Abstract: An extended differential output gear including a gear body portion and a tubular portion. The gear body portion includes an outer gear portion and an inner spline portion at least partially overlapping the outer gear portion in a radial direction. The tubular portion extends axially from the inner spline portion. The tubular portion may include a speed sensor target. The tubular portion may include a thicker portion adjacent to the inner spline portion, and a thinner portion adjacent to the thicker portion. The tubular portion may include a stepped tube pressed onto the thinner portion, and the stepped tube may include a speed sensor target. A differential assembly including the extended differential output gear and an axle assembly including the differential assembly are also disclosed.

Abstract: An electric axle with an electric motor having a rotor supported by only three bearings. The electric axle includes a housing in which the electric motor is supported. The electric motor includes a rotor having a rotor body and an output shaft. A first bearing supports the rotor body in the housing, a second bearing supports an end of the output shaft in the housing, and a single intermediate bearing supports the rotor at a position between the first and second bearings.

Abstract: A sealing device may include the tone wheel and a lip seal which are coupled together. The sealing device may also include an over-mold chamfer coupled to the tone wheel. The tone wheel may include a wheel outer axial portion defining axial slots. An axle assembly may include a sensor which sense the axial slots. The lip seal may include an outer ring, a carrier coupled to the tone wheel, a garter spring, a spring gasket coupled to the garter spring and sealing the outer ring and the carrier, a carrier gasket sealing the outer ring and the carrier, and an insert.

Abstract: A generator module for a vehicle includes a housing arranged for fixing to a combustion engine, a generator arranged in the housing, a shaft, a spring, circumscribing the shaft, and a cup, circumscribing the spring. The generator has a stator, fixed to the housing, and a rotor, rotatable within the housing and including a rotor carrier. The shaft is fixed to the rotor carrier and the cup has an annular flange disposed axially between the spring and the housing. In an example embodiment, the housing has a pump housing for a cooling pump and the cup contacts the spring and the pump housing before the generator module is installed in the vehicle. In an example embodiment, the housing and the rotor carrier have complementary conical surfaces, and the spring is arranged to urge the complementary conical surfaces into contact.

Abstract: An electric axle assembly that includes an electric drive unit mounted in a banjo-style axle housing. The electric drive unit includes a motor, gear box, and differential within a housing. The electric drive unit is inserted into the banjo-style axle housing from a first side of the banjo-style axle housing such that at least a portion of the housing of the electric drive unit is contained within the banjo-style axle housing. Fasteners are installed from a second side of the banjo-style axle housing opposite the first side for securing the housing of the electric drive unit to the banjo-style axle housing.

Abstract: A generator module for a vehicle includes a housing arranged for fixing to a combustion engine, a generator arranged in the housing, a shaft, a spring, circumscribing the shaft, and a cup, circumscribing the spring. The generator has a stator, fixed to the housing, and a rotor, rotatable within the housing and including a rotor carrier. The shaft is fixed to the rotor carrier and the cup has an annular flange disposed axially between the spring and the housing. In an example embodiment, the housing has a pump housing for a cooling pump and the cup contacts the spring and the pump housing before the generator module is installed in the vehicle. In an example embodiment, the housing and the rotor carrier have complementary conical surfaces, and the spring is arranged to urge the complementary conical surfaces into contact.

Abstract: An electrical machine for use in a vehicle, comprising a stator configured to output a rotating magnetic field, a primary rotor located radially between an output shaft and the stator, a secondary rotor, wherein the secondary rotor is located radially between the stator and the output shaft, and a hydraulic pump attached to the secondary rotor, wherein the hydraulic pump is configured to output lubricant to an outlet in response to the rotating magnetic field generated therebetween by the stator and the secondary rotor.

Abstract: A hybrid module for a vehicle includes a damper, a pulley, a clutch, and a torque converter. The damper is arranged for fixing to a crank shaft of an engine. The pulley circumscribes the damper and is arranged for connecting to an electric motor via a belt drive. The clutch has a first output flange for drivingly engaging the damper with the pulley. The torque converter has a pilot drivingly engaged with the first output flange.

Abstract: A hybrid drive unit configured for arrangement in a torque path upstream from a transmission and downstream from an internal combustion engine is provided. The hybrid drive unit includes an electric motor, a clutch configured for selectively coupling the internal combustion engine to the electric motor for driving the transmission, and a housing supporting the electric motor. The housing includes a fluid inlet channel for directing cooling fluid from the transmission to the electric motor. The hybrid drive unit also includes a filter assembly attached to the housing. The filter assembly is arranged in a fluid flow path of the cooling fluid downstream of the inlet and upstream of the electric motor. The filter assembly is configured for removing ferrous metallic particles from the cooling fluid.

Abstract: A hybrid module is configured for arrangement in the torque path upstream from a transmission and downstream from an internal combustion engine. The hybrid module includes a housing, an electric motor including a stator non-rotatably fixed to the housing and a rotor rotatable within the stator, a shaft configured for non-rotatably connecting to a crankshaft of an internal combustion engine and a clutch having a clutch output non-rotatably fixed to the rotor. The clutch is configured for being actuated between an engaged orientation for drivingly connecting the shaft to the clutch output and a disengaged orientation for drivingly disconnecting the shaft from the clutch output. The hybrid module also includes an actuator fixed to the housing. The actuator is configured for hydraulically actuating the clutch between the engaged orientation and the disengaged orientation.

Abstract: The permanent magnet machine includes a stator, a rotor inside the stator and a ferromagnetic component fixed axially movably to the rotor. The ferromagnetic component is configured for actuating axially toward the rotor to weaken a magnetic field of the rotor. The method of constructing a permanent magnet machine includes providing a stator and a rotor inside the stator; and axially movably fixing a ferromagnetic component to the rotor such that the ferromagnetic component is configured for actuating axially toward the rotor to weaken a magnetic field of the rotor.

Abstract: A hybrid module is configured for arrangement in the torque path upstream from a transmission and downstream from an internal combustion engine. The hybrid module includes a torque converter and an electric motor including a rotor connected to the torque converter for driving the torque converter. The hybrid module also includes a connect/disconnect clutch configured for being actuated between an engaged orientation for drivingly connecting the internal combustion engine to an output of the connect/disconnect clutch for driving the torque converter and a disengaged orientation for drivingly disconnecting the internal combustion engine from the output of the connect/disconnect clutch.

Abstract: A motor assembly for a hybrid vehicle includes an electric motor, a shaft, a multiplate clutch, and a housing. The electric motor has a rotatable rotor with a carrier. The shaft is arranged for drivingly engaging a combustion engine. The multiplate clutch is drivingly engaged with the carrier for releasably engaging the electric motor to the shaft. The housing includes a center support with a hydraulic channel extending from radially outside of the electric motor to radially inside of the electric motor. In an example embodiment, the motor assembly has a torque converter fixed to the carrier. In some example embodiments, the motor assembly has a concentric slave cylinder for engaging the clutch. The concentric slave cylinder is hydraulically connected to the center support hydraulic channel. In an example embodiment, the motor assembly has a pressing plate in contact with the slave cylinder and the multiplate clutch.

Abstract: A hybrid module is configured for arrangement in the torque path upstream from a transmission and downstream from an internal combustion engine. The hybrid module includes a torque converter and an electric motor including a rotor connected to the torque converter for driving the torque converter. The hybrid module also includes a connect/disconnect clutch configured for being actuated between an engaged orientation for drivingly connecting the internal combustion engine to an output of the connect/disconnect clutch for driving the torque converter and a disengaged orientation for drivingly disconnecting the internal combustion engine from the output of the connect/disconnect clutch.

Abstract: A hybrid drive train assembly for a motor vehicle drive train includes an electric motor; a differential configured for connecting a first front axle and a second front axle of the motor vehicle drive train to each other; a motor output gearing connecting an output of the electric motor to the differential; and a transmission output gearing configured for connecting an output of a transmission to the differential.

Abstract: A hybrid motor assembly, including: an axis of rotation; a torque converter; an electric motor including a stator and a rotor; and a rotor carrier. The torque converter includes: a cover arranged to receive torque; an impeller non-rotatably connected to the cover; and a turbine in fluid communication with the impeller. The rotor carrier is connected to the rotor and includes a cooling chamber. The cooling chamber is bounded at least in part by the rotor, is sealed from the stator, and is arranged to receive cooling fluid.

Abstract: A hybrid module is configured for arrangement in the torque path upstream from a transmission and downstream from an internal combustion engine. The hybrid module includes a housing, an electric motor including a stator non-rotatably fixed to the housing and a rotor rotatable within the stator, a shaft configured for non-rotatably connecting to a crankshaft of an internal combustion engine and a clutch having a clutch output non-rotatably fixed to the rotor. The clutch is configured for being actuated between an engaged orientation for drivingly connecting the shaft to the clutch output and a disengaged orientation for drivingly disconnecting the shaft from the clutch output. The hybrid module also includes an actuator fixed to the housing. The actuator is configured for hydraulically actuating the clutch between the engaged orientation and the disengaged orientation.

Abstract: An electrical machine for use in a vehicle, comprising a stator configured to output a rotating magnetic field, a primary rotor located radially between an output shaft and the stator, a secondary rotor, wherein the secondary rotor is located radially between the stator and the output shaft, and a hydraulic pump attached to the secondary rotor, wherein the hydraulic pump is configured to output lubricant to an outlet in response to the rotating magnetic field generated therebetween by the stator and the secondary rotor.

Abstract: A hybrid motor assembly, including: an axis of rotation; a torque converter; an electric motor including a stator and a rotor; and a rotor carrier. The torque converter includes: a cover arranged to receive torque; an impeller non-rotatably connected to the cover; and a turbine in fluid communication with the impeller. The rotor carrier is connected to the rotor and includes a cooling chamber. The cooling chamber is bounded at least in part by the rotor, is sealed from the stator, and is arranged to receive cooling fluid.

Abstract: A hybrid drive train assembly for a motor vehicle drive train includes an electric motor; a differential configured for connecting a first front axle and a second front axle of the motor vehicle drive train to each other; a motor output gearing connecting an output of the electric motor to the differential; and a transmission output gearing configured for connecting an output of a transmission to the differential.