Abstract: A rotating assembly may include a rotor, a rotor shaft, a park lock gear, and a balancing plate. The park lock gear and the balancing plate may statically balance and dynamically balance the rotating assembly. The park lock gear may include balancing holes for statically and dynamically balancing the rotating assembly. The balancing holes may extend axially through a select thickness of a cylindrical body of the park lock gear. The rotating assembly may be a component of an electric drive unit. The electric drive unit may include a stator. The rotating assembly may be configured to rotate relative to the stator. The electric drive unit may also include a parking pawl which may lock the rotating assembly to the stator via the park lock gear.

Abstract: An electric drive unit includes an electric motor and a housing that houses the electric motor. The housing includes a heat exchanging wall portion that includes an inner surface that defines a fluid jacket cavity for conveying a first fluid and an outer surface that is opposite the inner surface and that defines a fluid chamber for conveying a second fluid. The heat is transferred between the first and second fluids through the heat exchanging wall portion.

Abstract: An electric motor housing assembly includes a first housing portion, a second housing portion fixed to the first housing portion, and a stator sealed to the housing portions. The first housing portion includes a first integrated oil cavity and the second housing portion includes a second integrated oil cavity. The stator includes a first plurality of wire coils extending into the first integrated oil cavity, and a second plurality of wire coils extending into the second integrated oil cavity.

Abstract: A drive unit for an electric vehicle including a gearbox having rotating components supported in a gearbox portion of the housing, an oil circuit in fluid communication with the gearbox portion of the housing for circulating oil in response to dynamic pressure generated by the rotating components of the gearbox when in operation, and a bleed passage connecting the oil circuit to the gearbox portion of the housing. Dynamic pressure in the gearbox portion of the housing generated by the rotating components when in operation restricts flow of oil through the bleed passage from the oil circuit to the gearbox portion of the housing, and static pressure in the gearbox portion of the housing when the gearbox is not in operation permits flow of oil from the oil circuit to the gearbox portion of the housing.

Abstract: A park mechanism in an electric drive unit may relocate an oil passage within an end housing and add a sensor dam. The sensor dam may separate a park mechanism cavity and a sensor cavity. The sensor dam may trap oil in the park mechanism cavity and prevent the sensor cavity from filling with the oil. The oil may trap the air above the oil in the sensor cavity, preventing the oil from reaching a height of a manual shaft. Thus, a seal of the manual shaft may be prevented from being submerged in the oil.

Abstract: An electric motor cooling system includes wire coils, a housing, a busbar, and a phase bar secured to the busbar. The housing encloses at least a portion of the wire coils. The busbar is connected to the wire coils and extends through an opening in the housing. The cooling system is arranged to direct a cooling fluid through the plurality of wire coils and a gap between the opening and the busbar to spray the phase bar.

Abstract: A drive unit includes a motor and a rotor shaft operably coupled with the motor. The rotor shaft has an inner surface that defines a hollow that extends axially from a first opening at a first end of the rotor shaft to a second opening at a second end of the rotor shaft and has a tapered portion that tapers radially inboard as the tapered portion of the inner surface extends axially away from the second end of the rotor shaft. The rotor shaft further defines a plurality of ports disposed axially between the tapered portion and the second end of the rotor shaft. The motor is configured to drive rotation of the rotor shaft, such that a fluid disposed within the hollow is propelled axially away from the first end of the rotor shaft and through the plurality of ports defined by the rotor shaft.

Abstract: Electronic axles may utilize lubrication and cooling of an electric motor with pure parasitic collection of fluid from a gearbox assembly, to be fed into a heat exchanging system to cool the rotor of the electric motor. An impingement pump may feed the fluid, without the cost addition of a dedicated fluid pump. Rotation of the gearset carrier may cause an impingement pump catcher to pump the fluid into an impingement pump pipe.

Abstract: A drive unit for an electric vehicle including a gearbox having rotating components supported in a gearbox portion of the housing, an oil circuit in fluid communication with the gearbox portion of the housing for circulating oil in response to dynamic pressure generated by the rotating components of the gearbox when in operation, and a bleed passage connecting the oil circuit to the gearbox portion of the housing. Dynamic pressure in the gearbox portion of the housing generated by the rotating components when in operation restricts flow of oil through the bleed passage from the oil circuit to the gearbox portion of the housing, and static pressure in the gearbox portion of the housing when the gearbox is not in operation permits flow of oil from the oil circuit to the gearbox portion of the housing.

Abstract: A bearing arrangement utilizing a typical lip seal pressed into a bore to act as a reacting spring surface which keeps a bearing outer race preloaded to prevent unintentional bad bearing operation (e.g., outer race spinning or ball sliding). This spring reacting surface serves to discourage, for example, outer race spinning or ball sliding, packaged in a tight, space efficient location to permit critical space to be used for other functions. Aspects include retention feature for retaining a biasing element in the bore prior to assembly.

Abstract: An electric drive unit includes a motor that drives rotation of a rotor shaft about an axis, and a housing. The housing includes a bearing shield between motor housing and gearbox regions. The bearing shield has a first side that faces toward the motor housing region and a second side that includes adjacent reference and protruding portions. The protruding portion protrudes axially outward relative to the reference portion away from the motor housing region. The reference portion is radially aligned with the protruding portion, the protruding portion extends circumferentially between first and second circumferential ends of the protruding portion in a first circumferential direction, the reference portion extends from the second circumferential end to the first circumferential end in the first circumferential direction, and a circumferential extent of the protruding portion delimited by the first and second circumferential ends is between 20 and 50 percent of a full circumference.

Abstract: An electric drive unit includes a housing, a motor, a sleeve, first and second seals, and a bearing. The housing defines gearbox and motor housing regions, and first and second channels extending between the gearbox and motor housing regions. The motor is disposed within the motor housing region and has a rotor and a rotor shaft that is rotationally driven about an axis. The sleeve extends circumferentially along an exterior surface of the rotor shaft and has an inner surface that interfaces with the exterior surface, and an outer surface opposite the inner surface. The first seal extends between the outer surface of the sleeve and the housing. The second seal extends between the inner surface of the sleeve and the exterior surface of the rotor shaft. The bearing is positioned radially between the rotor shaft and the housing and axially between the first seal and the gearbox region.

Abstract: A method of manufacturing a stator carrier includes the step of fashioning a stator carrier body that includes a side wall that extends circumferentially about a hollow. The side wall has an interior surface that defines the hollow and an exterior surface opposite the interior surface. The method of manufacturing the stator carrier further includes the step of, subsequently, providing a fin on the exterior surface of the side wall of the stator carrier body. The fin is coupled to the exterior surface of the side wall and extends axially and circumferentially along the exterior surface of the of the side wall in a winding fashion.

Abstract: An electric drive unit includes an electric motor having a rotor shaft that defines a hollow that is accessible via an opening defined at an axial end of the rotor shaft. The hollow defines a portion of a fluid flow path. The electric drive unit also includes an output shaft that extends into the hollow through the opening. The electric drive unit further includes a baffle that extends into the hollow through the opening. The baffle is arranged to redirect fluid flowing along the fluid flow path away from a portion of at least one of the rotor shaft and the output shaft.

Abstract: An electric drive unit includes an electric motor and a housing that houses the electric motor. The housing includes a heat exchanging wall portion that includes an inner surface that defines a fluid jacket cavity for conveying a first fluid and an outer surface that is opposite the inner surface and that defines a fluid chamber for conveying a second fluid. The heat is transferred between the first and second fluids through the heat exchanging wall portion.

Abstract: A junction box assembly including a cover secured to a housing with fasteners, wherein the spacing between fasteners can be increased while maintaining electromagnetic compatibility (EMC). In one example, the cover includes contact tabs between adjacent fasteners. The contact tabs ensure proper contact of the cover with the housing to maintain EMC. Accordingly, the number of fasteners can be reduced and/or the location of the fasteners can be customized more readily. Junction box assemblies in accordance with the present disclosure can be lighter, more easily assembled, and cost less than conventional junction box assemblies.

Abstract: An electric drive unit includes an electric motor and a housing that houses the electric motor. The housing includes a heat exchanging wall portion that includes an inner surface that defines a fluid jacket cavity for conveying a first fluid and an outer surface that is opposite the inner surface and that defines a fluid chamber for conveying a second fluid. The heat is transferred between the first and second fluids through the heat exchanging wall portion.

Abstract: An electric drive unit includes: a motor that rotates a rotor shaft; a housing with a bearing shield extending between motor housing and gearbox regions, the bearing shield having a first side that faces toward the motor housing region and a second side that partially defines the gearbox region and along which a channel extends; a planetary gearset including a sun gear, planet gears, and a carrier; and a wiper coupled to the housing proximate to the channel and abutting the carrier, such that fluid is wiped off of the carrier by the wiper as the carrier rotates and flows to the channel therefrom.

Abstract: A method of manufacturing a stator carrier includes the step of fashioning a stator carrier body that includes a side wall that extends circumferentially about a hollow. The side wall has an interior surface that defines the hollow and an exterior surface opposite the interior surface. The method of manufacturing the stator carrier further includes the step of, subsequently, providing a fin on the exterior surface of the side wall of the stator carrier body. The fin is coupled to the exterior surface of the side wall and extends axially and circumferentially along the exterior surface of the of the side wall in a winding fashion.

Abstract: A drive unit includes a motor and a rotor shaft operably coupled with the motor. The rotor shaft has an inner surface that defines a hollow that extends axially from a first opening at a first end of the rotor shaft to a second opening at a second end of the rotor shaft and has a tapered portion that tapers radially inboard as the tapered portion of the inner surface extends axially away from the second end of the rotor shaft. The rotor shaft further defines a plurality of ports disposed axially between the tapered portion and the second end of the rotor shaft. The motor is configured to drive rotation of the rotor shaft, such that a fluid disposed within the hollow is propelled axially away from the first end of the rotor shaft and through the plurality of ports defined by the rotor shaft.