Magna Powertrain of America, Inc.

Wade Smith

Bradley Ketchel

Ryan Shaw

Ryan Strand

Brad Ketchel

Michael P Bujold

Ralph Larson

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.

High voltage wire protection system for electric vehicles

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.

Ultra-lightweight rear axle drive (ULRAD) assembly with clutch lubrication system

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.

Method of joining a pinion cartridge and an axle housing

A clutch assembly incorporated into a power transfer assembly () of a motor vehicle is presented. The clutch assembly includes a power-operated clutch actuator () for moving a clutch sleeve () 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 () further includes an electromagnetic solenoid with an output member having an extended condition and a retracted condition urging the clutch sleeve () between positions. A shift isolation linkage mechanism () interconnects the output member of the solenoid to the clutch sleeve () and permits movement of the output member to its retracted position while a blocked tooth condition inhibits movement of the clutch sleeve () to its engaged position. Once the blocked tooth condition is removed, the isolation linkage mechanism () forces the clutch sleeve () to its engaged position.

Shift isolation lever system for power-actuated coupling device

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.

Powertrain system actuator and powertrain system therewith

An integrated pinion/bearing/coupling (PBC) assembly for use with a hypoid gearset in power transfer assemblies of motor vehicles having mounting features and venting features, The integrated PBC assembly includes a hollow pinion unit made of steel and including a pinion shaft segment and a pinion gear segment, and a coupling unit having a hub segment made of aluminum. A brazing sleeve is used to braze the aluminum hub segment of the coupling unit to the steel pinion shaft segment of the pinion unit.

Power transfer assembly with hypoid gearset having optimized pinion unit

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.

Differential assembly with two-piece carrier and welded ring gear

An integrated pinion/bearing/coupling (PBC) assembly for use with a hypoid gearset in power transfer assemblies of motor vehicles having mounting features and venting features. The integrated PBC assembly includes a hollow pinion unit made of steel and including a pinion shaft segment and a pinion gear segment, and a coupling unit having a hub segment made of aluminum. A brazing sleeve is used to braze the aluminum hub segment of the coupling unit to the steel pinion shaft segment of the pinion unit. The PBC assembly can further include a constant velocity joint (CVJ) unit connected to, or formed as part of, the coupling unit.

Power transfer assembly with hypoid gearset having integrated pinion and CV joint coupling unit

An integrated pinion, bearing and coupling (PBC) assembly for use with a hypoid gearset in power transfer assemblies of motor vehicles. The PBC assembly includes a pinion unit having a pinion gear segment and a pinion stub shaft segment, and a coupler unit having a coupling flange segment and a coupler shaft segment. The pinion stub shaft segment surrounds and is in press fit engagement with the coupler shaft segment. A portion of the coupler shaft segment is deformed to be retained within one of a receiver groove and raised projections formed in the pinion stub shaft segment so as to fixedly secure the coupler unit to the pinion unit.

Power transfer assemblies for motor vehicle drivelines having integrated two-piece pinion shaft and coupling unit

An integrated pinion shaft and constant velocity joint (PS/CVJ) assembly for use in motor vehicle driveline applications to transfer torque between a propshaft and a ring gear. The PS/CVJ assembly includes a pinion shaft having a pinion gear segment meshed with the ring gear and a hollow pinion shaft segment. The PS/CVJ assembly also includes a constant velocity joint having an inner race coupled to the propshaft and an outer race integral with or fixed to an end portion of the pinion shaft segment.

Growing community of inventors

Mussey, MI, United States of America

Wade Smith