Abstract: A method of controlling a secondary drivetrain of an electrically powered vehicle includes receiving a connect request for a disconnect mechanism, which includes a first and second clutch member. The second clutch member is biased to a disconnected state from the first clutch member and axially moveable into a connected state to transfer torque from an electric motor to the wheels. An initial current is applied to an actuator of the second clutch member, but the initial current does not overcome the bias on the second clutch member. The electric motor rotates the first clutch member such that a speed difference relative to the second clutch member is reduced below a threshold level. The method applies an additional current to the actuator, which overcomes the bias and connects the clutch members to transfer torque. The time to connect the clutch members is reduced because the initial current was already applied.

Abstract: The present disclosure is directed to electric vehicles and electric powertrains for such electric vehicles. The electric powertrain in configured to include an electric motor and disconnectable differential assembly arranged for transmitting the motive power generated by the electric motor to a pair of ground-engaging wheels. The disconnectable differential assembly includes a power transfer mechanism driven by the electric motor, a differential mechanism interconnected to the pair of ground-engaging wheels, and a power-operated disconnect mechanism for selectively coupling and uncoupling the power transfer mechanism and the differential mechanism.

Abstract: A disconnectable differential assembly has a reduced axial length and a side gear disconnectable from an axle shaft via a clutch unit. Various components of the disconnect mechanism are axially aligned and concentric to reduce the axial length. An output hub splined on the axle shaft and is actuatable, via an axially shiftable armature, into toothed engagement with the side gear via respective axially extending teeth. The output hub and armature include radially extending flanges that are axially adjacent and radially aligned with the teeth so that force is transmitted to the teeth at the same diameter. A thrust bearing is disposed between the flanges so that the output hub rotates relative to the armature. The side gear is supported for rotation on the axle shaft, and a bearing is disposed radially therebetween to improve radial alignment of the second side gear with the output hub.

Abstract: A disconnectable differential assembly has a reduced axial length and a side gear disconnectable from an axle shaft via a clutch unit. Various components of the disconnect mechanism are axially aligned and concentric to reduce the axial length. An output hub splined on the axle shaft and is actuatable, via an axially shiftable armature, into toothed engagement with the side gear via respective axially extending teeth. The output hub and armature include radially extending flanges that are axially adjacent and radially aligned with the teeth so that force is transmitted to the teeth at the same diameter. A thrust bearing is disposed between the flanges so that the output hub rotates relative to the armature. The side gear is supported for rotation on the axle shaft, and a bearing is disposed radially therebetween to improve radial alignment of the second side gear with the output hub.

Abstract: A press assembly for forming outer helical splines on a blank includes an upper press shoe assembly and a die shoe assembly. The upper press shoe assembly includes an upper rotatable portion rotatable relative to an upper stationary portion. The lower portion includes a lower rotatable portion rotatable relative to a lower stationary portion. The unfinished blank is supported by the lower portion, and the upper portion is moveable into engagement with the blank. The upper rotatable portion joins with the lower rotatable portion for conjoint rotation relative to the upper and lower stationary portions via upper and lower helical meshes defined between the rotatable and stationary portions. The helical meshes convert downward force into rotation and translation of the blank into a spline forming die of the lower stationary portion to create the outer helical splines.

Abstract: A controllable one-way clutch assembly having an actuator module equipped with a solenoid actuator, an active strut moveable in response to energization of the solenoid actuator from a released position to a locked position, a strut spring biasing the active strut toward its released position, and an indirect strut actuation arrangement between the solenoid actuator and the active strut. The indirect strut actuation arrangement includes an intermediate actuation component having a first lug establishing a coupling interface with a translatable plunger of the solenoid actuator and a second lug establishing an engagement interface with the active strut.

Abstract: A dual-acting selectable one-way coupling (SOWC) device configured to include a clutch module and an electromagnetic actuator module. The clutch module includes an outer race and an inner race assembly rotatable relative to the outer race. The inner race assembly including a rotatably driven first inner race member, a second inner race member, and compliant connector members drivingly interconnecting the first and second race members. The electromagnetic actuator module includes an electromagnetic actuator operable to releasably engage the second inner race member. An auxiliary locking assembly is operable to independently releasably engage the second inner race member.

Abstract: A selectable one-way clutch includes a clutch module and an electromagnetic actuator module. The electromagnetic actuator module includes an electromagnetic actuator and a strut assembly. The electromagnetic actuator having a coil assembly with a magnetic pole piece. The strut assembly having a strut and a magnetic armature mechanically interconnected to the strut for moving the strut between released and deployed positions in response to energization of the coil assembly. A contamination shroud is disposed between the armature and the pole piece to prevent collection of debris therebetween.

Abstract: A method for gas metal arc welding a first component formed of nitrided steel to a second component with reduced porosity in the weld is provided. A welding wire including a core surrounded by a tube is used to weld the components. The material of the core is formed of mild steel including 0.7 to 3.0 wt. % aluminum and 0.7 to 1.5 wt. % titanium. The material of the tube is formed entirely of low carbon steel. During the weld process, the nitrogen from the nitrided steel combines with the aluminum and titanium of the welding wire to form aluminum nitride and titanium nitride, instead of nitrogen bubbles which lead to high porosity. The method can be used to weld components used in automotive applications, for example to weld a ring gear and can of a flexplate, but alternatively could be used for another automotive or non-automotive applications.

Abstract: A selectable one-way clutch includes a clutch module and at least one electromagnetic actuator module. Each electromagnetic actuator module includes at least one electromagnetic actuator assembly having a coil assembly, a locking strut, and a connection member mechanically interconnected to the locking strut for moving it between released and deployed positions in response to energization of the coil assembly.

Abstract: A flexplate assembly comprising a central plate having a general disc shape disposed about and extending radially from an axis. The central plate has a first radial width. A ring gear is annularly secured about the central plate and presents an outer circumference that defines a plurality of ring teeth extending therefrom. At least one noise plate is disposed adjacent to the central plate and extends circumferentially about the axis for reducing vibrations and noise from the flexplate assembly. The noise plate has a second radial width that is at least one half of the first radial width of the central plate. A method of constructing such a flexplate assembly is also provided.

Abstract: A bi-directional clutch assembly, method of construction thereof and method of setting a preset gap between a magnetically permeable core and armature thereof is provided, An outer race has inner ratchet teeth and an inner race has outer ratchet teeth. A passive one-way clutch has passive struts pivotally supported for locked engagement with the inner ratchet teeth in a first direction. A selectable one-way clutch has an active strut selectively pivotal from an unlocked position to a locked position for engaging the outer ratchet teeth during rotation of the inner race in a second direction opposite the first direction. A protrusion extends radially outwardly from the outer race and has an orifice extending therethrough. A coil is operably supported by the protrusion. The magnetically permeable core is operably fixed in the orifice to be magnetized by the coil to move the at least one active strut to the locked position.

Abstract: A dual-acting selectable one-way coupling (SOWC) device configured to include a clutch module and an electromagnetic actuator module. The clutch module includes an outer race and an inner race assembly rotatable relative to the outer race. The inner race assembly including a rotatably driven first inner race member, a second inner race member, and compliant connector members drivingly interconnecting the first and second race members. The electromagnetic actuator module includes an electromagnetic actuator operable to releasably engage the second inner race member. An auxiliary locking assembly is operable to independently releasably engage the second inner race member.

Abstract: A new method of manufacturing a torque-transmitting clutch component is provided. The method includes coining an interface between a flange segment and a hub segment of the clutch component. Additionally, a torque-transmitting clutch component manufactured by the new manufacturing method is provided.

Abstract: A reduced noise flexplate assembly and method of construction is provided. The assembly includes a central plate that is generally disc shaped and extends radially from an axis. A ring gear is disposed annularly about the central plate and presents a plurality of ring teeth that extend radially therefrom for engaging a pinion gear coupled to a starter of an automobile. A noise plate is attached to the central plate with a plurality of plate fasteners and extends circumferentially about the axis. The noise plate includes a flange and a lower lip extending generally axially and radially outwardly from the inside flange to a maximum deflection zone adjacent to the ring teeth of the ring gear. The noise plate is frictionally engaged with and slideably moveable relative to the central plate and/or ring gear to reduce noise and reduce vibrations during starting of the automobile by converting friction into heat.

Abstract: A clutch ring gear assembly and method of construction thereof are provided. The assembly has a bearing seat including a flange extending radially outwardly from a central axis. The flange has a plurality of holes spaced circumferentially from one another about the central axis. A ring gear carrier includes a rim extending radially outwardly from the central axis. The rim has a plurality of through openings. Each of the through openings of the rim has an annular boss extending axially away from the rim in generally parallel relation to the central axis. The annular bosses are disposed within the holes and have hollow, annular end portions flared radially outwardly into engagement with the flange of said bearing seat to fixedly attach the ring gear carrier to the bearing seat.

Abstract: A harmonic damper for use in vehicular accessory drive systems. The harmonic damper includes a one-piece inertia ring manufactured from a sheet metal blank using a cold forming process to define a series of interconnected folded ring sections.

Abstract: A transfer case includes an input shaft, first and second output shafts and a planetary gearset having a sun gear, a ring gear and a pinion gear meshingly engaged with the sun and ring gears. A range actuator includes first, second and third range sleeves abutted in series being axially translatable between a first position to provide a drive connection between the input shaft and the first output shaft, a second position providing a direct drive ratio connection between the input shaft and the first output shaft as well as the input shaft and a second output shaft, and a third position to provide a reduced speed drive ratio connection between the input shaft and the first output shaft as well as the input shaft and the second output shaft. The gears of the planetary gearset are not driven when the range sleeves are at the first and second positions.

Abstract: Disclosed is a method and structure for sealing an electrical connector. The structure includes a sealing insert for insertion into the housing of an electrical connector. The sealing insert has a flared lip spaced from and extending above a base and the flared lip has a diameter that is larger than a diameter of the base. The sealing insert further includes a retention feature and at least one electrical pin guide. The sealing insert is inserted into the housing of an electrical connector after applying a form in place sealant inside the housing. The flared lip forms a seal against an inner wall of the housing and the retention feature of the sealing insert engages a retention feature inside the housing thereby locking the sealing insert into the housing and forcing the sealant into a sealant gap formed between the housing and the sealing insert thereby sealing the electrical connector.

Abstract: An electromagnetic clutch includes a rotatable input member and a rotatable output member. A clutch plate is fixed tar rotation with one of the input member and the output member. An armature plate is axially moveable relative to the other of the input member and the output member. A self-energizing actuator includes energizing elements for converting rotary motion of the input member to linear movement of the armature plate. The actuator includes a biasing member urging relative rotation between the one of the input member and the output member and the armature plate to initially engage the armature plate and the clutch plate. The self-energizing actuator provides an additional clutch engagement force once the input member is driven and also includes an electromagnet to axially translate the armature plate and disengage the armature plate and the clutch plate.