Abstract: An electric drive module has an electric motor with a hollow rotor and a gearbox output shaft extending coaxially within the hollow rotor. Cooling medium cycles through an annular volume defined between the rotor and the shaft. A distribution housing is fixed relative to the motor housing and extends around the output shaft to define an annular chamber that receives cooling medium from an inlet of the distribution housing. The shaft and rotor rotate relative to the annular chamber, and cooling medium from the annular chamber is directed by the distribution housing into the annular volume to cool the rotor. The distribution housing may include an annular seal that engages an end face of the hollow rotor. The distribution sleeve may extend into the annular volume, or may be a two-piece structure with an outer housing and an inner sleeve.

Abstract: Systems and methods for welding first and second foils together. A method includes a step of positioning the first and second foils on a lower section of an aluminum fixture. The method further includes a step of compressing the first and second foils together over a first ridge of the lower section via an upper section of the aluminum fixture thereby defining a first weld location coinciding with the first ridge. The method further includes a step of activating a blue or green laser along the first weld location thereby welding the first and second foils together such that the aluminum fixture remains unwelded. Another method includes compressing first and second foils together over an aluminum fixture via a vacuum.

Abstract: An axle assembly includes a carrier housing defining a receiving bore that receives a hollow axle tube. An axle shaft extends through the axle tube to an outboard end and is fixed to a wheel hub that extends around the axle tube and is rotatable relative thereto. The axle tube is attached within the receiving bore via an interference fit. The receiving bore is defined by an inner ring of a dual ring structure. A plurality of ribs extend radially between the inner ring and the outer ring of the dual ring structure. The dual ring structure has a reduced stress concentration relative to a single ring structure caused by bending loads resulting from upward reaction forces at the wheel end in response to downward chassis loads on the axle tube. The carrier housing and axle tube are different materials and fixed together without the use of welding.

Abstract: An electric vehicle is comprised of a first driveline equipped with a first electric drive axle assembly having a first electric drive module configured to drive a pair of first wheels, a second driveline equipped with a second electric drive axle assembly having a second electric drive module configured to drive a pair of second wheels and a vehicle control system controlling coordinated operation of the first and second electric drive modules to generate tractive drive torque transmitted to the wheels and provide low-radius turning functionality.

Abstract: A flexible wire support structure extends between an axle and an inverter for an electric vehicle. The inverter is fixed relative to the vehicle body and the axle is moveable relative to the inverter during vehicle use. A wire extends between the inverter and the axle through a channel defined by the wire support structure. The wire support structure is attached at opposite ends to a first and second support structure, each of which allow pivoting of the flexible wire support structure in response to movement of the axle relative to the inverter. The wire support structure has a limited bend radius in response to movement of the axle, and blocks the wire extending within the support structure from being bent to a tight radius, thereby protecting the wire.

Abstract: A flexible wire support structure extends between an axle and an inverter for an electric vehicle. The inverter is fixed relative to the vehicle body and the axle is moveable relative to the inverter during vehicle use. A wire extends between the inverter and the axle through a channel defined by the wire support structure. The wire support structure is attached at opposite ends to a first and second support structure, each of which allow pivoting of the flexible wire support structure in response to movement of the axle relative to the inverter. The wire support structure has a limited bend radius in response to movement of the axle, and blocks the wire extending within the support structure from being bent to a tight radius, thereby protecting the wire.

Abstract: A pumpless lubrication system for a power transfer assembly equipped with a hypoid gearset having a ring gear and a hollow pinion unit. Lubricant splashed from one of the ring gear and the pinion unit is collected in a collection reservoir and directed through a conduit unit into the hollow pinion unit. The lubricant is delivered to a torque transfer coupling for lubricating and cooling a multi-plate clutch pack.

Abstract: A method for joining components of a vehicle drive axle assembly. The method includes heating an axle housing to a first predetermined temperature and cooling a pinion cartridge to be installed with the housing to a second predetermined temperature. Removing the axle housing from exposure to the first predetermined temperature and removing the pinion cartridge from the second predetermined temperature and rapidly installing the pinion cartridge within the axle assembly before the axle assembly and the pinion return to ambient temperature provides a frictional fit, joining the two components without use of additional fastening devices.

Abstract: An electric vehicle is comprised of a first driveline equipped with a first electric drive axle assembly having a first electric drive module configured to drive a pair of first wheels, a second driveline equipped with a second electric drive axle assembly having a second electric drive module configured to drive a pair of second wheels and a vehicle control system controlling coordinated operation of the first and second electric drive modules to generate tractive drive torque transmitted to the wheels and provide low-radius turning functionality.

Abstract: A clutch assembly incorporated into a power transfer assembly (72) of a motor vehicle is presented. The clutch assembly includes a power-operated clutch actuator (306) for moving a clutch sleeve (354) axially between released and engaged positions between two rotatory members. In the released position, relative rotation between two rotary members is prevented. Whereas in the engaged position, relative rotation is permitted. The power-operated clutch actuator (306) further includes an electromagnetic solenoid with an output member having an extended condition and a retracted condition urging the clutch sleeve (354) between positions. A shift isolation linkage mechanism (304) interconnects the output member of the solenoid to the clutch sleeve (354) and permits movement of the output member to its retracted position while a blocked tooth condition inhibits movement of the clutch sleeve (354) to its engaged position.

Abstract: A pumpless lubrication system for a power transfer assembly equipped with a hypoid gearset having a ring gear and a hollow pinion unit. Lubricant splashed from one of the ring gear and the pinion unit is collected in a collection reservoir and directed through a conduit unit into the hollow pinion unit. The lubricant is delivered to a torque transfer coupling for lubricating and cooling a multi-plate clutch pack.

Abstract: A vehicle powertrain system and powertrain actuator therefor is provided. The powertrain actuator selectively couples a first rotatable member to a second rotatable member to transfer torque therebetween and selectively decouples the first rotatable member from the second rotatable member to prevent the transfer of torque therebetween. The powertrain actuator includes a tubular cam assembly having a tubular first member and a tubular second member. The tubular first and second tubular members have end surfaces that interact with one another upon energizing a unidirectional solenoid. Upon a first energization of the solenoid, the first and second tubular members interact to operably couple the first and second rotatable members to allow torque to be transferred therebetween, and upon a second energization of the solenoid, the first and second tubular members interact to selectively decouple the first the second rotatable members to prevent the transfer of torque therebetween.

Abstract: A vehicle powertrain system and powertrain actuator therefor is provided. The powertrain actuator selectively couples a first rotatable member to a second rotatable member to transfer torque therebetween and selectively decouples the first rotatable member from the second rotatable member to prevent the transfer of torque therebetween. The powertrain actuator includes a tubular cam assembly having a tubular first member and a tubular second member. The tubular first and second tubular members have end surfaces that interact with one another upon energizing a unidirectional solenoid. Upon a first energization of the solenoid, the first and second tubular members interact to operably couple the first and second rotatable members to allow torque to be transferred therebetween, and upon a second energization of the solenoid, the first and second tubular members interact to selectively decouple the first the second rotatable members to prevent the transfer of torque therebetween.

Abstract: Disclosed is a circuit including a sensor, a battery and a reservoir capacitance, the sensor being configured to generate sensor data and the capacitance being provided by one or more discrete capacitors. A first circuit component is configured to drain current from the battery to the reservoir capacitor to store energy in the reservoir capacitor at a safe rate. The safe rate does not adversely affect the battery's life. A second circuit component is configured to generate a series of data packets including sensor data at particular time intervals. A third circuit component is configured to transmit the series of data packets with the stored energy of the reservoir capacitor so that the transmitting does not drain the reservoir capacitor of all stored energy.

Abstract: The following description is directed to managing routing resources of a communication network. In one example, a method can include determining an amount of routing capacity from a network device and toward a routing prefix. An attribute associated with the routing prefix can be modified based on the amount of routing capacity toward the routing prefix. The modified attribute associated with the routing prefix can be announced to a peer of the network device.

Abstract: A differential assembly is provided to include a two-piece differential carrier, a differential gearset installed within a gearset chamber formed in the differential carrier, and a ring gear. An interlocking feature mechanically interconnects the ring gear to the first and second case members of the two-piece differential carrier and defines first and second weldment junctions. A first weld seam is located in the first weldment junction and connects the ring gear to the first case member while a second weld seam is located in the second weldment junction and connects the ring gear to the second case member.

Abstract: A clutch assembly incorporated into a power transfer assembly (72) of a motor vehicle is presented. The clutch assembly includes a power-operated clutch actuator (306) for moving a clutch sleeve (354) axially between released and engaged positions between two rotatory members. In the released position, relative rotation between two rotary members is prevented. Whereas in the engaged position, relative rotation is permitted. The power-operated clutch actuator (306) further includes an electromagnetic solenoid with an output member having an extended condition and a retracted condition urging the clutch sleeve (354) between positions. A shift isolation linkage mechanism (304) interconnects the output member of the solenoid to the clutch sleeve (354) and permits movement of the output member to its retracted position while a blocked tooth condition inhibits movement of the clutch sleeve (354) to its engaged position.

Abstract: A method for joining components of a vehicle drive axle assembly. The method includes heating an axle housing to a first predetermined temperature and cooling a pinion cartridge to be installed with the housing to a second predetermined temperature. Removing the axle housing from exposure to the first predetermined temperature and removing the pinion cartridge from the second predetermined temperature and rapidly installing the pinion cartridge within the axle assembly before the axle assembly and the pinion return to ambient temperature provides a frictional fit, joining the two components without use of additional fastening devices.

Abstract: Against this backdrop systems and methods have been developed for identifying popular segments of media objects. A remix system is provided to users allowing the easy remixing of a library of media objects. The remixes created by the users are recorded. From this information, the relative popularity of the segments and media objects in the library are identified based on how often they appear in the user-generated remixes. Actions may then be automatically taken related to the popularity of segments and media objects such as changing payment terms, alerting users of the popular content, and notifying interested parties of the popular or unpopular content.

Abstract: A differential assembly is provided to include a two-piece differential carrier, a differential gearset installed within a gearset chamber formed in the differential carrier, and a ring gear. An interlocking feature mechanically interconnects the ring gear to the first and second case members of the two-piece differential carrier and defines first and second weldment junctions.