Abstract: A lubricant supported electric motor includes a stator presenting a stator raceway, and a rotor movable relative to the stator about an axis. The rotor presents a rotor raceway disposed in radially spaced and opposing relationship with the stator raceway to define a gap therebetween. A lubricant is disposed in the gap for supporting the rotor relative to the stator. The stator raceway includes a bearing structure comprised of a plurality of hydrodynamic surfaces aligned in parallel relationship along the stator raceway and a plurality of hydrostatic pockets disposed in radially recessed relationship relative to the hydrodynamic surfaces.

Abstract: A lubricant supported electric motor includes a stator presenting an outer raceway and a rotor extending along an axis and rotatably disposed within the stator. The rotor presents an inner raceway disposed in spaced relationship with said outer raceway to define at least one hydrostatic support chamber disposed therebetween. A lubricant is disposed in the hydrostatic support chamber for supporting the rotor within the stator. A monitoring port is disposed in fluid communication with the at least one hydrostatic support chamber, and a sensor is coupled with the monitoring port for monitoring an operating characteristic of the lubricant disposed in said at least one hydrostatic support chamber. This monitored operating characteristic is then used to determine a real-time operating condition of the lubricant supported electric motor.

Abstract: A shaft and hub connection assembly including a shaft and a hub each extending along and rotatable about an axis. One of the shaft and the hub defines a male connection portion, and the other of the shaft and the hub defines a female connection portion. The female connection portion has a radially inner surface comprised of a plurality of inside faces. The male connection portion has a radially outer surface comprised of a plurality of outside faces that nest within the inside faces. A plurality of outside transition regions are located between the outside faces in a circumferential direction and are blended at an outside radius. A plurality of inside transition regions are located between the inside faces of the female connection portion in the circumferential direction and are blended at an inside radius. A gap is provided between the outside and inside transition regions.

Abstract: A lubricant supported electric motor includes a stator and a rotor and a drive hub. The rotor is moveable relative to the stator and a gap is defined between the rotor and the stator. A lubricant is disposed within the gap to support the rotor relative to the stator and provide a bearing mechanism. The drive hub is coupled to the rotor such that rotation of the rotor causes rotation of the drive hub. The drive hub may be connected to the rotor via a coupler member that is torsionally stiff and axially and radially compliant. The stator may be fixed relative to a connection structure that extends radially within the stator. The connection member may support the drive hub for rotation. Lubricant is supplied via a passageway extending through the connection member into a chamber that includes the gap.

Abstract: An electric motor comprises a stator presenting a first surface. A rotor is rotatable relative to the stator. The rotor presents a rotor raceway disposed in spaced relationship with the first surface of the stator. The first surface of the stator defines a plurality of slots in spaced relationship with one another to define a plurality of spaced teeth between the slots. At least one electrical conductor is disposed in each of the slots and configured to selectively create a moving magnetic field for acting upon the rotor for providing rotational movement of the rotor. A portion of the at least one electrical conductor extends substantially into radial alignment with, or past the first surface of the stator to at least partially define a stator raceway of the stator for engaging the rotor raceway of the rotor during relative radial movement between the rotor and the stator.

Abstract: A lubricant supported electric motor includes an outer stator and an inner stator each extending around an axis in radially spaced relationship with one another. A rotor is rotatably disposed between the inner and outer stators to define an inner gap extending radially between the rotor and the inner stator and an outer gap extending radially between the rotor and the outer stator. A lubricant is disposed in both of the inner and outer gaps for supporting the rotor radially between the inner and outer stators. The lubricant supported motor with a two-sided radial flux configuration results in improved rotor-to-stator system stiffness to allow the lubricant supported electric motor to be used in high shock and high vibration environments, while also providing high torque in a small and lightweight design package.

Abstract: A propeller shaft assembly for a vehicle including a first shaft extending along an axis between a proximal end and a distal end. The first shaft has an externally splined region presenting a plurality of external splines axially adjacent to the distal end. The externally splined region has a spline region outside diameter. A second shaft extends axially between a base end and a terminal end. The second shaft has a tube portion that extends from the base end, and an internally splined sleeve region that extends from the terminal end. The internally splined sleeve region receives the externally splined region of the first shaft and presents a plurality of internal splines interleaved with the external splines of the first shaft for providing relative axial movement between the first and second shafts while rotationally fixing the first and second shafts to one another.

Abstract: A joint assembly includes a first member having splines formed therein. A second member includes splines formed thereon and is coupled to the first member. The splines of the first member engage the splines of the second member. An access window is formed on the first member. A ring retains the first member to the second member. A seal extends across a joint between the first member and the second member and covers the access window. A portion of the ring is accessible through the access window following removal of the seal, where the ring can be manipulated to release the first member from the second member.

Abstract: A lubricant supply system for an electric vehicle includes a lubricant supported electric motor and a lubricant supply line extending from a high pressure source to the lubricant supported electric motor for supplying lubricant to the lubricant supported electric motor. In one arrangement, at least one powertrain component is disposed in fluid communication with the lubricant supply line and fluidly connected in parallel with the lubricant supported electric motor for supplying lubricant to the powertrain component. In an alternative arrangement, the powertrain component is fluidly connected in series with and downstream from the lubricant supported electric motor for supplying lubricant from the lubricant supported electric motor to the powertrain component.

Abstract: A lubricant supported electric motor includes a stator presenting an outer raceway and a rotor extending along an axis and rotatably disposed within the stator. The rotor presents an inner raceway disposed in spaced relationship with the outer raceway to define a gap therebetween, and a lubricant is disposed in the gap for supporting the rotor within the stator. At least one of the outer raceway or the inner raceway is movable radially towards or away from the other to adjust the gap and optimize operation of the lubricant supported electric motor.

Abstract: A constant-velocity rotary joint includes an outer joint portion with outer ball tracks, an inner joint portion with inner ball tracks, balls guided in a track pair formed by one outer ball track and one inner ball track, and a cage with windows to accommodate and retain the balls. Each outer ball track has an outer ball track center line. Each inner ball track has an inner ball track center line. When the constant-velocity rotary joint is straight, the inner ball track center line and the outer ball track center line of the track pair intersect in an intersection point and are not mirror-symmetrical with respect to a mirror plane through the intersection point, and the inner portion of the inner ball track center line widens more, with respect to a longitudinal axis of the outer joint portion, than the outer portion of the outer ball track center line.

Abstract: A system for manufacturing a drive shaft assembly comprises a welding apparatus configured to weld a tube to an end fitting to form the drive shaft assembly having an annular weld. A transport apparatus is configured to transport the drive shaft assembly away from the welding apparatus. A knurling apparatus receives the drive shaft assembly from the transport apparatus. The knurling apparatus is configured to knurl the weld of the drive shaft assembly. The knurling apparatus includes a pair of knurling plates having textured surfaces in facing relationship. One of the knurling plates is configured to move relative to the other of the knurling plates to roll the drive shaft assembly between the textured surfaces, thereby knurling the weld to improve an appearance and texture of the outer surface of the drive shaft assembly.

Abstract: A multi-piece propeller shaft includes a constant velocity joint disposed between and operably interconnecting first and second shaft segments. The constant velocity joint includes an outer race extending along an axis A from a first outer race end operably connected to the second shaft segment to a second outer race end to define an inner surface bounding an internal cavity. A vent and seal assembly is disposed inside the outer race and defines a plurality of venting cavities disposed serially along the axis A in fluid communication with one another. A first one of the venting cavities is disposed in fluid communication with the internal cavity and a last one of the venting cavities is disposed in fluid communication with an environment of the constant velocity joint for venting air from the internal cavity to the environment.

Abstract: A joint assembly includes a first member having splines formed therein. A second member includes splines formed thereon and is coupled to the first member. The splines of the first member engage the splines of the second member. An access window is formed on the first member. A ring retains the first member to the second member. A portion of the ring is accessible through the access window, where the ring can be manipulated to release the first member from the second member.

Abstract: A lubricant supported electric motor including a stator presenting a stator raceway, and a rotor extending along an axis and rotatable relative to the stator. The rotor presents a rotor raceway disposed in spaced relationship with the stator raceway to define a gap there between. A lubricant is disposed in the gap for supporting the rotor relative to the stator. The rotor includes a plurality of rotor poles arranged adjacent the rotor raceway in circumferentially spaced relationship with one another, and the stator includes a plurality of stator poles extending radially towards the rotor in circumferentially spaced relationship with one another along the stator raceway. A plurality of stator coil windings are wrapped around the plurality of stator poles and individually controllable for generating a magnetic force to center the rotor within the stator with carefully-timed adjustments to magnetic fields generated by the stator.

Abstract: A method for providing vehicle alerts includes receiving an ignition signal indicating a current status of an ignition of a vehicle and receiving a gear position signal indicating a current gear position of a transmission of the vehicle. The method also includes receiving a vehicle speed signal indicating a current vehicle speed of the vehicle and identifying a vehicle alert data file based on at least the ignition signal, the gear position signal, the vehicle speed signal. The method also includes retrieving the vehicle alert data file from a vehicle alert database and loading data associated with the vehicle alert data file into a buffer. The method also includes outputting contents of the buffer to at least one output device of the vehicle.

Abstract: A driveline assembly including a pair of reducers each having a sun gear fixed about a primary shaft. A plurality of planet gears are meshed with and rotatable about the sun gear. A ring is positioned about and meshed with the planet gears. A planet carrier is connected to a center of each of the planet gears and fixed to a wheel output. A low gear clutch is moveable between an engaged position fixing the ring to a ground in the engaged position, and a disengaged position disconnecting the ring from the ground. An upshift clutch is moveable between a contact position fixing the primary axle to the wheel output, and a released position disconnecting the primary axle from direct connection with the wheel output. A controller selectively shifts the center clutch, the low gear clutch and the upshift clutch. Methods of using the driveline assembly are also provided.

Abstract: A joint assembly comprising a hollow outer joint member including a wall forming an open end and a closed end, the outer joint member having a plurality of tracks in its inner surface. An inner joint member received in the outer joint member and plurality of torque-transmitting elements, whereby the plurality of torque-transmitting elements rotationally engage with the inner joint member and the tracks of the outer joint member. Each track comprises two opposing side walls and a torque-transmitting element engages these side walls of the outer joint member and is configured to move in an axial direction along the side walls. Furthermore, a boot covering the open end of the outer joint member and at least one restrictor configured to engage at least one of the plurality of torque-transmitting elements to militate against undesired displacement of the inner joint member with respect to the outer joint member.

Abstract: A constant velocity joint includes an outer joint portion with a first longitudinal axis, a first attaching end, an aperture end and outer ball tracks on an inner circumferential surface, an inner joint portion with a second longitudinal axis, a second attaching end, an inner face facing towards the outer joint portion and inner ball tracks on its outer circumferential surface, balls for torque transmission between the outer and inner joint portions, an annular ball cage between the outer and inner joint portions with several cage windows in which the balls are guided. The inner and outer joint portions are arranged so that one outer ball track and one inner ball track are in each case arranged opposite to each other to form three different types of track pairs to receive one respective balls. The balls have different controlling behaviors due to different track geometries.

Abstract: A lubricant supported electric motor includes a stator presenting an stator raceway, and a rotor movable relative to the stator and presenting a rotor raceway disposed in spaced relationship with the stator raceway to define a gap therebetween. A lubricant is disposed in the gap for supporting the rotor relative to the stator. The stator defines at least one hydrostatic support chamber disposed in radially recessed relationship relative to the stator raceway and in fluid communication with the gap. The stator also defines a passageway disposed in fluid communication with the at least one hydrostatic support chamber for providing lubricant to the at least one hydrostatic support chamber and the gap. A flow restriction mechanism is disposed in fluid communication with the passageway for controlling and balancing a supply and pressure of the lubricant in the hydrostatic support chamber.