Abstract: An electric powertrain includes a first electric motor that has an uninterrupted connection with a drive shaft of a vehicle. The electric powertrain further includes a second electric motor that has an interruptible connection with the drive shaft. In one form, this interruptible connection includes a clutch. The electric powertrain further includes a first gear train in the form of a first planetary gear and a second gear train in the form of a second planetary gear. To provide a compact configuration, the first electric motor and second electric motor are arranged in a centerline orientation with the drive shaft.

Abstract: An electric motor includes a stator assembly and a rotor configured to rotate within the stator assembly about an axis. The stator assembly includes a stator case having a channel and a laminate steel core having a retention feature aligned with the channel of the stator case. The stator case is fixed to the laminate steel core via displacement of material of the stator case at the channel toward the laminate steel core to capture the retention feature. An electro-mechanical drive-unit employing the above-described electric motor and a method of generating a stator assembly for such an electric motor are also contemplated.

Abstract: An electric motor includes a stator assembly and a rotor configured to rotate within the stator assembly about an axis. The stator assembly includes a stator case having a channel and a laminate steel core having a retention feature aligned with the channel of the stator case. The stator case is fixed to the laminate steel core via displacement of material of the stator case at the channel toward the laminate steel core to capture the retention feature. An electro-mechanical drive-unit employing the above-described electric motor and a method of generating a stator assembly for such an electric motor are also contemplated.

Abstract: A drive unit, method, and control system are provided that warm drive unit fluid in a drive unit having a main pump, a scavenge pump, and an electric motor for powering an axle of a vehicle. The control system and method are configured to fill a main sump of the drive unit with drive unit fluid to a predetermined fill level. In a warm-up mode, the method and control system operate the electric motor to heat the drive unit fluid within the main sump while the vehicle is stationary and the electric motor is at least partially disposed in the drive unit fluid within the main sump. Further in the warm-up mode, the method and control system are configured to operate the scavenge pump to pump the drive unit fluid from the main sump into an auxiliary reservoir after the drive unit fluid has been heated by the electric motor.

Abstract: A drive unit, method, and control system are provided that warm drive unit fluid in a drive unit having a main pump, a scavenge pump, and an electric motor for powering an axle of a vehicle. The control system and method are configured to fill a main sump of the drive unit with drive unit fluid to a predetermined fill level. In a warm-up mode, the method and control system operate the electric motor to heat the drive unit fluid within the main sump while the vehicle is stationary and the electric motor is at least partially disposed in the drive unit fluid within the main sump. Further in the warm-up mode, the method and control system are configured to operate the scavenge pump to pump the drive unit fluid from the main sump into an auxiliary reservoir after the drive unit fluid has been heated by the electric motor.

Abstract: A transmission with a common carrier planetary gear set is provided for a vehicle that has drive axle half shafts defining an axis of rotation, an electric motor/generator with a motor shaft parallel with the axis of rotation, either concentric with the axis of rotation or spaced therefrom, and a differential with a differential carrier connected with the drive axle half shafts. The planetary gear set has a first sun gear member continuously or selectively connectable with the motor shaft, first and second pinion gears, a carrier member rotatably supporting the first and the second pinion gears so that the first pinion gear meshes with the first sun gear member, and a ring gear member meshing with one of the pinion gears. The ring gear is connectable to a non-rotating housing. The carrier member is operatively connected with the differential carrier.

Abstract: A vehicle and a locking assembly are disclosed. The locking assembly includes a pawl rotatable about a pivot axis between an engaged position and a disengaged position. The pawl is adapted to engage the ring gear when in the engaged position for preventing movement of the ring gear. The locking assembly further includes an actuator selectively actuated to move the pawl to the engaged position. Additionally, the locking assembly includes a biasing mechanism engaging the pawl to continuously bias the pawl toward the disengaged position. The pawl includes a first tooth and a second tooth spaced from each other to define a gap therebetween. The first tooth and the second tooth are adapted to trap a tooth of the ring gear in the gap when the pawl is in the engaged position for preventing rotation of the ring gear.

Abstract: An internal combustion engine for a hybrid vehicle includes an engine block, a flywheel, and a grounding clutch coupled to the block. The block defines a bore along a first longitudinal axis. The flywheel is rotatable about the axis and includes a spline. The spline has a first tooth and a second tooth spaced apart from the first tooth to define a gap therebetween. The clutch is configured for preventing rotation of the flywheel about the first axis and includes a locking pin. The pin is transitionable between a locked position in which the pin is disposed within the gap and abuts the first and second teeth such that the flywheel does not rotate, and an unlocked position in which the pin does not abut the first and second teeth such that the flywheel rotates. A hybrid vehicle is also disclosed.

Abstract: A transmission with a common carrier planetary gear set is provided for a vehicle that has drive axle half shafts defining an axis of rotation, an electric motor/generator with a motor shaft parallel with the axis of rotation, either concentric with the axis of rotation or spaced therefrom, and a differential with a differential carrier connected with the drive axle half shafts. The planetary gear set has a first sun gear member continuously or selectively connectable with the motor shaft, first and second pinion gears, a carrier member rotatably supporting the first and the second pinion gears so that the first pinion gear meshes with the first sun gear member, and a ring gear member meshing with one of the pinion gears. The ring gear is connectable to a non-rotating housing. The carrier member is operatively connected with the differential carrier.

Abstract: An internal combustion engine for a hybrid vehicle includes an engine block, a flywheel, and a grounding clutch coupled to the block. The block defines a bore along a first longitudinal axis. The flywheel is rotatable about the axis and includes a spline. The spline has a first tooth and a second tooth spaced apart from the first tooth to define a gap therebetween. The clutch is configured for preventing rotation of the flywheel about the first axis and includes a locking pin. The pin is transitionable between a locked position in which the pin is disposed within the gap and abuts the first and second teeth such that the flywheel does not rotate, and an unlocked position in which the pin does not abut the first and second teeth such that the flywheel rotates. A hybrid vehicle is also disclosed.

Abstract: A vehicle and a locking assembly are disclosed. The locking assembly includes a pawl rotatable about a pivot axis between an engaged position and a disengaged position. The pawl is adapted to engage the ring gear when in the engaged position for preventing movement of the ring gear. The locking assembly further includes an actuator selectively actuated to move the pawl to the engaged position. Additionally, the locking assembly includes a biasing mechanism engaging the pawl to continuously bias the pawl toward the disengaged position. The pawl includes a first tooth and a second tooth spaced from each other to define a gap therebetween. The first tooth and the second tooth are adapted to trap a tooth of the ring gear in the gap when the pawl is in the engaged position for preventing rotation of the ring gear.

Abstract: A method of manufacturing a squirrel-cage rotor includes: providing a laminated stack; attaching a plurality of rotor bars to the laminated stack, wherein the plurality of rotor bars each include opposite longitudinal ends; and die-casting a pair of end rings at the longitudinal ends of the plurality of rotor bars.

Abstract: A method of manufacturing an electric motor includes stacking a plurality of laminate layers to form a rotor stack. A plurality of conductor bars are inserted into a respective one of a plurality of rotor slots defined by the rotor stack, such that each of the plurality of conductor bars protrudes from the axial ends of the rotor stack. End pieces for the electric motor are rotated relative to the plurality of conductor bars to weld the end pieces to the conductor bars.

Abstract: A permanent magnet machine includes a rotor and a stator including plurality of stator pole sections. Each stator pole section comprises a core section having an inner end piece disposed adjacent to the core section, the inner end piece comprising a first magnetic material that is adapted to saturate during exposure to a first magnetic field strength, and an outer end piece disposed adjacent to the core section radially outwardly relative to the inner end piece, the outer end piece comprising a second magnetic material that is adapted to be unsaturated during exposure to the first magnetic field strength and to saturate during exposure to a second magnetic field strength, wherein the second magnetic field strength is greater than the first magnetic field strength.

Abstract: A permanent magnet machine includes a stator, a rotor configured to coaxially rotate with respect to the stator and having a plurality of permanent magnets coupled thereto, and an air gap between the stator and the rotor having a magnitude that is continuously adjustable. The air gap may be adjusted to optimize torque, minimize back EMF, or optimize any characteristic of the permanent magnet machine during rotation.

Abstract: A permanent magnet machine includes a rotor and a stator including plurality of stator pole sections. Each stator pole section comprises a core section having an inner end piece disposed adjacent to the core section, the inner end piece comprising a first magnetic material that is adapted to saturate during exposure to a first magnetic field strength, and an outer end piece disposed adjacent to the core section radially outwardly relative to the inner end piece, the outer end piece comprising a second magnetic material that is adapted to be unsaturated during exposure to the first magnetic field strength and to saturate during exposure to a second magnetic field strength, wherein the second magnetic field strength is greater than the first magnetic field strength.

Abstract: A power electronics module includes an electronics module and a connector housing. The electronics module includes at least one interface section having at least one conductive surface. At least one connector is configured for attachment to the electronics module to establish electrical communication between the connector and the electronics module. The connector includes a connector housing, an insulative housing, a terminal and a biasing device. The insulative housing is supported by the connector housing. The terminal is configured to transmit electrical current to the conductive surface of the electronics module. The biasing device is configured to bias the terminal in a first direction to establish electrical contact with the conductive surface and the conductive surface biases the terminal in a second direction, opposite the first direction.

Abstract: The present invention provides a stator assembly for an electromechanical hybrid transmission. The stator assembly is generally annular and defines a centrally located rotor aperture configured to accommodate a rotor. The stator assembly includes a stator core having a plurality of radially inwardly extending stator teeth, and a stator wire wound around each of the stator teeth to form a plurality of stator coils. Epoxy resin is applied between each pair of adjacent stator teeth. The epoxy resin defines a plurality of stator cooling channels located in close proximity to the stator coils, and a plurality of rotor cooling channels located in close proximity to the rotor aperture. A cooling medium is disposed within the stator cooling channels and the rotor cooling channels such that the stator coils and a later assembled rotor can be cooled.

Abstract: A method of manufacturing a squirrel-cage rotor includes: providing a laminated stack; attaching a plurality of rotor bars to the laminated stack, wherein the plurality of rotor bars each include opposite longitudinal ends; and die-casting a pair of end rings at the longitudinal ends of the plurality of rotor bars.

Abstract: Provided are stir-welded rotors and methods of making these. An exemplary stir-welded rotor may include a stack of laminations that each has spaced-apart slots arrayed on an outer circumference. The slots register with slot bars that each has a first extremity extending above the stack of laminations and a second extremity extending below the stack of laminations. A first weld extends between first extremities of adjacent slot bars, and a second stir weld extending between adjacent second extremities of adjacent slot bars.