Abstract: An electric drive unit having a disconnecting differential a multi-phase electric motor and an inverter that controls power to the electric motor. The inverter has an inverter mount, a plurality of power semiconductors that are mounted to the inverter mount, and a plurality of busbars. Each of the busbars has first and second busbar portions, each having a body and a plurality of fingers. The fingers on the first and second busbar portions are mechanically and electrically coupled to opposite sides of terminals on corresponding ones of the power semiconductors.

Abstract: An electronic locking differential that includes a movable electromagnet to selectively operate a dog clutch for locking a side gear to a carrier. The dog clutch includes a dog member having a plurality of legs that extend through leg apertures in the carrier. A cam mechanism is employed on the legs and the carrier to generate and apply a force to the dog member to maintain the dog member in an engaged position when torque is transmitted through the cam mechanism. The carrier is configured with an annular rib that surrounds a pocket. The annular rib has a frustoconical shape that matches that of a pole piece on the electromagnet. The electromagnet is received into the pocket when the electromagnet is operated and the dog member is in its engaged position.

Abstract: An electronic locking differential that includes a movable electromagnet to selectively operate a dog clutch for locking a side gear to a carrier. The dog clutch includes a dog member having a plurality of legs that extend through leg apertures in the carrier. A cam mechanism is employed on the legs and the carrier to generate and apply a force to the dog member to maintain the dog member in an engaged position when torque is transmitted through the cam mechanism. The carrier is configured with an annular rib that surrounds a pocket. The annular rib has a frustoconical shape that matches that of a pole piece on the electromagnet. The electromagnet is received into the pocket when the electromagnet is operated and the dog member is in its engaged position.

Abstract: A vehicle driveline component includes a case defining lever apertures, a coupling having a movable member that is movable along a movement axis between a first and a second position, a linear having a motor output member movable along the movement axis, and a plurality of levers. Each lever is disposed in an associated lever aperture and coupled to the case for pivoting motion about a respective lever pivot axis. The levers urge the movable member in a first direction along the movement axis from one of the first and second positions to the other one of the first and second positions in response to pivoting motion of the levers about the lever pivot axes caused by contact between the levers and the motor output member when the motor output member is driven in a second direction along the movement axis that is opposite the first direction.

Abstract: A vehicle driveline component includes a case defining lever apertures, a coupling having a movable member that is movable along a movement axis between a first and a second position, a linear having a motor output member movable along the movement axis, and a plurality of levers. Each lever is disposed in an associated lever aperture and coupled to the case for pivoting motion about a respective lever pivot axis. The levers urge the movable member in a first direction along the movement axis from one of the first and second positions to the other one of the first and second positions in response to pivoting motion of the levers about the lever pivot axes caused by contact between the levers and the motor output member when the motor output member is driven in a second direction along the movement axis that is opposite the first direction.

Abstract: A differential assembly includes a differential, a collar, and a coupling. The differential has a differential input and differential gearing. The differential input is rotatable about a differential axis. The differential gearing has first and second differential output gears that are rotatable relative to the differential input about the differential axis. The differential gearing transmits rotary power between the differential input and the first and second differential output gears. The collar is rotatable about the differential axis. The coupling has first and second coupling members. The first coupling member is fixedly coupled to the first side gear. The second coupling member is fixedly coupled to the collar. The coupling is operable in a disengaged mode, in which the collar is rotationally decoupled from the first differential output gear, and an engaged mode in which the collar is rotatably coupled to the first differential output gear.

Abstract: A differential assembly that includes a differential input member, a differential gear set, a first clutch, and a second clutch. The differential input member is rotatable about a differential axis and defines an internal cavity. The differential gear set is received in the differential cavity and includes first and second side gears. The first clutch has a plurality of first clutch plates and a plurality of second clutch plates. The first clutch plates are rotatably coupled to the differential input member. The second clutch plates are interleaved with the first clutch plates and are rotatably coupled to the first side gear. The second clutch is selectively operable to non-rotatably couple one of the first and second side gears to the differential input member.

Abstract: A vehicle driveline component that employs a latching actuator to toggle between a first operation mode and a second operational mode. The latching actuator includes first and second actuator structures, a biasing spring, which biases the second actuator structure away from the first actuator structure, a linear motor, which can be operated to drive the second actuator structure toward the first actuator structure, and a plurality of linkages that cooperate with the biasing spring to releasably lock the second actuator structure relative to the first actuator structure in each of an extended position and a retracted position.

Abstract: A vehicle driveline component having a differential input, which is rotatable about a differential axis, a differential gearset that is driven by the differential input, first and second differential outputs, which are rotatable about the differential axis, a first disconnect clutch and a second disconnect clutch. The differential gearset has a first gearset output and a second gearset output that are rotatable about the differential axis. The first disconnect clutch selectively couples the first differential output to the first gearset output, while the second disconnect clutch selectively couples the second differential output to the second gearset output.

Abstract: A differential assembly that includes a differential input member, a differential gear set, a first clutch, and a second clutch. The differential input member is rotatable about a differential axis and defines an internal cavity. The differential gear set is received in the differential cavity and includes first and second side gears. The first clutch has a plurality of first clutch plates and a plurality of second clutch plates. The first clutch plates are rotatably coupled to the differential input member. The second clutch plates are interleaved with the first clutch plates and are rotatably coupled to the first side gear. The second clutch is selectively operable to non-rotatably couple one of the first and second side gears to the differential input member.

Abstract: A driveline component with a differential having a differential gearset mounted in a differential case. The differential gearset has first and second side gears and one or more pinion gears that are meshed with the first and second side gears. The differential gearset is configured to limit inboard thrusting of the first and second side gears so that backlash will be always be present between the pinion gears and each of first and second side gears.

Abstract: A vehicle driveline component having a differential input, which is rotatable about a differential axis, a differential gearset that is driven by the differential input, first and second differential outputs, which are rotatable about the differential axis, a first disconnect clutch and a second disconnect clutch. The differential gearset has a first gearset output and a second gearset output that are rotatable about the differential axis. The first disconnect clutch selectively couples the first differential output to the first gearset output, while the second disconnect clutch selectively couples the second differential output to the second gearset output.

Abstract: A vehicle driveline component that employs a latching actuator to toggle between a first operation mode and a second operational mode. The latching actuator includes first and second actuator structures, a biasing spring, which biases the second actuator structure away from the first actuator structure, a linear motor, which can be operated to drive the second actuator structure toward the first actuator structure, and a plurality of linkages that cooperate with the biasing spring to releasably lock the second actuator structure relative to the first actuator structure in each of an extended position and a retracted position.

Abstract: A disconnecting differential assembly includes a first dog, a second dog, and an actuator. The first dog can include first engagement features fixedly coupled to a first side gear and disposed within the differential case. The second dog can include second engagement features and an annular body. The second engagement features can be radially outward of the annular body and fixedly coupled thereto. The annular body and second engagement features can be disposed within the differential case. The second dog can be rotatable relative to the differential case and the actuator can axially move the second dog between a first position wherein the first and second engagement features are disengaged, and a second position wherein the first and second engagement features are engaged to selectively non-rotatably couple the first and second dogs. The annular body can be adapted to be non-rotatably coupled to an output shaft.

Abstract: A disconnecting differential assembly includes a first dog, a second dog, and an actuator. The first dog can include first engagement features fixedly coupled to a first side gear and disposed within the differential case. The second dog can include second engagement features and an annular body. The second engagement features can be radially outward of the annular body and fixedly coupled thereto. The annular body and second engagement features can be disposed within the differential case. The second dog can be rotatable relative to the differential case and the actuator can axially move the second dog between a first position wherein the first and second engagement features are disengaged, and a second position wherein the first and second engagement features are engaged to selectively non-rotatably couple the first and second dogs. The annular body can be adapted to be non-rotatably coupled to an output shaft.

Abstract: A driveline component with a differential having a differential gearset mounted in a differential case. The differential gearset has first and second side gears and one or more pinion gears that are meshed with the first and second side gears. The differential gearset is configured to limit inboard thrusting of the first and second side gears so that backlash will be always be present between the pinion gears and each of first and second side gears.

Abstract: A differential assembly can include a case, a first side gear, a second side gear, a first pinion gear, a second pinion gear, a third pinion gear, and a cross-pin assembly. The case can be adapted to be supported for rotation about an output axis. The first and second side gears can be disposed within the case and rotatable about the output axis relative to the case. The first, second, and third pinion gears can be disposed within the case and meshingly engaged with the first and second side gears. The cross-pin assembly can include a spider, first, second, and third pins. The proximal end of the first pin can define a first bore that can receive a post of the spider to couple the first pin to the spider. Each pinion gear can be supported by one of the pins for rotation relative to the case.

Abstract: A differential assembly can include a case, a first side gear, a second side gear, a first pinion gear, a second pinion gear, a third pinion gear, and a cross-pin assembly. The case can be adapted to be supported for rotation about an output axis. The first and second side gears can be disposed within the case and rotatable about the output axis relative to the case. The first, second, and third pinion gears can be disposed within the case and meshingly engaged with the first and second side gears. The cross-pin assembly can include a spider, first, second, and third pins. The proximal end of the first pin can define a first bore that can receive a post of the spider to couple the first pin to the spider. Each pinion gear can be supported by one of the pins for rotation relative to the case.

Abstract: A differential includes a cross-pin assembly. The case can rotate about an output axis. First and second side gears can be rotatable about the output axis relative to the case. First, second, and third pinion gears can be meshingly engaged with the first and second side gears. The cross-pin assembly can include first, second, and third pin members, each having a cylindrical body and a finger fixedly coupled to a proximal end of the corresponding cylindrical body. The first, second, and third pinion gears can be rotatably disposed about the corresponding first, second, or third cylindrical body. The first, second, and third fingers can overlap along the output axis to non-rotatably couple the first, second, and third pin members together.

Abstract: A disconnecting differential assembly includes a first dog, a second dog, and an actuator. The first dog can include first engagement features fixedly coupled to a first side gear and disposed within the differential case. The second dog can include second engagement features and an annular body. The second engagement features can be radially outward of the annular body and fixedly coupled thereto. The annular body and second engagement features can be disposed within the differential case. The second dog can be rotatable relative to the differential case and the actuator can axially move the second dog between a first position wherein the first and second engagement features are disengaged, and a second position wherein the first and second engagement features are engaged to selectively non-rotatably couple the first and second dogs. The annular body can be adapted to be non-rotatably coupled to an output shaft.