Abstract: A transmission having an electric motor/generator includes a transmission housing and a bearing support rigidly connected to the transmission housing and substantially enclosed by the transmission housing. A stator housing is substantially enclosed by the transmission housing, and is rigidly joined to the bearing support by a plurality of rivets, such that torque may be transferred between the stator housing and bearing support. The stator housing may be formed from a first material, and the bearing support may be formed from a second material, different from the first material. The stator housing and bearing support meet at an interface region, which may be characterized by an absence of a welded connection between the stator housing and the bearing support. The interface region may be characterized as a slip fit, such that the stator housing and bearing support are matable by hand.

Abstract: A seal for use between the housing of an automatic transmission and the housing (can) of a transmission drive motor is disposed at each end of the drive motor housing. The seal includes a preferably metal annulus having inner and outer elastomeric ribbed seals secured thereto. The annulus, which defines a non-hardened “S” shape in cross section, maintains the shape and strength of the seal and the ribbed inner seal provides a fluid tight seal with the motor housing while the ribbed outer seal provides a fluid tight seal with the transmission housing.

Abstract: A cooling system for an electrically variable transmission includes an electric motor having a plurality of connectors. The plurality of connectors are each assembled within a plurality of connector openings in a terminal block. Fluid from within a passageway is supplied by a pressurized fluid source, and an orifice for the passageway is located adjacent to one of the plurality of connector opening. The fluid flowing from the passageway is directed onto one of the plurality of connectors.

Abstract: A motor module is configured for attachment to a transmission housing of a modular transmission assembly. The motor module includes a motor and a support structure. The motor is configured for rotation about a central axis and extends between a first end and a second end. The support structure is operatively connected to the motor such that the support structure at least partially supports the motor. The support structure at least partially extends across the second end of the motor. The support structure is configured for internal attachment to the housing.

Abstract: A vehicle assembly includes an engine having a damper assembly secured to the engine. The damper assembly includes a ring gear. A hybrid transmission having an input shaft is mounted on the mounting shaft of the damper assembly. The damper assembly includes an engine face plate and a transmission face plate secured to the engine face plate. The ring gear is secured to at least one of the transmission face plate and the engine face plate.

Abstract: A seal for use between the housing of an automatic transmission and the housing (can) of a transmission drive motor is disposed at each end of the drive motor housing. The seal includes a preferably metal annulus having inner and outer elastomeric ribbed seals secured thereto. The annulus, which defines a non-hardened “S” shape in cross section, maintains the shape and strength of the seal and the ribbed inner seal provides a fluid tight seal with the motor housing while the ribbed outer seal provides a fluid tight seal with the transmission housing.

Abstract: A motor/generator for a hybrid transmission includes a bearing support configured for attachment to the hybrid transmission. A stator can is bonded directly to the bearing support, possibly by welding. The motor/generator may further include a stator press-fit into said stator can. A method of assembling a hybrid transmission includes welding a stator can to a bearing support, forming a motor/generator housing. A stator is then pressed into the housing. A substantially-complete motor/generator is assembled by installing a rotor, a rotor hub, and a ball bearing into the housing, which are held in the motor/generator housing with a snap ring. The method may include rigidly attaching the substantially-complete motor/generator to a main case. The method may further include testing the substantially-complete motor/generator prior to transporting the motor/generator to a final place of assembly and rigidly attaching the motor/generator to the transmission main case.

Abstract: An automotive drive assembly includes a housing configured to be installed in an automobile, a first electric motor component coupled to the housing, a second electric motor component rotatably coupled to the first electric motor component, the first and second electric motor components jointly including at least one magnet and at least one conductive coil configured such that when current flows through the at least one conductive coil, the second electric motor component rotates relative to the first electric motor component, and a transmission assembly including at least one gear coupled to the second electric motor component such that the rotation of the second electric motor component causes movement of the at least one gear. The second electric motor component and the transmission assembly are coupled to the housing such that the transmission assembly substantially supports the second electric motor component when the housing is installed in the automobile.

Abstract: An input shaft for a hybrid transmission includes a cylindrical hollow shaft portion having internal and external surfaces. The internal surface defines an internal cavity coaxial with the hollow shaft portion and has a splined portion configured to allow power to be transferred to the hollow shaft portion. The input shaft may further include a freeze plug press-fit in the internal cavity, configured to fluidly seal the inner cavity in embodiments with a cavity extending throughout the input shaft. The splined portion may be a broached spline. A method of manufacturing a hybrid powertrain includes forming a hollow transmission input shaft and press-fitting a plug into it, such that the shaft is internally fluid sealed. The shaft is mated to the transmission which may then be filled with fluid and tested for operability. The shaft may be dry-mated to an engine output member for common rotation therewith.

Abstract: A hybrid powertrain includes an engine driving an engine output member, such as a crankshaft. A damper is directly connected to the engine output member, and a transmission input shaft is directly connected to the damper, for common rotation therewith. A dry damper is configured to allow the hybrid powertrain to be characterized by a lack of either a flexplate or a flywheel. A method of manufacturing a hybrid powertrain is also provided, including assembling a fully-functional hybrid transmission at a first manufacturing facility and assembling a fully-functional engine by joining a dry damper to an engine at a second manufacturing facility different from the first. Each of the fully-functional engine and hybrid transmission may be tested separately from the other. The fully-functional engine and hybrid transmission may then be shipped to a common assembly facility, and dry-mated at the common assembly facility, forming an assembled hybrid powertrain.

Abstract: A pump for a hybrid transmission includes an input shaft having a mating surface—which may include a flat portion—on an outer surface thereof, and a pump rotor coaxial with the input shaft. The pump rotor has an inner surface corresponding to the mating surface of the input shaft, and is directly and drivingly coupled to the input shaft for common rotation therewith. The hybrid transmission may further include an input housing and pump housing, and a pump pocket—in which the pump rotor operates—defined by the input housing, pump housing, and input shaft. The pump is configured to be testable prior to mating the hybrid transmission to an engine. The pump rotor is bounded axially by the input shaft, and a pump guide is configured to center the pump rotor, and to be installed prior to installation of the pump rotor.

Abstract: The present invention presents a means for simultaneously testing the compressive strength and measuring the thermal energy dissipated by a given friction material during slip. The testing apparatus includes a rotatable flywheel that rotates a transmission reaction plate to simulate a typical reaction plate in a vehicle transmission assembly. A plurality of test samples selectively interact with the reaction plate while being elevated by hydraulically actuated cylinders. The thermal energy dissipated between the reaction plate and each test sample is measured for each test sample. A method for accomplishing the same for a bill-of-design reference is also included.