Abstract: The present disclosure includes a method of assembling a plurality of rotor cores for an electric converter. The method includes providing a core robotic system employing force control feedback and an insert assembly robotic (IAR) system; placing a rotor core of the plurality of rotor cores on a mandrel by the core robotic system employing force control feedback, wherein each rotor core from the plurality of rotor cores includes a plurality of cavities; and placing a plurality of magnetizable inserts into the plurality of cavities in the rotor core by the insert assembly robotic (IAR) system employing force control feedback.

Abstract: The present disclosure is generally directed toward a method of assembling a plurality of rotor cores for an electric converter. The method includes placing, by a core robotic system employing force control feedback, a rotor core on a mandrel, and for each of the plurality of rotor cores, placing, a plurality of magnetizable inserts into a plurality of cavities in the rotor core by an insert assembly robotic (IAR) system employing force control feedback.

Abstract: A rotor assembly system includes a central robotic system, which itself includes a conveyor platform and a multi-axial central robot arranged on the conveyor platform. The multi-axial central robot is configured to perform a set of manufacturing processes from among a plurality of rotor manufacturing processes related to at least one rotor component. The conveyor platform is operable to move the multi-axial central robot within the manufacturing cell to transfer the at least one rotor component between one or more rotor manufacturing processes from among the plurality of rotor manufacturing processes.

Abstract: A rotor assembly system for a manufacturing cell includes a central robotic system comprising a multi-axial central robot and a conveyor platform and one or more multi-axial auxiliary robotic systems secured at one or more locations within the cell. The conveyor platform is operable to move the central robot within the cell. The central robotic system and the one or more auxiliary robotic systems are configured to perform a plurality of rotor manufacturing processes on at least one rotor component in coordination with one another, and the central robotic system is configured to transfer the at least one rotor component between one or more rotor manufacturing processes of the plurality of rotor manufacturing processes.

Abstract: A rotor assembly system for a manufacturing cell includes a central robotic system comprising a multi-axial central robot and a conveyor platform and one or more multi-axial auxiliary robotic systems secured at one or more locations within the cell. The conveyor platform is operable to move the central robot within the cell. The central robotic system and the one or more auxiliary robotic systems are configured to perform a plurality of rotor manufacturing processes on at least one rotor component in coordination with one another, and the central robotic system is configured to transfer the at least one rotor component between one or more rotor manufacturing processes of the plurality of rotor manufacturing processes.

Abstract: An end of arm tool (EOAT) for use with a robotic end effector includes radially opposed gripper fingers secured to a distal end portion of the robotic end effector, each radially opposed gripper finger having a recess with a first sidewall and a second sidewall oriented at an acute angle relative to the first sidewall. The radially opposed gripper fingers are configured to translate radially to grip a part within the recesses and to release the part for placement in an assembly.

Abstract: The present disclosure is generally directed toward a method of assembling a plurality of rotor cores for an electric converter. The method includes placing, by a core robotic system employing force control feedback, a rotor core on a mandrel, and for each of the plurality of rotor cores, placing, a plurality of magnetizable inserts into a plurality of cavities in the rotor core by an insert assembly robotic (IAR) system employing force control feedback.

Abstract: A method of securing magnetizable inserts within cores of an electric converter includes placing an assembly of rotor cores in a transfer molding press, the magnetizable inserts being disposed within cavities of the rotor cores and the cavities of the rotor cores being in fluid communication, placing a polymer preform proximate a central portion of the assembly of rotor cores, displacing the polymer preform such that the polymer preform changes state and flows radially and then axially through each of the cavities of the rotor cores, removing the assembly of rotor cores from the transfer molding press, and removing polymer waste from the assembly of rotor cores.

Abstract: A method for manufacturing a case-hardened ring gear/differential case assembly includes attaching a ring gear to a differential case. The case-hardened ring gear and the differential case are fabricated of materials each having differing properties of at least carbon content and melting temperature. The attaching includes placing a flange of the case-hardened ring gear in intimate contact with a flange of the differential case whereby a predetermined gap is defined between a remainder of the ring gear and a remainder of the differential case. The ring gear flange is attached to the differential case flange by a friction welding process. The predetermined gap defines an outflow channel that receives a carburized portion of the case-hardened ring gear as overflow material created by an upset forging step of the friction welding process. Differential assemblies and vehicles including such are described.

Abstract: A method for manufacturing a case-hardened ring gear/differential case assembly includes attaching a ring gear to a differential case. The case-hardened ring gear and the differential case are fabricated of materials each having differing properties of at least carbon content and melting temperature. The attaching includes placing a flange of the case-hardened ring gear in intimate contact with a flange of the differential case whereby a predetermined gap is defined between a remainder of the ring gear and a remainder of the differential case. The ring gear flange is attached to the differential case flange by a friction welding process. The predetermined gap defines an outflow channel that receives a carburized portion of the case-hardened ring gear as overflow material created by an upset forging step of the friction welding process. Differential assemblies and vehicles including such are described.

Abstract: A method for manufacturing a ring gear/differential case assembly includes attaching a ring gear to a differential case. The ring gear and the differential case are fabricated of materials having differing properties. The attaching includes placing a first portion of the ring gear in intimate contact with a first portion of the differential case whereby a predetermined gap is defined between another portion of the ring gear and another portion of the differential case. The ring gear first portion is attached to the differential case first portion by a friction welding process. The predetermined gap defines an outflow channel for receiving an overflow material created by an upset forging step of the friction welding process. Differential assemblies and vehicles including such are described.

Abstract: A carrier assembly for an automatic transmission includes a first plate, a second plate spaced along an axis from the first plate, a third plate spaced axially from the first plate and the second plate by angularly spaced legs, the third plate being formed with angularly spaced recesses. Short pinions, supported on the first plate and the third plate, each has a major diameter sized to move between at least two of the legs along a chordal path into one of the recesses during installation in the carrier. Long pinions, supported on the first plate and the second plate, each has a major diameter sized to move between at least two of the legs along a radial path into one of the recesses during installation in the carrier.

Abstract: A carrier assembly for an automatic transmission includes a first plate, a second plate spaced along an axis from the first plate, a third plate spaced axially from the first plate and the second plate by angularly spaced legs, the third plate being formed with angularly spaced recesses. Short pinions, supported on the first plate and the third plate, each has a major diameter sized to move between at least two of the legs along a chordal path into one of the recesses during installation in the carrier. Long pinions, supported on the first plate and the second plate, each has a major diameter sized to move between at least two of the legs along a radial path into one of the recesses during installation in the carrier.