Abstract: A drive system for a hybrid or electric vehicle that includes a transmission with three forward and three reverse gears. The transmission optionally includes a first and a second planetary gearset, a first and a second clutch, and a brake. The system may be configured to separately engage these components in concert. The drive system may include a single electric motor with a corresponding transmission, or multiple electric motors individually driving separate transmissions. Motors may be arranged upstream or downstream of portions of a transmission, and they may be aligned parallel with or perpendicular to a drive axle.

Abstract: An assembly in a transmission of a motor vehicle for communicating lubrication oil to a bearing in a planetary gear set includes a planet carrier having a plate with an inner groove in communication with a slot of a bushing, a pinion hole, and a second passage that communicates between the inner groove and the pinion hole. The planet carrier further includes a pinion disposed within the pinion hole and a bearing disposed on the pinion for supporting a planetary gear. A groove is disposed in the pinion and is in communication with the second passage. A third passage extends from the groove into the pinion. A fourth passage extends from the third passage into the pinion along an axis of the pinion. A fifth passage extends from the fourth passage to the outer surface. Pressurized lubrication oil is communicated through the plate and pinion to the bearing.

Abstract: An electric motor comprises a rotor hub defining a first slot and a rotor stack defining a second slot. A rotor key has a shape corresponding to the cross-sectional shape of the first slot such that the rotor key is removably retained within the first slot. The rotor key is inserted into the first slot on the rotor hub and the second slot on the rotor stack.

Abstract: An input shaft for a hybrid transmission includes a cylindrical hollow shaft portion having internal and external surfaces. The internal surface defines an internal cavity coaxial with the hollow shaft portion and has a splined portion configured to allow power to be transferred to the hollow shaft portion. The input shaft may further include a freeze plug press-fit in the internal cavity, configured to fluidly seal the inner cavity in embodiments with a cavity extending throughout the input shaft. The splined portion may be a broached spline. A method of manufacturing a hybrid powertrain includes forming a hollow transmission input shaft and press-fitting a plug into it, such that the shaft is internally fluid sealed. The shaft is mated to the transmission which may then be filled with fluid and tested for operability. The shaft may be dry-mated to an engine output member for common rotation therewith.

Abstract: A transmission having an electric motor/generator includes a transmission housing and a bearing support rigidly connected to the transmission housing and substantially enclosed by the transmission housing. A stator housing is substantially enclosed by the transmission housing, and is rigidly joined to the bearing support by a plurality of rivets, such that torque may be transferred between the stator housing and bearing support. The stator housing may be formed from a first material, and the bearing support may be formed from a second material, different from the first material. The stator housing and bearing support meet at an interface region, which may be characterized by an absence of a welded connection between the stator housing and the bearing support. The interface region may be characterized as a slip fit, such that the stator housing and bearing support are matable by hand.

Abstract: A transmission includes first and second clutch members rotatable about the same axis. An axial groove is formed in one of the members to distribute lubricating fluid to the other member. Preferably, clutch plates with radial grooves extend between the clutch members. Fluid flows from the axial groove through the radial groove and across faces of the clutch plates to separate the plates during disengagement in order to minimize spin losses.

Abstract: A method for establishing electrical communication between a control module and a motor/generator in a hybrid electromechanical transmission includes providing a preassembled terminal subassembly including a first plurality of wire terminals sufficiently interconnected for selective, substantially unitary movement with respect to a transmission housing, aligning the preassembled terminal subassembly with a second plurality of wire terminals affixed with respect to at least one electric motor/generator, and establishing electrical communication between each of said first plurality of wire terminals and a respective one of said second plurality of terminals.

Abstract: An input shaft for a hybrid transmission includes a cylindrical hollow shaft portion having internal and external surfaces. The internal surface defines an internal cavity coaxial with the hollow shaft portion and has a splined portion configured to allow power to be transferred to the hollow shaft portion. The input shaft may further include a freeze plug press-fit in the internal cavity, configured to fluidly seal the inner cavity in embodiments with a cavity extending throughout the input shaft. The splined portion may be a broached spline. A method of manufacturing a hybrid powertrain includes forming a hollow transmission input shaft and press-fitting a plug into it, such that the shaft is internally fluid sealed. The shaft is mated to the transmission which may then be filled with fluid and tested for operability. The shaft may be dry-mated to an engine output member for common rotation therewith.

Abstract: A hybrid powertrain includes an engine driving an engine output member, such as a crankshaft. A damper is directly connected to the engine output member, and a transmission input shaft is directly connected to the damper, for common rotation therewith. A dry damper is configured to allow the hybrid powertrain to be characterized by a lack of either a flexplate or a flywheel. A method of manufacturing a hybrid powertrain is also provided, including assembling a fully-functional hybrid transmission at a first manufacturing facility and assembling a fully-functional engine by joining a dry damper to an engine at a second manufacturing facility different from the first. Each of the fully-functional engine and hybrid transmission may be tested separately from the other. The fully-functional engine and hybrid transmission may then be shipped to a common assembly facility, and dry-mated at the common assembly facility, forming an assembled hybrid powertrain.

Abstract: A hybrid transmission includes two electric motor modules and a plurality of planetary gear sets operatively connectable to the motor modules and to an engine. The motor modules each include integral wire connections such that as the motor modules are physically inserted into the hybrid transmission during assembly, the electrical connections may be easily established.

Abstract: This invention relates to the housing of a hybrid electro-mechanical transmission consisting of park pawl system located in the end cover portion of the transmission housing. The end cover portion is configured to cover the park pawl system and allow access to the components of the park pawl system for assembly or service even as the end cover portion remains attached to the main housing of the transmission. Beyond providing coverage to the park pawl system, the end cover portion also provides structural support to a main housing portion during operation of the transmission. A method of assembling a park pawl system between main and end cover portions of a transmission housing is also provided.

Abstract: This invention relates to grounding the mechanical loads of an electrically variable transmission with a park pawl system located in the end cover portion of the transmission housing. The end cover portion is configured to cover the park pawl system and engagement gear. A support hub is interfittable with the end cover portion of the transmission and sufficiently secured thereto so as to ground the park pawl loads. The hub also functions to guide oil to the cavity of a piston-clutch assembly. A method of securing a hub to an electrically variable transmission housing is also provided.

Abstract: This invention relates to an actuable park pawl system for a hybrid electro-mechanical transmission located in the end cover portion of the transmission housing. The end cover portion is configured to cover the park pawl system and ancillary components such as the actuator guide. This enables the actuator guide to be an open-ended structure. A method of securing a park engagement system with an open-ended actuator guide in a vehicle transmission is further provided.

Abstract: A hybrid transmission including two electric motors and a plurality of planetary gear sets operatively connectable to the motors and to an engine is provided. Novel motor features are provided including structure adapted to improve reliability and to facilitate assembly. More precisely, a method is provided for locating and installing the components of a motor, including a rotor and a stator, within a covered housing to form a motor module. A plurality of rotor bearings and a position/speed sensor are also preferably added to the motor module. After the motor module is assembled, the motor may be tested and thereafter the motor module can be installed into a hybrid transmission as a single component utilizing conventional transmission assembly methods.

Abstract: A hybrid electro-mechanical vehicular transmission is provided that may be selectively configured to accommodate a two-wheel drive or a four-wheel drive vehicular configuration. This is accomplished using a two-wheel drive adapter housing affixed with respect to the transmission end housing.

Abstract: The present invention relates to a torsional damper for an electrically-variable transmission. The torsional damper is equipped with a lock-out clutch to directly couple the engine to the input shaft of the transmission. The electric motors provided with the electrically-variable transmission can serve to effectively cancel out engine compression pulses when the springs of the torsional damper are locked out. The present invention also includes damper springs of variable rates to effectively attenuate distinctive or inconsistent torque fluctuations when the engine is operating in displacement-on-demand mode.

Abstract: The present invention relates to a torsional damper for an electrically variable transmission. The torsional damper is equipped with a hydraulically actuable lock-out clutch to selectively directly couple the engine to the input shaft of the transmission. The electric motors provided with the electrically variable transmission can serve to effectively cancel out engine compression pulses when the springs of the torsional damper are locked out. During higher speeds the centrifugal loading placed on oil in the torsional damper increases, which may cause the lock-out clutch to inappropriately engage. The present invention hydraulically balances the hydraulic actuator (or piston) driving the lock-out clutch to appropriately regulate lock-out clutch engagement.

Abstract: This invention relates to the housing of a hybrid electro-mechanical transmission consisting of park pawl system located in the end cover portion of the transmission housing. The end cover portion is configured to cover the park pawl system and allow access to the components of the park pawl system for assembly or service even as the end cover portion remains attached to the main housing of the transmission. An access cover and seal for the access opening in the end cover portion is also provided. The access opening is designed to be small enough so that the end cover portion can also provides structural support to a main housing portion during operation of the transmission. A method of selectively providing access to a park pawl system located in the end cover portion of a transmission housing is also provided.

Abstract: An electrical connector assembly for use in establishing electrical communication between a control module and a motor/generator in a hybrid electro-mechanical transmission includes an insulating wire isolator and nuts nonrotatably preassembled thereto. The electrical connector reduces the quantity of loose parts during transmission assembly. The nuts, being nonrotatably connected to the isolator, which in turn is affixed with respect to a motor housing, are able to accept torque from bolts without assisted retention.

Abstract: An improved hybrid electro-mechanical vehicular transmission includes motor/generator modules assembled from like components. This is accomplished by providing “punch-out” tabs on the motor/generator module housing enabling the housing to be used on either the first or second motor/generator module within a hybrid electro-mechanical vehicular transmission, thus enabling like components to be used within both the first and second motor/generator module.