Abstract: A motor drive system has a rotor assembly that is rotatable about an axis and includes a hollow shaft, a tube, and one or more fin sets. The tube is received in the shaft and defines a first passage. The fin sets are disposed about the tube and are engaged to the shaft. Each fin set defines a plurality of circumferentially spaced apart fins that are coupled to the shaft and the tube. The first passage is configured to discharge fluid communicated therethrough into a return chamber that is formed in the rotor assembly. A plurality of second passages are formed between the shaft and fins and are in fluid communication with the return chamber.

Abstract: A motor drive system with a rotor assembly having an insert, which is received into a blind hollow rotor space in a rotor shaft. The insert is unitarily and integrally formed and defines a central hole, which is disposed along a rotational axis of the rotor assembly, and a plurality of slots that extend through an outer circumferential surface of the insert. The insert is disposed in the rotor shaft such that the outer circumferential surface of the insert is engaged to the inside circumferential surface of the rotor shaft. The central hole forms a first fluid passage through the insert, while the slots form a plurality of second fluid passages through the insert.

Abstract: An electric drive unit having a multi-phase electric motor and an inverter with a plurality of power semiconductors, an inverter mount, and a plurality of busbars. The power semiconductors are mounted to the base of the inverter mount in an annular arrangement and with the terminals of the power semiconductors extending through the base. Each of the busbars has a first busbar portion, which includes a first body and a set of first fingers that are fixedly coupled to the first body, and a second busbar portion that includes a second body and a set of second fingers that are fixedly coupled to the second body. Associated fingers in the first and second sets of fingers of each bus bar are mechanically and electrically coupled to opposite sides of a corresponding one of the terminals.

Abstract: A motor drive system with a rotor assembly having an insert, which is received into a blind hollow rotor space in a rotor shaft. The insert is unitarily and integrally formed and defines a central hole, which is disposed along a rotational axis of the rotor assembly, and a plurality of slots that extend through an outer circumferential surface of the insert. The insert is disposed in the rotor shaft such that the outer circumferential surface of the insert is engaged to the inside circumferential surface of the rotor shaft. The central hole forms a first fluid passage through the insert, while the slots form a plurality of second fluid passages through the insert.

Abstract: A motor drive assembly having an electric motor with a rotor that includes a rotor shaft and a heat exchanger received in the rotor shaft. The heat exchanger has an insert body with an outer insert surface that is engaged to an inside surface of the rotor shaft. The insert body includes a plurality of segments. Each of the segments defines a first through-hole, and a plurality of second through-holes. Each of the segments is fixedly coupled to one another. A first flow passage extends through the first through-holes in the plurality of segments. Each of the second through-holes defines a portion of a corresponding second flow passage. The second flow passages are disposed concentrically about the first flow passage.

Abstract: An electric drive unit having a multi-phase electric motor and an inverter with a plurality of power semiconductors, an inverter mount, and a plurality of busbars. The power semiconductors are mounted to the base of the inverter mount in an annular arrangement and with the terminals of the power semiconductors extending through the base. Each of the busbars has a first busbar portion, which includes a first body and a set of first fingers that are fixedly coupled to the first body, and a second busbar portion that includes a second body and a set of second fingers that are fixedly coupled to the second body. Associated fingers in the first and second sets of fingers of each bus bar are mechanically and electrically coupled to opposite sides of a corresponding one of the terminals.

Abstract: A motor drive system with a rotor assembly having an insert, which is received into a blind hollow rotor space in a shaft, a coolant inlet and a coolant outlet. The insert has an insert body, a first flow passage and a plurality of second flow passages. The insert body has an outer insert surface that is engaged to an inside surface of a shaft wall of the shaft. The first flow passage extends longitudinally through the insert body. The second flow passages extend longitudinally through the insert body radially between the outer insert surface and the first flow passage. The coolant inlet is fluidly coupled to one of the first and second flow passages, while the coolant outlet is fluidly coupled to the other one of the first and second flow passages.

Abstract: A G-rotor pump assembly is disclosed. The assembly makes use of a housing having a pump/motor housing portion and a laterally projecting housing portion. An electric motor is disposed within the pump/motor housing portion. A controller has a circuit board with a portion which is positioned within the pump/motor housing portion so as to be generally axially aligned with the electric motor and in proximity to the electric motor. A lower cover is configured to engage with the housing to encapsulate the controller and the electric motor within the housing.

Abstract: A vehicle axle assembly including an electric motor, an electric power source, a mode shift gearset, an actuator and a differential within a housing. The motor can include a first output member. The mode shift gearset can include a second output member and a shift member. The shift member can transmit torque between the first and second output members when the shift member is in a second position. The actuator can be coupled to the shift member to move the shift member between first and second positions. The differential can include a differential case and a differential gearset. The differential case can be drivingly coupled to the second output member to receive rotary power therefrom. The differential gearset can transmit rotary power between the differential case and first and second output shafts.

Abstract: A G-rotor pump assembly is disclosed. The assembly makes use of a housing having a pump/motor housing portion and a laterally projecting housing portion. An electric motor is disposed within the pump/motor housing portion. A controller has a circuit board with a portion which is positioned within the pump/motor housing portion so as to be generally axially aligned with the electric motor and in proximity to the electric motor. A lower cover is configured to engage with the housing to encapsulate the controller and the electric motor within the housing.

Abstract: An assembly that includes a tube mount, a tube, a first fillet weld, and a second fillet weld. The tube mount has a tubular side wall, a plurality of circumferentially spaced apart notches formed on a first end of the tubular side wall, and a securing aperture formed through the tubular side wall. The notches form a plurality of teeth. The tube is received into the tube mount. The first fillet weld couples the tube to the tube mount. The first fillet weld is formed about a perimeter the first end such that each of the first welds is formed substantially completely over the entirety of the teeth. The second fillet weld couples the tube to the tube mount. The second fillet weld is formed about a perimeter of the securing aperture such that the second fillet weld is formed substantially completely over an inside perimeter of the securing aperture.

Abstract: An assembly that includes a tube mount, a tube, a first fillet weld, and a second fillet weld. The tube mount has a tubular side wall, a plurality of circumferentially spaced apart notches formed on a first end of the tubular side wall, and a securing aperture formed through the tubular side wall. The notches form a plurality of teeth. The tube is received into the tube mount. The first fillet weld couples the tube to the tube mount. The first fillet weld is formed about a perimeter the first end such that each of the first welds is formed substantially completely over the entirety of the teeth. The second fillet weld couples the tube to the tube mount. The second fillet weld is formed about a perimeter of the securing aperture such that the second fillet weld is formed substantially completely over an inside perimeter of the securing aperture.

Abstract: An overrunning torque transmitting device that employs a plurality of cone clutches and an overload mechanism for limiting the torque transmitted through the device in a predetermined rotational direction. A method for transmitting torque is also provided.

Abstract: A vehicle with an axle assembly, which has a housing, a differential, an input shaft, a pair of shafts and a pair of wheel hubs, and an auxiliary drive unit that includes an electric motor and an overrunning clutch. The differential and the input shaft are disposed in the housing for rotation therein. The differential includes a case and a ring gear that is coupled to the case. The input shaft has a pinion that is meshingly engaged to the ring gear. Each shaft couples the differential to one of the wheel hubs. The clutch includes an input portion, which is coupled to the output shaft of the electric motor, and an output portion, which is coupled to the input shaft. The output portion is de-coupled from the input portion when a rotational speed of the input portion is not greater than a rotational speed of the output portion.

Abstract: An overrunning torque transmitting device that employs a plurality of cone clutches and an overload mechanism for limiting the torque transmitted through the device in a predetermined rotational direction. A method for transmitting torque is also provided.

Abstract: A vehicle with an axle assembly, which has a housing, a differential, an input shaft, a pair of shafts and a pair of wheel hubs, and an auxiliary drive unit that includes an electric motor and an overrunning clutch. The differential and the input shaft are disposed in the housing for rotation therein. The differential includes a case and a ring gear that is coupled to the case. The input shaft has a pinion that is meshingly engaged to the ring gear. Each shaft couples the differential to one of the wheel hubs. The clutch includes an input portion, which is coupled to the output shaft of the electric motor, and an output portion, which is coupled to the input shaft. The output portion is de-coupled from the input portion when a rotational speed of the input portion is not greater than a rotational speed of the output portion.

Abstract: A module with an axle assembly, which has a housing, a differential, an input shaft, a pair of shafts and a pair of wheel hubs, and an auxiliary drive unit that includes an electric motor and an overrunning clutch. The differential and the input shaft are disposed in the housing for rotation therein. The differential includes a case and a ring gear that is coupled to the case. The input shaft has a pinion that is meshingly engaged to the ring gear. Each shaft couples the differential to one of the wheel hubs. The overrunning clutch includes an input portion, which is coupled to the output shaft of the electric motor, and an output portion, which is coupled to the input shaft. The output portion is de-coupled from the input portion when a rotational speed of the input portion is not greater than a rotational speed of the output portion.

Abstract: A module with an axle assembly, which has a housing, a differential, an input shaft, a pair of shafts and a pair of wheel hubs, and an auxiliary drive unit that includes an electric motor and an overrunning clutch. The differential and the input shaft are disposed in the housing for rotation therein. The differential includes a case and a ring gear that is coupled to the case. The input shaft has a pinion that is meshingly engaged to the ring gear. Each shaft couples the differential to one of the wheel hubs. The overrunning clutch includes an input portion, which is coupled to the output shaft of the electric motor, and an output portion, which is coupled to the input shaft. The output portion is de-coupled from the input portion when a rotational speed of the input portion is not greater than a rotational speed of the output portion.

Abstract: An apparatus for attachment to the body (240) of a vehicle (12) which has a front, rear and opposite sides and which has steerable wheels. The apparatus comprises a lower part (22) having structure (40, 48) for fixed attachment at each of the opposite sides of the vehicle. A first steering control arm (150) is pivotally connected to the lower part (22) at one side of the vehicle. A second steering control arm (160) is pivotally connected to the lower part (22) at an opposite side of the vehicle. An upper part (24) is connected with the lower part (22). A rack and pinion steering mechanism (10) includes a rack bar (180) movable axially in opposite directions to effect steering movement of the steerable wheels of the vehicle. The steering mechanism (10) includes a chamber (80) through which the rack bar (180) extends. The chamber is defined by surfaces of the upper and lower parts (22, 24).