Abstract: A thermal energy recovery and management system for an internal combustion engine for balancing the heat energy between a primary reservoir and the engine to maximize an operating efficiency of the engine and associated engine components. The primary reservoir storing or releasing heat energy produced by the engine to achieve a balance of energy between the engine and associated components.

Abstract: A thermal energy recovery and management system for an internal combustion engine for balancing the heat energy between a primary reservoir and the engine to maximize an operating efficiency of the engine and associated engine components. The primary reservoir storing or releasing heat energy produced by the engine to achieve a balance of energy between the engine and associated components.

Abstract: An automotive transmission is equipped with a variety of gears that may be combined to yield one or more output speeds as compared to an input speed. One or more electromechanical actuators is used to engage or disengage a particular desired mix of gears. The electromechanical actuator engages one mix of gears or another to set the desired ratio of input speed to output speed. The transmission may be used to provide a straight-through, an underdrive speed range, or an overdrive speed range in an automotive transmission.

Abstract: A lightweight damper for reducing noise and vibration in torque transferring assemblies that is easily assembled and cost efficient. The damper may be formed from a foam material having a density less than 1.4 lb/ft3, and includes an outer surface that is resiliently biased against the inner surface of a tubular shaft when installed. In a second embodiment, the damper is formed from a sheet of material that dissipates energy such as noises and vibrations through movement of the layers relative to each other. In third embodiment, the dampening sheet and foam damper are combined to provide a damper that dampens noises and vibrations across a large frequency range.

Abstract: One preferred embodiment of the invention is a shaft to transfer torque in a vehicle including a first member having internal splines and a second member having external splines engagable with the internal splines to allow telescopic movement between the first member and the second member and to transfer torque between the first member and the second member. The external spline has a coating to reduce friction during the telescopic movement. Another preferred embodiment of the invention is a suspension system for a vehicle including a biasing device and the above-described shaft.

Abstract: A planetary differential including a differential case rotatable about an axis and a method of manufacturing thereof. The differential case includes a cover, a housing, an annulus gear, and a ring gear. The differential case defines a differential cavity having a clutch cavity and a planet cavity separated by a retainer plate coupled to the housing. The modular nature of this system allows both open and torque biasing constructions in the same packaging space. The method of manufacturing the differential includes the steps of coupling a retainer plate to the housing between the clutch cavity and the axial opening, placing a planetary gear set in the planetary cavity, and fixing the housing to the annulus gear and ring gear.

Abstract: This invention describes a control method for a hydraulic coupling system that includes pressurizing a fluid in an actuator coupled to a multi-disk clutch pack to engage the clutch pack, pumping the fluid through the clutch pack to cool the clutch pack, and controlling one or more valve actuators and one or more pump-motors with a controller. The control method may incorporate pulse width modulation of the actuators, such as the actuators for the pump-motor and valve.

Abstract: A wheel end assembly includes a bearing shaft having a wheel hub mounted onto an outboard end, and a detachable outboard joint mounted onto an inboard end. A wheel bearing is mounted onto the bearing shaft, and includes a knuckle flange having an inner diameter that defines an inboard outer race and an outboard outer race. An inboard inner race and an outboard inner race are supported on the bearing shaft. Bearing elements are positioned between the inner and outer races. An inboard bearing ring is mounted onto the bearing shaft. The inboard bearing ring defines the inboard inner race and includes an engagement portion extending axially inward that engages the detachable outboard joint. The bearing shaft includes a flange portion that supports the inboard bearing ring and the wheel bearing when the outboard joint is removed.

Abstract: A lightweight damper for reducing noise and vibration in torque transferring assemblies that is easily assembled and cost efficient. The damper may be formed from a foam material having a density less than 1.4 lb/ft3, and includes an outer surface that is resiliently biased against the inner surface of a tubular shaft when installed. In a second embodiment, the damper is formed from a sheet of material that dissipates energy such as noises and vibrations through movement of the layers relative to each other. In third embodiment, the dampening sheet and foam damper are combined to provide a damper that dampens noises and vibrations across a large frequency range.

Abstract: A method of induction heat treatment of articles having curved outer surfaces, such as differential housings. The method employs a semi-rectangular induction coil that is adapted to provide a plurality of lateral magnetic fields that are used to induce currents in, and thereby provide heat to, a portion of the curved section of the article. The method and induction coil are particularly adapted to provide an induction hardening heat treatment of a curved heat treatment portion of a differential housing. The differential housing was cast from nodular iron. The induction-hardening heat treatment comprised heating the heat treatment portion of the differential housing above the austenite transition temperature and quenching to below the martensite transformation temperature.

Abstract: The present invention describes a planetary differential including a differential case rotatable about an axis. The differential case includes a cover, a housing, an annulus gear, and a ring gear. The differential case defines a differential cavity having a clutch cavity and a planet cavity separated by a retainer plate coupled to the housing. The modular nature of this system allows both open and torque biasing constructions in the same packaging space. The present invention is further directed to a method of manufacturing a planetary differential having a differential case with a cover and a housing, an annulus gear, and a ring gear. The differential case has a clutch cavity and axial opening defined by the housing and a planet cavity. The method includes the steps of coupling a retainer plate to the housing between the clutch cavity and the axial opening, placing a planetary gear set in the planetary cavity, and fixing the housing to the annulus gear and ring gear.

Abstract: A wheel end assembly includes a bearing shaft having a wheel hub mounted onto an outboard end, and a detachable outboard joint mounted onto an inboard end. A wheel bearing is mounted onto the bearing shaft, and includes a knuckle flange having an inner diameter that defines an inboard outer race and an outboard outer race. An inboard inner race and an outboard inner race are supported on the bearing shaft. Bearing elements are positioned between the inner and outer races. An inboard bearing ring is mounted onto the bearing shaft. The inboard bearing ring defines the inboard inner race and includes an engagement portion extending axially inward that engages the detachable outboard joint. The bearing shaft includes a flange portion that supports the inboard bearing ring and the wheel bearing when the outboard joint is removed.

Abstract: A method of induction heat treatment of articles having curved outer surfaces, such as differential housings. The method employs a semi-rectangular induction coil that is adapted to provide a plurality of lateral magnetic fields that are used to induce currents in, and thereby provide heat to, a portion of the curved section of the article. The method and induction coil are particularly adapted to provide an induction hardening heat treatment of a curved heat treatment portion of a differential housing. The differential housing was cast from nodular iron. The induction-hardening heat treatment comprised heating the heat treatment portion of the differential housing above the austenite transition temperature and quenching to below the martensite transformation temperature.

Abstract: A method of induction heat-treating certain surfaces of an article comprising a hub and a plurality of trunnions or shafts extending therefrom, wherein the surfaces to be heat-treated comprise the surfaces of the trunnions. The method employs an induction coil that provides a planar magnetic field that is adapted to the irregular shape of the article, such that the induction coil produces magnetic fields that are adapted to induce currents in, and thereby heat, the trunnion surfaces of the article. The method and induction coil are particularly adapted to provide an induction hardening heat treatment for trunnion surfaces of trunnions used in steel spiders of spider or tripod-type constant velocity joints.

Abstract: A method of induction heat treating the outer surface of articles having an irregular surface shape. The method employs an induction coil that provides a non-planar magnetic field that is adapted to the irregular shape of the article, such that distinct sections of the induction coil produce distinct magnetic fields that are adapted to induce currents in, and thereby provide heat to, distinct sections of the outer surface of the article. The method and induction coil are particularly adapted to provide an induction hardening heat treatment for the outer surfaces of the inner races of Rzeppa-type constant velocity joints.

Abstract: A lightweight limited slip differential for a tubular or independent axle assembly. The differential biases the torque applied to the wheels through clutch rings engaged on the pinions. The pinions include a mating surface that engage a similar profile on the clutch rings. The clutch rings may be frictionally restrained or coupled together so that the pinion movement is restrained to bias the torque between the wheels.

Abstract: The independent suspension includes a suspension system and a support assembly. The support assembly generally includes a central member having a first end and a second end to which first and second end members are coupled. The support assembly generally spans between vehicle rails with the central member acting as a structural bridge between the end members. The central member defines a cavity and an input passage communicating with the cavity. A driveshaft may be coupled to an input member retained within the input passage which in turn is operably coupled to a torque transferring device disposed within the cavity. The torque transferring device transfers torque from the input member to a pair of output shafts. The end members are also coupled to a suspension system so that the end members may receive suspension load from the suspension system and transfer the suspension load to the other end member through the central member.

Abstract: A support assembly for an independent rear suspension includes a generally-tubular central member having first end and a second end. A U-shaped end member is coupled to each end of the central member, such that the end members are structurally bridged by the central member. Lands defined on the ends of the arms of each end member are adapted to engage the vehicle frame rails through suitable isolation mounts. An attachment point defined on each end member is adapted to pivotally support a lateral link coupling a respective wheelend assembly to the support assembly. The central member advantageously defines at least a portion of a housing adapted to receive a driveline component, such as an electric motor, coupled to the vehicle's rear wheelend assemblies by a pair of shafts extending from the central member, with the further benefit that the shared suspension and driveline isolation mounts providing enhanced NVH characteristics.

Abstract: A differential having a first side gear, a second side gear, and a fastener assembly to restrain the first and second side gears against axial movement. The first and second side gears each include an abutment face and a passage. The fastener assembly includes a bolt and a nut. The bolt has a shaft passing through the passages and a head operatively engaging one of the abutment faces of the side gears. The nut is coupled to the bolt and operatively engages the other abutment face. The invention is also directed to an independent axle differential having a ring gear rotatable about an axis, a geared pinion coupled to rotate with and relative to the ring gear, the first and second side gears and fastener assembly discussed above, and first and second output shafts. The first and second output shafts are disposed in the cavity and coupled to rotate with the first and second side gears, respectively, and each have a shaft end located proximate to one of the bolt head and nut.

Abstract: A differential having a first side gear, a second side gear, and a fastener assembly to restrain the first and second side gears against axial movement. The first and second side gears each include an abutment face and a passage. The fastener assembly includes a bolt and a nut. The bolt has a shaft passing through the passages and a head operatively engaging one of the abutment faces of the side gears. The nut is coupled to the bolt and operatively engages the other abutment face.