systems.

Abstract: An inverted portal drive axle includes an off-center driving input that is coupled to first and second axle shafts. The first axle shaft drives a first gear box that is coupled to a first wheel assembly. The second axle shaft extends underneath a vehicle floor and drives a second gear box that is coupled to a second wheel assembly. An axle housing extends between the first and second gear boxes. The second axle shaft includes an exposed central portion that is positioned directly between the vehicle floor and the axle housing. Seal assemblies seal first and second ends of the second axle shaft to the axle housing.

Abstract: An axle housing assembly includes web members that define lubricant containment chambers within an interior space of a housing. Each lubricant containment chamber contains a fixed amount of lubricant. The containment chambers defined within the housing confine lubricant to critical areas to reduce the amount of lubricant required within the housing to properly lubricate internal components.

Abstract: An independent suspension undercarriage module includes a first subframe segment and a second subframe segment. The subframe is manufactured of a composite material to provide a truss-like structural unibody which is mounted as a unit to the underside of a low floor vehicle through a plurality of resilient dampers. Passengers are thereby provided with a secondary vibration isolation structure separate from the suspension systems which filter out high frequency content generated by the suspension systems.

Abstract: A steering system for a vehicle is provided that includes a steering knuckle which is rotatable about an axis. The steering knuckle includes an upper attachment point and a lower attachment point. The attachment points define the steer axis. A rotational drive unit is connected to the steering knuckle for rotating the steering knuckle about the steer axis. A control module receives a steering input corresponding to the desired Ackerman angle and commands the rotational drive unit to rotate the steering knuckle about the axis to the desired Ackerman angle. Rotational drive units for each side of the vehicle ensure that the wheels are turned to the appropriate Ackerman angle for each wheel. The rotational drive unit may include an electric motor, or a pneumatic or hydraulic pump. In one preferred embodiment, the rotational drive unit includes a fluid housing and the shaft connected to the steering knuckle. The shaft includes a vane extending therefrom and into the housing.

Abstract: A steering system for a vehicle is provided that includes a steering knuckle which is rotatable about an axis. The steering knuckle includes an upper attachment point and a lower attachment point. The attachment points define the steer axis. A rotational drive unit is connected to the steering knuckle for rotating the steering knuckle about the steer axis. A control module receives a steering input corresponding to the desired Ackerman angle and commands the rotational drive unit to rotate the steering knuckle about the axis to the desired Ackerman angle. Rotational drive units for each side of the vehicle ensure that the wheels are turned to the appropriate Ackerman angle for each wheel. The rotational drive unit may include an electric motor, or a pneumatic or hydraulic pump. In one preferred embodiment, the rotational drive unit includes a fluid housing and the shaft connected to the steering knuckle. The shaft includes a vane extending therefrom and into the housing.