Abstract: An electric vehicle is comprised of a first driveline equipped with a first electric drive axle assembly having a first electric drive module configured to drive a pair of first wheels, a second driveline equipped with a second electric drive axle assembly having a second electric drive module configured to drive a pair of second wheels and a vehicle control system controlling coordinated operation of the first and second electric drive modules to generate tractive drive torque transmitted to the wheels and provide low-radius turning functionality.

Abstract: A flexible wire support structure extends between an axle and an inverter for an electric vehicle. The inverter is fixed relative to the vehicle body and the axle is moveable relative to the inverter during vehicle use. A wire extends between the inverter and the axle through a channel defined by the wire support structure. The wire support structure is attached at opposite ends to a first and second support structure, each of which allow pivoting of the flexible wire support structure in response to movement of the axle relative to the inverter. The wire support structure has a limited bend radius in response to movement of the axle, and blocks the wire extending within the support structure from being bent to a tight radius, thereby protecting the wire.

Abstract: A power transfer assembly for a vehicle including an input shaft, at least one output shaft, and at least one clutch configured to perform at least one of changing a gear ratio between the input shaft and the output shaft, and coupling the input shaft with a second output shaft of the at least one output shaft. An actuator assembly is configured to activate the at least one clutch. The actuator assembly has a motor with an output drive, a worm gear coupled with the output shaft, and a spur gear meshed with the worm gear and coupled with the at least one clutch for activating the at least one clutch. The worm gear and the spur gear have opposite gear hands.

Abstract: An electric machine is provided that includes a stator defining a rotor chamber and a plurality of stator slots disposed circumferentially about the stator. The stator includes a plurality of phase groups each including a plurality of circuits. Each circuit includes a plurality of winding sets of a plurality of phase conductors connected in series for carrying an alternating current voltage. A rotor is disposed in the rotor chamber for rotating relative to the stator. The phase conductors are laid in a plurality of layers of the plurality of stator slots. Stator slots that include phase conductors carrying different phases are shared slots and stator slots that include phase conductors carrying the same phase are same slots. The circuits are arranged with balanced quantities of same slots and shared slots for reducing stator losses at high rotational speeds of the rotor relative to the stator.

Abstract: A pumpless lubrication system for a power transfer assembly equipped with a hypoid gearset having a ring gear and a hollow pinion unit. Lubricant splashed from one of the ring gear and the pinion unit is collected in a collection reservoir and directed through a conduit unit into the hollow pinion unit. The lubricant is delivered to a torque transfer coupling for lubricating and cooling a multi-plate clutch pack.

Abstract: An active transfer case is equipped with a multi-plate clutch assembly, a clutch actuation mechanism configured to selectively engage the clutch assembly, a power-operated clutch actuator configured to control actuation of the clutch actuation mechanism, a power-operated actuator brake associated with the power-operated clutch actuator, and a control system configured to control actuation of the clutch actuator and the actuator brake while employing a preemptive check of the functionality of the actuator brake.

Abstract: A method for joining components of a vehicle drive axle assembly. The method includes heating an axle housing to a first predetermined temperature and cooling a pinion cartridge to be installed with the housing to a second predetermined temperature. Removing the axle housing from exposure to the first predetermined temperature and removing the pinion cartridge from the second predetermined temperature and rapidly installing the pinion cartridge within the axle assembly before the axle assembly and the pinion return to ambient temperature provides a frictional fit, joining the two components without use of additional fastening devices.

Abstract: A clutch assembly incorporated into a power transfer assembly (72) of a motor vehicle is presented. The clutch assembly includes a power-operated clutch actuator (306) for moving a clutch sleeve (354) axially between released and engaged positions between two rotatory members. In the released position, relative rotation between two rotary members is prevented. Whereas in the engaged position, relative rotation is permitted. The power-operated clutch actuator (306) further includes an electromagnetic solenoid with an output member having an extended condition and a retracted condition urging the clutch sleeve (354) between positions. A shift isolation linkage mechanism (304) interconnects the output member of the solenoid to the clutch sleeve (354) and permits movement of the output member to its retracted position while a blocked tooth condition inhibits movement of the clutch sleeve (354) to its engaged position.

Abstract: A multi-speed transfer case equipped with a planetary reduction gearset and a range clutch disposed between an input shaft and an output shaft. A clutch actuation mechanism controls actuation of the range clutch to establish distinct ratio drive connections between the input shaft and the output shaft.

Abstract: A vehicle powertrain system and powertrain actuator therefor is provided. The powertrain actuator selectively couples a first rotatable member to a second rotatable member to transfer torque therebetween and selectively decouples the first rotatable member from the second rotatable member to prevent the transfer of torque therebetween. The powertrain actuator includes a tubular cam assembly having a tubular first member and a tubular second member. The tubular first and second tubular members have end surfaces that interact with one another upon energizing a unidirectional solenoid. Upon a first energization of the solenoid, the first and second tubular members interact to operably couple the first and second rotatable members to allow torque to be transferred therebetween, and upon a second energization of the solenoid, the first and second tubular members interact to selectively decouple the first the second rotatable members to prevent the transfer of torque therebetween.

Abstract: An integrated pinion/bearing/coupling (PBC) assembly for use with a hypoid gearset in power transfer assemblies of motor vehicles having mounting features and venting features, The integrated PBC assembly includes a hollow pinion unit made of steel and including a pinion shaft segment and a pinion gear segment, and a coupling unit having a hub segment made of aluminum. A brazing sleeve is used to braze the aluminum hub segment of the coupling unit to the steel pinion shaft segment of the pinion unit.

Abstract: A differential assembly is provided to include a two-piece differential carrier, a differential gearset installed within a gearset chamber formed in the differential carrier, and a ring gear. An interlocking feature mechanically interconnects the ring gear to the first and second case members of the two-piece differential carrier and defines first and second weldment junctions. A first weld seam is located in the first weldment junction and connects the ring gear to the first case member while a second weld seam is located in the second weldment junction and connects the ring gear to the second case member.

Abstract: A drive axle unit for use in a motor vehicle having a multi-piece axle housing assembly including at least two housing components interconnected via at least one in-situ molded retainer component. A method for securing at least two housing components of an axle housing assembly by injecting a molten material into a pair of aligned mold indentations formed in the two housing components which solidifies to create an in-situ molded retainer component.

Abstract: A two-speed transfer case for a four-wheel drive vehicle is provided. The transfer case has a two-speed planetary gearset, a range clutch, and a range shift mechanism. The planetary gearset includes a carrier unit having at least one crack arresting feature configured to limit propagation of a stress crack. The carrier unit includes a plurality of mounting holes for securing planet gears for rotation relative to the carrier unit. The gearset includes a sun gear configured for and a ring gear, with the planet gears in meshed engagement with the sun gear and the ring gear. The crack arresting feature extends at least partially through a portion of the carrier unit and is configured to receive a crack propagating from a central aperture of the carrier unit. The crack arresting feature is disposed radially between the central aperture and the mounting holes.

Abstract: An integrated pinion/bearing/coupling (PBC) assembly for use with a hypoid gearset in power transfer assemblies of motor vehicles having mounting features and venting features. The integrated PBC assembly includes a hollow pinion unit made of steel and including a pinion shaft segment and a pinion gear segment, and a coupling unit having a hub segment made of aluminum. A brazing sleeve is used to braze the aluminum hub segment of the coupling unit to the steel pinion shaft segment of the pinion unit. The PBC assembly can further include a constant velocity joint (CVJ) unit connected to, or formed as part of, the coupling unit.

Abstract: A transfer case for a four-wheel drive vehicle having a disconnectable secondary axle assembly. The transfer case is configured to include a pumpless lubrication sump maintained in relation to a mainshaft for lubricating rotary components surrounding the mainshaft.

Abstract: A power transfer assembly for a motor vehicle includes a clutch protection system to prevent damage to an actively-controlled multi-plate mode clutch of the power transfer assembly. The clutch protection system includes a transfer case control module (TCCM) and an engine control module (ECM) configured to regulate the distribution of torque applied from an engine to front and rear output shafts of the power transfer assembly. The TCCM is in operable communication with the engine control module ECM, wherein TCCM is configured to detect slip in the actively-controlled multi-plate friction clutch and to communicate with the ECM to selectively reduce the output torque of the engine in response to detected slip.

Abstract: A power transmission assembly includes an input member adapted to receive drive torque from a source of torque, an output member adapted to provide drive torque to an output device and a bi-directional roller clutch including a first ring fixed for rotation with one of the input and output members. A second ring is spaced apart from the other of the input and output members. Rollers are positioned in aligned cam tracks formed in facing surfaces of the first and second rings. Neither the first ring nor the second ring support the input member or the output member on the other. The second ring may circumferentially index relative to the first ring for causing the rollers to ride up the cam tracks and force the second ring to frictionally engage the other of the input and output members, thereby establishing a drive connection between the input and output members.

Abstract: An integrated pinion, bearing and coupling (PBC) assembly for use with a hypoid gearset in power transfer assemblies of motor vehicles. The PBC assembly includes a pinion unit having a pinion gear segment and a pinion stub shaft segment, and a coupler unit having a coupling flange segment and a coupler shaft segment. The pinion stub shaft segment surrounds and is in press fit engagement with the coupler shaft segment. A portion of the coupler shaft segment is deformed to be retained within one of a receiver groove and raised projections formed in the pinion stub shaft segment so as to fixedly secure the coupler unit to the pinion unit.

Abstract: An AWD drivetrain is configured to primarily direct drive torque from a transversely-aligned powertrain assembly through an auxiliary power transfer unit to a rear driveline and selectively transmit drive torque to a front driveline via actuation of at least one power-operated clutch. The auxiliary power transfer unit includes an input component drivingly connected to the powertrain assembly, and an output component connected to the input component by a hypoid gearset The output component is operatively connected to the rear driveline and is configured to normally transfer the drive torque to the rear driveline.