Abstract: An electromagnetic clutch assembly includes a rotor assembly operable to rotate about an axis. The electromagnetic clutch assembly also includes an armature assembly operable to rotate about the axis. The electromagnetic clutch assembly also includes an electromagnetic coupling system operable to generate a magnetic field. The magnetic field induces the rotor assembly and the armature assembly against one another along the axis for frictional engagement such that the rotor assembly and the armature assembly rotate together. The electromagnetic clutch assembly also includes an air gap defined between the rotor assembly and the armature assembly when the rotor assembly and the armature assembly are in frictional engagement. In another implementation, at least one plate is positioned between the rotor assembly and the armature assembly such that magnetic flux passes through the at least one plate. The plate is formed from a mixture of powdered metal and solid lubricant.

Abstract: An electromagnetic clutch assembly includes a rotor assembly operable to rotate about an axis. The electromagnetic clutch assembly also includes an armature assembly operable to rotate about the axis. The electromagnetic clutch assembly also includes an electromagnetic coupling system operable to generate a magnetic field. The magnetic field induces the rotor assembly and the armature assembly against one another along the axis for frictional engagement such that the rotor assembly and the armature assembly rotate together. The electromagnetic clutch assembly also includes an air gap defined between the rotor assembly and the armature assembly when the rotor assembly and the armature assembly are in frictional engagement. In another implementation, at least one plate is positioned between the rotor assembly and the armature assembly such that magnetic flux passes through the at least one plate. The plate is formed from a mixture of powdered metal and solid lubricant.

Abstract: An electromagnetic clutch assembly includes a rotor assembly operable to rotate about an axis. The electromagnetic clutch assembly also includes an armature assembly operable to rotate about the axis. The electromagnetic clutch assembly also includes an electromagnetic coupling system operable to generate a magnetic field. The magnetic field induces the rotor assembly and the armature assembly against one another along the axis for frictional engagement such that the rotor assembly and the armature assembly rotate together. The electromagnetic clutch assembly also includes an air gap defined between the rotor assembly and the armature assembly when the rotor assembly and the armature assembly are in frictional engagement. In another implementation, at least one plate is positioned between the rotor assembly and the armature assembly such that magnetic flux passes through the at least one plate. The plate is formed from a mixture of powdered metal and solid lubricant.

Abstract: A torque transmitting apparatus includes a cover portion generally defined by a first axis. The cover portion includes a plurality of adjustment apertures. The apparatus also includes a flywheel coupled to the cover portion for rotation therewith, wherein the flywheel is restrained from axial movement relative to the cover portion. The apparatus also includes a pressure plate coupled to the cover portion for rotation therewith. The pressure plate is axially moveable relative to the cover portion. The apparatus also includes a clutch disk at least partially interposed between the flywheel and the pressure plate. The apparatus also includes a plurality of first members extending between the pressure plate and the cover. Each first member exerts a biasing outward radial force on the adjustment aperture to resist axial movement therebetween. The apparatus also includes a plurality of biasing members. At least one biasing member is interposed between one of the first members and the flywheel.

Abstract: An inertia brake assembly is disclosed. In an embodiment, the inertia brake includes a rotor hub subassembly and an inertia brake subassembly. The inertia brake subassembly includes a first reaction plate arranged opposite a first side of the rotor hub assembly, a second reaction plate arranged opposite a second side of the rotor hub assembly, and one or more connector subassemblies connecting the first reaction plate to the second reaction plate. The one or more connector subassemblies include at least one or more resilient straps, and a spacer disposed between the one or more resilient straps and one of the first and second reaction plates. The spacer is arranged about a diameter of the rotor hub subassembly. In an embodiment, the inertia brake assembly includes a sleeve. An inertia brake subassembly is also disclosed.

Abstract: A torque transmitting apparatus includes a cover portion generally defined by a first axis. The cover portion includes a plurality of adjustment apertures. The apparatus also includes a flywheel coupled to the cover portion for rotation therewith, wherein the flywheel is restrained from axial movement relative to the cover portion. The apparatus also includes a pressure plate coupled to the cover portion for rotation therewith. The pressure plate is axially moveable relative to the cover portion. The apparatus also includes a clutch disk at least partially interposed between the flywheel and the pressure plate. The apparatus also includes a plurality of first members extending between the pressure plate and the cover. Each first member exerts a biasing outward radial force on the adjustment aperture to resist axial movement therebetween. The apparatus also includes a plurality of biasing members. At least one biasing member is interposed between one of the first members and the flywheel.

Abstract: An inertia brake assembly is disclosed. In an embodiment, the inertia brake includes a rotor hub subassembly and an inertia brake subassembly. The inertia brake subassembly includes a first reaction plate arranged opposite a first side of the rotor hub assembly, a second reaction plate arranged opposite a second side of the rotor hub assembly, and one or more connector subassemblies connecting the first reaction plate to the second reaction plate. The one or more connector subassemblies include at least one or more resilient straps, and a spacer disposed between the one or more resilient straps and one of the first and second reaction plates. The spacer is arranged about a diameter of the rotor hub subassembly. In an embodiment, the inertia brake assembly includes a sleeve. An inertia brake subassembly is also disclosed.

Abstract: An adjustable pinion offset in a differential axle assembly. The offset between a pinion gear and shaft relative to a ring gear in the differential axle assembly is adjustable due to an eccentric mounting of the pinion assembly relative to the differential housing containing the ring gear. The pinion shaft is eccentrically mounted within a bore of the differential housing such that a simple rotation of the pinion assembly about the eccentric pilot mounting adjusts the position of the pinion shaft with respect to the ring gear to adjust pinion offset. Once properly positioned, the pinion assembly is secured to the differential housing to maintain the desired position. This invention substantially reduces the noise associated with gear offset error.

Abstract: A differential having a housing for receiving differential components. An input shaft, for example a drive pinion gear, is rotatably mounted within the differential housing. A drive line connection point is affixed to the drive pinion gear and is the mounting point for the drive shaft. A fan is disposed on the drive line connection point and is used to force air over the differential housing. The fan may be formed integrally with a drive train part, or be separable therefrom. Rotation of the fan forces air over the surface of the differential housing causing forced convection cooling of the differential components.

Abstract: An apparatus comprising a support structure having at least one trunnion which is adapted to receive a generally cylindrical hollow tube. The trunnion includes an annular groove formed in an outer surface. The apparatus further comprises an annular reinforcing ring disposed in the annular groove. The support structure is preferably made of a non-ferrous metallic alloy and the reinforcing ring may be made of either a ferrous metal, such as iron or a steel alloy, or may be made of a composite material. The support structure may comprise an axle carrier or a disconnect housing of an axle drive assembly, or any other support structure having a trunnion which accepts a generally cylindrical hollow tube. The support structure may comprise a casting, and the reinforcing ring may comprise a prefabricated, one-piece construction which is cast in place in the trunnion groove of the support structure.

Abstract: A structure for supporting a generally cylindrical hollow tube comprising at least one trunnion which is adapted for receiving a generally cylindrical hollow tube. The trunnion includes a radially stepped bore formed therein and extending between first and second ends of the trunnion. The stepped bore includes a first generally cylindrical portion extending axially from the first end toward the second end. The first portion of the bore has a diameter which is less than an outside diameter of the tube, so that the tube engages the trunnion in an interference fit throughout the first portion of the bore. The stepped bore further includes a second axially extending, generally cylindrical portion having a diameter which is greater than the diameter of the first portion of the bore and greater than the outside diameter of the tube, so that the tube does not engage the trunnion in an interference fit in the area corresponding to the second portion of the bore.

Abstract: A selectively lockable differential assembly comprising a rotatable case, first and second output shafts journalled in the case for rotation relative thereto, and a differential mechanism disposed within the case and linking the two output shafts so as to permit differential rotation between the two shafts. The assembly further includes first and second clutches each connected to the case and coupled with one of the output shafts. The differential mechanism includes a pinion shaft, upon which spaced apart pinion gears are rotatably mounted, and a pair of side gears rigidly affixed to corresponding ones of the output shafts, which meshingly engage the pinion gears. The pinion shaft includes a cam portion disposed between the inboard ends of the two output shafts. Rotation of the pinion shaft about its longitudinal centerline axis engages the two clutches and therefore limits differential rotation between the two output shafts.

Abstract: A structure for a housing for an axle assembly and method for manufacturing same is disclosed. The housing includes a tube which is formed by casting. The tube is cast having a brake flange, a spring seat, a shock absorber pad, and an outer end for mounting wheel bearings, all of which are integrally formed therewith. The tube is generally hollow and cylindrical in shape, but is formed having an outer circumferential surface which is generally circular in shape and an inner circumferential surface which is generally oval in shape. Thus, the wall thickness of the tube is not uniform about the circumference thereof. Rather, the wall thicknesses of the upper and lower portions of the tube are somewhat greater than the wall thicknesses of the side portions thereof. The wall thicknesses of the upper and lower portions of the tube are sized to accommodate vertically oriented loads induced therein which are generally larger than horizontally oriented loads which are normally encountered in use.

Abstract: A torsional sleeve coupling provides a spring system for dampening torsional vibrations in a driveline coupling during low torque modes of operation. In a preferred form, the coupling is adapted for use with a driving and a driven shaft which are coaxially aligned. The coupling includes a lost motion connection for torsionally coupling the driven and driving shaft ends for joint rotation. In a preferred embodiment, the coupling incorporates a sleeve which contains a C-spring having an annular metallic body positioned in coaxial registration with one of the shafts. The spring includes a pair of spaced, radially oriented ears. The sleeve and the shaft about which the spring is positioned each contain a slotted portion. The two slotted portions are in radial alignment with each other, and each is adapted to receive both of the ears of the spring.