Abstract: A stamped crankshaft seal retainer plate is provided, including a molded encoder sensor support feature for mounting an encoder sensor of an engine speed sensing system. The use of a stamped crankshaft seal retainer plate reduces the cost of the retainer plate as well as the overall weight of the vehicle while precisely locating the encoder sensor for position and required air gap.

Abstract: A method of making an encoder for use in a speed sensor includes providing a metal tube. A material containing ferrite is then extruded over the metal tube to produce an encoder tube. The encoder tube is cut to a given length to form an encoder. The encoder is then magnetized within a magnetic field.

Abstract: A steerable drive axle for a motor vehicle including a rigid tubular housing, a pair of steering knuckles at opposite ends of the rigid tubular housing, an expanded chamber in the middle of the rigid tubular housing open on one side for access to a differential gear set in the expanded chamber, a differential cover for closing the open side of the expanded chamber, and an electrically-powered steering apparatus on the cover linked to the steering knuckles. The electrically-powered steering apparatus includes a rack bar passage in the differential cover, a rack bar supported in the rack bar passage for linear translation and linked to the steering knuckles, a pinion head rotatably supported on the differential cover having a pinion gear meshing with a rack gear on the rack bar, an electric motor mounted on the differential cover, and a speed reducer on the differential cover between the pinion head and an output shaft of the electric motor.

Abstract: A gear assembly comprising a linear differential disposed at the gear assembly wherein the linear differential has a predetermined ratio from an input shaft to an output shaft, the ratio being adjustable by axially rotating the linear differential. A method of adjusting steering output as compared to steering input, which comprises powering a motor in operable communication with a worm and worm gear mechanism and rotating the worm and the worm gear mechanism fixed to a differential carrier. The method also comprises rotating the differential carrier, which comprises an input sun gear meshed with input differential planet gear, an input differential planet gear meshed with an output differential planet gear, and an output sun gear meshed with the output differential planet gear. The method further comprises rotating the output sun gear fixed to a differential output shaft.

Abstract: A steer-by-wire handwheel actuator in a vehicle is presented. The handwheel actuator comprises a controller operative to accept as input thereto data from the steer-by-wire system and generate therefrom control signals; a driver input shaft; a gear train connected to the driver input shaft; a variable stop motor responsive to the control signals from the controller and variably geared to the gear train; a feedback motor responsive to the control signals from the controller and geared to one of the driver input shaft and the gear train; and a stop mechanism attached to a housing and coupled to one of the feedback motor and the gear train.

Abstract: A steerable drive axle for a motor vehicle including a rigid tubular housing, a pair of steering knuckles at opposite ends of the rigid tubular housing, an expanded chamber in the middle of the rigid tubular housing open on one side for access to a differential gear set in the expanded chamber, a differential cover for closing the open side of the expanded chamber, and an electrically-powered steering apparatus on the cover linked to the steering knuckles. The electrically-powered steering apparatus includes a rack bar passage in the differential cover, a rack bar supported in the rack bar passage for linear translation and linked to the steering knuckles, a pinion head rotatably supported on the differential cover having a pinion gear meshing with a rack gear on the rack bar, an electric motor mounted on the differential cover, and a speed reducer on the differential cover between the pinion head and an output shaft of the electric motor.

Abstract: A rotary position transducer and method of mounting the same. The transducer includes a housing having a disc-shaped end plate, a guide in a main aperture in the end plate, a plurality of frangible coupling elements rigidly supporting the guide on the end plate, a stator rigidly supported on the transducer housing behind the end plate, and a rotor rigidly attached to the guide and supported inside of the stator with an annular gap therebetween. The transducer is mounted on a structural member around a shaft rotatably supported on the structural member by first mounting the guide on the shaft, then rigidly clamping the transducer housing to the structural member, and then applying torque to the shaft to fracture the frangible coupling elements and release the rotor for rotation with the shaft relative to the transducer housing and the stator.

Abstract: A gear assembly comprising a linear differential disposed at the gear assembly wherein the linear differential has a predetermined ratio from an input shaft to an output shaft, the ratio being adjustable by axially rotating the linear differential. A method of adjusting steering output as compared to steering input, which comprises powering a motor in operable communication with a worm and worm gear mechanism and rotating the worm and the worm gear mechanism fixed to a differential carrier. The method also comprises rotating the differential carrier, which comprises an input sun gear meshed with input differential planet gear, an input differential planet gear meshed with an output differential planet gear, and an output sun gear meshed with the output differential planet gear. The method further comprises rotating the output sun gear fixed to a differential output shaft.

Abstract: A steerable drive axle for a motor vehicle including a rigid tubular housing, a pair of steering knuckles at opposite ends of the rigid tubular housing, an expanded chamber in the middle of the rigid tubular housing open on one side for access to a differential gear set in the expanded chamber, a differential cover for closing the open side of the expanded chamber, and an electrically-powered steering apparatus on the cover linked to the steering knuckles. The electrically-powered steering apparatus includes a rack bar passage in the differential cover, a rack bar supported in the rack bar passage for linear translation and linked to the steering knuckles, a pinion head rotatably supported on the differential cover having a pinion gear meshing with a rack gear on the rack bar, an electric motor mounted on the differential cover, and a speed reducer on the differential cover between the pinion head and an output shaft of the electric motor.