Abstract: A cooling jacket for a motor includes an extruded jacket body having an outer peripheral surface, an inner peripheral surface, and a plurality of discrete cooling passages located between the inner and outer peripheral surfaces that provide multi-directional fluid flow. A fluid inlet is provided to direct cooling fluid into the jacket body and a fluid outlet to direct heated fluid away from the jacket body.

Abstract: A transverse flux, switched reluctance motor includes a stator, a rotor mounted for rotation relative to the stator about an axis, and a plurality of phased coils. The stator and rotor are spaced apart from each other by a gap and a first phased coil is positioned to extend at least partially across the gap.

Abstract: A wheel drive assembly and suspension for a vehicle wheel includes a spindle, a wheel drive shaft that rotates relative to the spindle about an axis of rotation, and an electric motor that has a motor output shaft for driving the wheel drive shaft. A motor housing encloses a speed reducing planetary gear set that is driven by the motor output shaft. The motor output shaft and the wheel drive shaft are co-axial. A suspension arm extends in a direction transverse to the axis of rotation. The suspension arm includes a pivot end attached to a vehicle structure and an attachment end that is rigidly attached to the motor housing such that the electric motor is a structural part of the suspension.

Abstract: A cooling jacket for a motor includes an extruded jacket body having an outer peripheral surface, an inner peripheral surface, and a plurality of discrete cooling passages located between the inner and outer peripheral surfaces that provide multi-directional fluid flow. A fluid inlet is provided to direct cooling fluid into the jacket body and a fluid outlet to direct heated fluid away from the jacket body.

Abstract: A switched reluctance motor includes a stator, a rotor, and a planetary gear assembly. The rotor defines an internal cavity that houses the planetary gear assembly. The switched reluctance motor receives input and provides output through a common single shaft. The shaft is part of a vehicle driveline and can be positioned to provide driving input to a transmission or drive axle, for example. The planetary gear assembly includes a planet carrier that is fixed for rotation with the shaft and a sun gear that is coupled to the rotor. The planetary gear assembly allows the rotor to rotate at a higher speed than the shaft such that the switched reluctance motor can operate more efficiently for low speed vehicle applications.

Abstract: A simple parking brake includes an electric motor having an internally threaded nut. The internally threaded nut receives an externally threaded shaft. The shaft is pinned to a lever, such that it cannot rotate. The shaft thus moves linearly when the electric motor drives the nut to rotate. As the shaft moves, it drives the brake actuator between a parking position and a release position. A control supplies a pulse to drive the motor in the appropriate direction and for the particular appropriate distance. The pulse length is preferably selected to be longer than that necessary to move the shaft the necessary distance. The motor is preferably sized to stall once the desired park or open position is achieved. In this manner, a simple control is able to control the motor.

Abstract: A cooling jacket for an electric motor includes a plurality of jacket portions that are attached to each other to surround a motor stator. Each jacket portion is an extruded component that includes an outer peripheral wall and an inner peripheral wall spaced inwardly from the outer peripheral wall to form a cooling space between the inner and the outer peripheral walls. A plurality of connecting walls extends between the inner and the outer peripheral walls. The connecting walls cooperate with each other to define a plurality of discrete cooling passages within the cooling space of each jacket portion. First and second end caps are mounted to the plurality of jacket portions to enclose the plurality of discrete cooling passages such that a continuous cooling loop is provided through the plurality of jacket portions and the first and second end caps.

Abstract: A force sensor is incorporated into a disc brake, and is operable to sense the point of force application increase during application of the disc brake. The force will increase sharply once the brake pad initially contacts the rotor. The sensor is able to determine the point of this force increase, and provide this information to a control. The control powers an electric motor for providing electric motor adjustment of the position of the piston which drives the brake pad, to compensate for wear. In a preferred embodiment, the sensor includes a protective cover with a thin anvil between the cover and the sensor. The anvil is operable to transmit the force, and limit the force applied, to protect the sensor.

Abstract: A drive unit assembly for a vehicle wheel includes a rigidly mounted electric motor coupled to the vehicle wheel via a gear drive. The gear drive includes a cycloid or epicycloid gear arrangement that provides significant speed reduction at the wheel.

Abstract: A parking brake system pneumatically actuates an air cylinder to mechanically lock a wheel brake in an applied position in response to a parking demand request. The parking brake system includes a dual hand control that has an electronic control element and a pneumatic control element. The electronic control element communicates with an electronic braking system control unit and the pneumatic control element communicates with a parking brake air reservoir. When the dual hand control is moved to a park position, the electronic control element generates an electronic control signal that applies a parking brake force to the wheel brake. The pneumatic control element generates an air signal that is sent to the air cylinder. The air cylinder includes an extendable shaft that supports a lock member. The air signal moves the lock member into engagement with a brake operating member to lock the wheel brake in the applied condition.

Abstract: The present invention deals with a transverse flux machine of the switched reluctance variety. The transverse flux machine consists of multiple phases where each phase is spaced axially along the shaft. Axial spacing provides many benefits including a decreased weight and a capability to use simple wound bobbin coils for the windings. An embedded cooling loop is provided within the coils themselves. This cooling loop provides internal temperature regulation for the windings and allows for a higher efficiency among other benefits.

Abstract: An electric drive unit is pre-assembled within a cradle housing that is to be mounted as a single unit on a vehicle structure to provide a hybrid vehicle. The electric drive unit includes a pair of inverters, a pair of battery packs, a pair of cooling units, and an electronic control unit (ECU) that are enclosed within the cradle housing. A transfer case with an associated pair of electric motors is also supported by the cradle housing. The cradle housing is mounted to a pair of vehicle frame rails and extends laterally across a vehicle.

Abstract: A wheel drive assembly and suspension for a vehicle wheel includes a spindle, a wheel drive shaft that rotates relative to the spindle about an axis of rotation, and an electric motor that has a motor output shaft for driving the wheel drive shaft. A motor housing encloses a speed reducing planetary gear set that is driven by the motor output shaft. The motor output shaft and the wheel drive shaft are co-axial. A suspension arm extends in a direction transverse to the axis of rotation. The suspension arm includes a pivot end attached to a vehicle structure and an attachment end that is rigidly attached to the motor housing such that the electric motor is a structural part of the suspension.

Abstract: The inventive parallel drive system is particularly well suited to be supported at the axle of the vehicle. A coupling arrangement includes a clutching mechanism and a gear reduction device that selectively couple an electric motor to the drive wheels for providing torque to the wheels alone or in combination with input from an internal combustion engine. The drive torque can also be provided exclusively from the internal combustion engine. The inventive arrangement also allows for the electric motor to be used as a generator during coasting or braking, for example.

Abstract: A displacement sensor utilizes a Hall effect sensor and a magnet, but has an extended range compared to conventional Hall effect displacement sensors. Relative movement between the sensor and the magnet is defined such that the path of movement is not parallel to an axis between the north and south poles of the magnet. Thus, the total path of movement is greater than in the prior art. One particularly preferred application for this sensor is in a disc brake, and as part of an adjustment mechanism for adjusting the position of the disc brake pistons. The displacement sensor is relatively small, and thus can be accommodated in the crowded environment of the disc brake adjustment mechanism. On the other hand, with the inventive large range displacement sensor, the simple and compact sensor can provide adequate measurement of the displacement of the piston.

Abstract: A self-energized disk brake assembly includes gain stabilization features for controlling the multiplication of applied force against a rotatable brake member. The brake assembly includes a first brake pad supported about a first pivot and a second brake pad supported about a second pivot. An actuator applies a force to drive the brake pads into the rotatable brake member. Frictional force between the brake pads and the rotatable brake member pulls the brake pads into further engagement generating an increase in braking force from self-energization. A position of the first and second pivots is adjustable to control the amount of braking force generated from self-energization.

Abstract: A brake assembly has a caliper with a first brake pad and a second brake pad. The first brake pad is moveable relative to the caliper. A brake actuator moves the first brake pad and has a first threaded member and a second threaded member. The first threaded member has first thread characteristics for moving the brake actuator at a first speed and a first force. The second threaded member has a second thread characteristics for moving the brake actuator at a second speed and a second force. The first speed is greater than the second speed while the first force is lower than the second force.

Abstract: A brake actuator assembly includes a sensor mounted to a push rod which is in communication with a transceiver antenna. The sensor provides positional information of the push rod relative to the antenna. A clearance between a friction element and a rotating brake member is determined based on displacement of the push rod and known mechanical relationships within the brake actuator.

Abstract: A low cost brake sensor incorporates a sensor portion extending through one of the rivet holes in the backing plate of the brake pad. A locking sleeve snaps onto the sensor portion and secures the sensor to the backing plate. Preferably, the locking sleeve has a lip which snaps into a groove in an outer periphery of a sensor portion. The present invention thus provides a relatively low cost and secure way for attaching the sensor to the brake pad. No modification of the lining or the backing plate is necessary.

Abstract: A vehicle parking brake system pneumatically actuates an air cylinder to mechanically lock a wheel brake in an applied position in response to a parking demand request. The air cylinder includes an extendable shaft that supports a lock member. When a parking demand request is initiated by moving a hand control, an air chamber is pressurized with air from a parking reservoir via a valve assembly to apply the wheel brake. Air pressure is released from the air cylinder and the lock member is moved into engagement with a brake component to lock the wheel brake in the applied condition. The wheel brake remains locked even if pressure is released from the air chamber. When a release command is initiated, the air cylinder is pressurized and the lock member is moved out of engagement with the brake component.