Rochester Hills, MI, United States
Rochester Hills, MI, United States

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Patent
American Axle and Manufacturing Inc. | Date: 2016-06-07

A method that includes: providing a blank; heating the blank; forging the heated blank to form a forged gear having a plurality of spiral bevel gear teeth; machining the forged gear to a predetermined thickness while locating off of the plurality of gear teeth to form a green machined forged gear; rotationally and axially engaging a die to the gear teeth of the green machined forged gear to induce plastic flow in the gear teeth to form an intermediate gear in which the plurality of gear teeth conform to a predetermined tooth form; heat-treating the intermediate gear to form a hardened intermediate gear; and lapping the plurality of gear teeth of the hardened intermediate gear with a spiral bevel pinion gear; wherein the plurality of gear teeth are not machined in a chip-producing machining operation before the plurality of gear teeth are lapped.


A torque transfer device can include a housing and a clutch. The housing can define a clutch cavity and a pocket. The pocket can be formed at an axial end of the clutch cavity and have a generally arcuate shape that extends circumferentially about the clutch cavity above a static lubrication level. The clutch can include an outer carrier, an inner carrier, a plurality of first and second interleaved friction plates. One of an outer and an inner plate carrier of the clutch can be coupled to an input member for common rotation. The other of the carriers can be coupled to a differential case for common rotation. Rotation of the outer carrier relative to the housing through a fluid in the clutch cavity can sling a portion of the fluid toward an inner surface of the housing to cause the portion of the fluid to collect in the pocket.


A method that includes: providing a structure that is movable along a first axis; coupling a sensor assembly to the structure, the sensor assembly comprising first and second eddy current sensors and first and second targets that are mounted to the structure for movement along the first axis; sensing the first target with the first eddy current sensor and responsively generating a first sensor signal; sensing the second target with the second eddy current sensor and responsively generating a second sensor signal; and using the first and second sensor signals to determine a location of the structure along the first axis in a manner that is insensitive to coordinated movement of the first and second targets along a second axis that is perpendicular to the first axis and a third axis that is perpendicular to both the first and second axes.


An actuator can include a housing, core assembly, and first and second electromagnets. The housing can have a first pole piece, second pole piece, and central pole piece disposed between the first and second pole pieces. The central pole piece can have a central body and a bridge. The bridge can be between the first and second pole pieces and axially movable relative thereto. The core assembly can be received in the housing. The core assembly can be movable along a first axis between a first core position and a second core position. The core assembly can include a permanent magnet, a first core, and a second core. The first and second cores can be coupled to the permanent magnet for common axial movement. The first and second electromagnets can be spaced axially apart by the central body and can have opposite polarities.


Patent
American Axle and Manufacturing Inc. | Date: 2016-08-04

An actuator can include a coil spring, a plunger, and a rotating member. The coil spring can include a plurality of coils disposed about an axis. The plunger can include a body and a follower. The follower can be fixedly coupled to the body. The body can be disposed about the axis. The follower can be received between adjacent ones of the coils. The rotating member can be rotatable about the axis and drivingly coupled to one of the coil spring and the plunger to rotate the one of the coil spring and the plunger about the axis. Rotation of the rotatable member can effect translation of the plunger, compression of the coil spring, or both translation of the plunger and compression of the coil spring.


Patent
American Axle and Manufacturing Inc. | Date: 2016-02-24

A brushless DC electric motor having a rotor with a single bearing, a multi-pole oriented magnet, an output coupling and a rotor shell. The rotor shell is formed of an electrically insulating material and can be overmolded onto the magnet, the bearing and the output coupling.


Patent
American Axle and Manufacturing Inc. | Date: 2016-02-24

An actuator that includes a housing, first and second drive portions, a rotary-to-linear converter and an output member. The housing defines a first housing part and a second housing part that is segregated from first housing part by a housing wall. The first drive portion is housed in the first housing part and has a source of rotary power and an intermediate output that is driven by the source of rotary power. The second drive portion is housed in the second housing part and has an intermediate input and a transmission. The intermediate input receives rotary power from the intermediate output and transmits rotary power to the transmission. The intermediate input does not physically contact the intermediate output and the housing wall is disposed between the intermediate output and the intermediate input. The rotary-to-linear converter driven by the transmission. The output member translated along an axis by the rotary-to-linear converter.


Patent
American Axle and Manufacturing Inc. | Date: 2016-05-19

A method for forming a propshaft assembly includes: providing a tube having an annular wall member and an axial end face; providing a yoke having body and a pair of arms that extend from the body, the body defining an annular groove having sidewalls and an end face, the sidewalls being spaced apart to receive the annular wall member; spinning at least one of the tube and the yoke while engaging the axial end face to the end face of the annular groove to plasticize a portion of the yoke and a portion of the tube; and driving the yoke and the tube together to fuse the plasticized portion of the yoke and the plasticized portion of the tube together and thereby form a friction weld; wherein the tube is fused to the yoke over portions of the yoke that correspond to the sidewalls and the end face.


Patent
American Axle and Manufacturing Inc. | Date: 2016-04-21

A propshaft with an universal joint, a first tubular member and a second tubular member. The universal joint has first and second yoke arms that are pivotally coupled to one another. The first tubular member is fixedly coupled to the first yoke arms and has a plurality of first teeth. The second tubular member slidably received over the first tubular member and includes a plurality of second teeth. The first and second teeth engage one another when the propshaft is in an extended condition. The second teeth engage the first yoke arms when the propshaft is in a retracted condition.


Patent
American Axle and Manufacturing Inc. | Date: 2016-02-16

Mating bevel gears generally include a pinion gear having a body that rotates about an axis and a side gear having a body that rotates about an axis that intersects the axis of the pinion gear. Pinion gear teeth of the pinion gear have a side that defines a curvature with an involute section through which a pitch line extends and a parabolic shape between the pinion gear teeth. Side gear teeth of the side gear have a side that defines a curvature with an involute section through which a pitch line extends and a parabolic shape between the side gear teeth. The curvatures on the pinion and the side gear teeth cooperatively define a controlled relative radius of curvature section except where the involute sections are located. The controlled relative radius of curvature section defines a sum of values of radius of curvature at a point of contact between the curvatures of the pinion gear teeth and the side gear teeth. The sum has a constant or decreasing value.

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