Abstract: A drive system with one or more electrically driven axles, a transmission subsystem, which is drivingly coupled to a drive gearbox of each of the electrically driven axles, first and second motors, which are each drivingly coupled to the transmission subsystem and have different motor characteristics, and a controller. The drive gearbox of each axle transmits rotary power to an associated set of vehicle wheels. The controller controls the first and second motors responsive to at least a torque request. Over a significant portion of the operating range of the drive system, the controller is configured to vary the respective magnitudes of the rotary power provided by the first and second motors to satisfy the torque request in a manner that maximizes a combined efficiency of the motors in a predetermined manner.

Abstract: An electric motor with a stator that is formed of a plurality of distinct laminations. Each of the distinct laminations has a radially inner lamination edge, which borders a rotor aperture configured to receive a rotor therein, a radially outer lamination edge and a plurality of cooling apertures formed there through that are disposed radially between the radially inner and outer lamination edges. Each cooling aperture in a lamination forms part of a separate and distinct cooling channel that extends helically through the laminations about a rotational axis of the electric motor.

Abstract: A motor drive assembly having an electric motor with a rotor that includes a rotor shaft and a heat exchanger received in the rotor shaft. The heat exchanger has an insert body with an outer insert surface that is engaged to an inside surface of the rotor shaft. The insert body includes a plurality of segments. Each of the segments defines a first through-hole, and a plurality of second through-holes. Each of the segments is fixedly coupled to one another. A first flow passage extends through the first through-holes in the plurality of segments. Each of the second through-holes defines a portion of a corresponding second flow passage. The second flow passages are disposed concentrically about the first flow passage.

Abstract: A vehicle driveline component with a housing, a tube and a plurality of slugs. The housing has a tube mount with a body and a plurality of slug bores. The body defines a tube bore that extends along an axis. The slug bores are spaced circumferentially apart about and are formed through the body. Each of the slug bores intersects the tube bore. The tube is received in the tube bore. Each of the slugs is received into an associated one of the slug bores and is welded to the tube. Each of the slugs engages an inside surface of one of the slug bores to inhibit movement of the tube relative to the tube mount. The body has a wall thickness and each of the slugs engages the inside surface of one of the slug bores over a distance that is less than the wall thickness.

Abstract: An electric motor can include a stator body defining fluid channels extending axially for fluid communication between axial ends of the stator body. Conductive windings can form first loops extending axially outward from the first end of the stator body and second loops extending axially outward from the second end of the stator body. A first cap can be coupled to the first end of the stator body and can include a first wall. The first wall can be between the first loops and the channels. Pins can extend from a side of the first wall that is opposite the first loops. The second cap can be coupled to the second end of the stator body and include a second wall. The second wall can be between the second loops and the channels. Pins can extend from a side of the second wall that is opposite the second loops.

Abstract: A vehicle driveline component having a housing with a lube feed ramp between a bearing bore and a surface in which a first end of a lubricant channel is formed. The bearing supports a pinion for rotation about a first axis. The surface is transverse to the bearing bore. The lube feed ramp is defined by a warped planar surface that provides a transverse transformation between the bearing bore and the surface that is transverse to the bearing bore. The lube feed ramp is configured to direct a portion of a lubricant exiting the bearing into the first end of the lubrication channel.

Abstract: A power transmission device includes a friction clutch, an actuator with an output member, and a controller. The friction clutch is lubricated with a lubricant. The controller is configured to determine a current power state of the friction clutch and determine values for a plurality of thermal coefficients based on the current power state, a set of operation variables, and one or more multi-variable correlation data. The controller is further configured to determine an approximated temperature change of the lubricant based on the values of the plurality of thermal coefficients and a lubricant temperature model. The controller is further configured to determine an approximated lubricant temperature based on the approximated temperature change and a device ambient temperature, and to control operation of the actuator based at least on the approximated lubricant temperature.

Abstract: A power transmission device includes a friction clutch, an actuator, and a controller configured to determine an approximated temperature change of the friction clutch. The controller is configured to determine a current power state of the friction clutch, determine a desired power state change based on the current power state and a previous power state, determine a plurality of thermal coefficients based on a thermal coefficient model, the desired power state change, and a set of operation variables, determine an approximated temperature change of the friction clutch based on the thermal coefficients and a friction clutch temperature model, determine an approximated clutch temperature based on the approximated temperature change and a contemporaneous value of an device ambient temperature, and control operation of the actuator based at least on the approximated clutch temperature.

Abstract: A method of assembling a vehicle driveline component that includes: positioning a rotary component and first race member on a fixture such that the first race member is concentric with a first race of the component; offsetting the first race member along the rotational axis relative to the first race; providing an annular bearing arrangement having balls and spacers; positioning the arrangement such that the centers of the balls are along a loading cylinder disposed concentrically about the rotational axis; moving the arrangement so the balls seat in the first race and the centers are distributed along an installation circle that is: a) larger in diameter than the loading cylinder if the first race is an outer race of a bearing assembly; or b) smaller in diameter than the loading cylinder if the first race is an inner race of a bearing assembly.

Abstract: A vehicle driveline component with a housing, a rotary power transmission system, a lubricant and a lubrication de-aerator. The housing defines a cavity and a sump. The rotary power transmission system is received in the cavity and includes a plurality of gears that are in meshing engagement. The lubricant is received in the sump and is employed to lubricate the rotary power transmission system. The lubrication de-aerator is received in the housing and has at least one matrix of de-aeration cells that extend between an upper surface and a lower surface. Each of the de-aeration cells has a cell inlet, which is formed through the upper surface, and a cell outlet that is formed through the lower surface. Each of the de-aeration cells tapers between its cell inlet and its cell outlet.

Abstract: A helical sector gear having a body and a gear segment having a plurality of helical teeth. The gear segment has a toothed sector, on which all of the helical teeth are formed, and spacing segments on the opposite circumferential ends of the toothed sector. Each of the spacing segments has a circumferential surface, which is longer than a pitch of the helical teeth, and a radial surface that is formed in a helical manner that conforms to the helix angle of helical teeth. A die set for forming the helical sector gear and a related method are also provided.

Abstract: An axle assembly with a housing, an annular gear, a bearing, a differential, and a pair of output shafts. The housing has an annular hub. The annular gear is received in the housing. The bearing, which is a four-point angular contact bearing, supports the gear for rotation about an axis relative to the housing and has an inner bearing race, which is mounted on the annular hub, and an outer bearing race that is fixedly coupled to the annular gear. The differential is received in the housing and includes an input member, which is coupled to the annular gear for rotation therewith, and a pair of output members that are rotatable relative to the input member about the output axis. Each of the output shafts is coupled to an associated one of the output members for rotation therewith. One of the output shafts extends through the annular hub.

Abstract: An electric drive module having a motor and an inverter that are disposed in a housing The motor includes a stator, which has a plurality of sets of windings. The inverter has a plurality of power semiconductors, which are mounted into a retaining member, an end plate, which is sealingly coupled to the retaining member, and an inlet port that extends through the end plate. Sets of the semiconductor devices are electrically coupled to corresponding sets of the windings. Power terminals on the semiconductor devices are coupled to a heat sink. Fins on the heat sinks extend into an annular region that is adjacent to axial ends of the windings. At least one of the retaining member and the end plate is sealingly coupled to the housing assembly. The inlet port, the annular region and cooling passages in the stator are coupled in fluid communication.

Abstract: A stabilizer bar assembly having a pair of bar members and a clutch assembly with a first and second couplers, which are fixedly coupled to the bar members, a coupling sleeve and a rotary lock. The coupling sleeve matingly engages the first coupler. The coupling sleeve is movable along an axis between a first position, in which the coupling sleeve is disengaged from the second coupler to permit relative rotation between the stabilizer bar members about the axis, and a second position in which the coupling sleeve is engaged to the first and second couplers. The rotary lock has lock members that are fixedly coupled to the coupling sleeve and the second coupler. The lock members engage one another when the coupling sleeve is in the second position to inhibit relative movement about the rotational axis between the coupling sleeve and the second coupler.

Abstract: A method includes powder forging and machining a workpiece that is fractured to divide the workpiece into separate components. In a green form in which the workpiece is formed of compacted powdered metal and has a body that is generally shaped as a parallelepiped with a pair of end faces. The body defines a bore, a pair of V-notches and a pair of channels. The V-notches are formed into the bore parallel to the central axis of the bore and cooperate to define a separation plane. Each of the channels is formed in an associated one of the end faces at a location where the separation plane intersects the end face. During forging, the channels are closed but create a stress riser that aids in directing the fracture when the components are separated from one another.

Abstract: A front axle assembly with an axle housing that has first and second housing halves that each include a main housing portion, a tubular portion and a steering yoke. The main housing portion defines a cavity that houses at least a portion of a speed differentiation mechanism. The tubular portions are fixedly coupled to an associated one of the main housing portions and extend between the main housing portion and an associated one of the steering yokes. Each steering yoke is fixedly coupled to an associated tubular portion. An annular joint structure is formed where the first and second first housing halves are coupled to one another. The annular joint structure is formed about the rotary axis such that one of the first and second housing halves is inserted into the other one of the first and second housing halves along an insertion axis that is coincident with the rotary axis.

Abstract: A vehicle driveline component includes a case defining lever apertures, a coupling having a movable member that is movable along a movement axis between a first and a second position, a linear having a motor output member movable along the movement axis, and a plurality of levers. Each lever is disposed in an associated lever aperture and coupled to the case for pivoting motion about a respective lever pivot axis. The levers urge the movable member in a first direction along the movement axis from one of the first and second positions to the other one of the first and second positions in response to pivoting motion of the levers about the lever pivot axes caused by contact between the levers and the motor output member when the motor output member is driven in a second direction along the movement axis that is opposite the first direction.

Abstract: A method of assembling a vehicle driveline component that includes: positioning a rotary component and first race member on a fixture such that the first race member is concentric with a first race of the component; offsetting the first race member along the rotational axis relative to the first race; providing an annular bearing arrangement having balls and spacers; positioning the arrangement such that the centers of the balls are along a loading cylinder disposed concentrically about the rotational axis; moving the arrangement so the balls seat in the first race and the centers are distributed along an installation circle that is: a) larger in diameter than the loading cylinder if the first race is an outer race of a bearing assembly; or b) smaller in diameter than the loading cylinder if the first race is an inner race of a bearing assembly. A related tooling system is also provided.

Abstract: A process for forming a finished spiral bevel gear includes forging a blank to form a forging having near net-shaped spiral bevel teeth, machining the forging, coining the forging to form a coined spiral bevel gear with net-shaped spiral bevel gear teeth; heat treating the coined spiral bevel and finishing the heat treated, coined spiral bevel gear without machining the net-shaped spiral bevel gear teeth in a machining operation that forms chips.

Abstract: A method for improving thermal conduction in a stator having electrically conductive windings wound in a plurality of gaps formed between adjacent pairs of a plurality of teeth of the stator. A plurality of interstitial spaces are formed within each of the gaps during winding of the electrically conductive windings around the teeth. A plug is arranged within each one of the gaps to close off slot openings. A thermally conductive filler compound is injected into each gap under sufficient pressure to at least substantially fill the interstitial spaces within each gap and to at least substantially encapsulate the electrically conductive windings. The thermally conductive filler compound is then allowed to set.