A weld structure includes a fitting portion at which a first member and a second member are engaged, a weld portion at which the first member and the second member are welded together, and a space between the fitting portion and the weld portion. One of the first member and the second member has a communication passage whose one end is open to the space and whose other end is open to an outside at a position other than the space. The communication passage is blocked by an insertion member that has a predetermined function in addition to blocking the communication passage.

An all-wheel drive vehicle driveline can include an input member, first intermediate member, output member, sleeve, ring gear, and pinion gear. The input member can be coupled to an input of a differential mechanism for common rotation. The output member can be coupled to an output of the differential mechanism for common rotation. The sleeve can be axially movable between a first position wherein the input, output, and first intermediate members are rotatable relative to each other, a second position wherein the sleeve couples the input member to the first intermediate member for common rotation, and a third position wherein the sleeve couples the input member to the output member for common rotation. The ring gear can receive rotary power from the first intermediate member. The pinion gear can be meshingly engaged to the ring gear.

A method for forming an axle shaft that includes friction welding a tubular shaft to a shaft portion of a wheel flange. Portions of the joint members on the tubular shaft and the wheel flange are extruded into an annular weld cavity in the wheel flange during the formation of the friction weld. A related axle shaft is also provided.

A worm gear assembly may include an input shaft having a first and second screw formed axially thereon, a first torque transfer unit comprising a first worm wheel operatively coupled to the first worm screw, a first radial pinion coaxially affixed to the first worm wheel, and a first axial crown wheel operatively coupled to the first radial pinion, and a second torque transfer unit comprising a second worm wheel operatively coupled to the second worm screw, a second radial pinion coaxially affixed to the second worm wheel, and a second axial crown wheel operatively coupled to the second radial pinion, wherein the first radial pinion is in meshed interface with the second radial pinion, and wherein torque differences between the first axial crown wheel and the second axial crown wheel are transmitted at least in part through said meshed interface.

A bevel head assembly is shown capable of fine motor control of a cutting tool (for instance, a laser or plasma cutter) in three simultaneous dimensions of movement. A rack-and-pinion system moves the bevel head assembly and cutter up and down in the Z-axis while a rotational motor attached to the rack-and-pinion system moves the bevel head assembly in a first rotational (X) axis, and a linear actuator pivotally connected to the cutting tool is mounted to the rotational motor to move the bevel head assembly in a second (Y) rotational axis.

An interrupter includes: an intermittent member having a meshing tooth meshing with a second rotary member, and moving in an axial direction between a coupled position and an uncoupled position; and an actuator making the intermittent member move in the axial direction. The actuator includes: a coil generating magnetic flux; and a plunger moving with the intermittent member in the axial direction. The plunger is disposed in a manner capable of making relative rotation to one of the first and second rotary members via first and second air gaps. When the coil is energized, the magnetic flux is introduced to the plunger from one of the first and second air gaps, the magnetic flux is led out of the plunger to the other air gap, and the plunger moves in the axial direction so as to reduce at least one air gap of the first and second air gaps.

A differential gear mechanism constructed in accordance to one example of the present disclosure can include a differential case, a clutch pack and a plurality of lock pins. The differential case can include a first differential case portion that defines a first output shaft opening and includes a plurality of clutch ear guides and a plurality of lock pin engaging surfaces. The clutch pack can include a plurality of annular plates that are interleaved between a plurality of annular friction disks. At least one of the annular plates and annular friction disks can include a plurality of radially extending plate ears that are received by the corresponding plurality of clutch ear guides. The plurality of lock pins can be received by the plurality of first lock pin engaging surfaces of the first differential case at locations in-line with the clutch ear guides.

A differential gear mechanism includes a differential case, a first and second side gear, a first, second and third pinion gear and a center block. The differential case can define a first, second and third counterbore formed therearound. The differential case rotates around an axis of rotation. Each cross-pin can have a cylindrical pin body that extends between first and second ends. The first, second and third pinion gears intermesh with the first and second side gears to form a torque transfer arrangement. The center block can have a cylindrical body that defines a first, second and third locating feature thereon. The center block can be disposed between the first and second side gears. Each first end of a respective cross-pin is received by a corresponding counterbore of the differential case. Each second end is received by a corresponding locating feature of the center block.

A differential gear mechanism includes a differential case, a first side gear, a second side gear, a first pinion and a second pinion. The first side gear is rotatably mounted within the differential case and has a first outer diameter. The second side gear is rotatably mounted within the differential case and has a second diameter. The first pinion gear is meshed for rotation with the first side gear during a first meshing event. The second pinion gear is meshed for rotation with the second side gear during a second meshing event. The first and second pinion gears form a torque transfer arrangement configured for transferring torque between the first and second pinion gears and the first and second side gears to rotate the first and second side gears. The first and second outer diameters are distinct such that the first and second meshing events are offset in time.

Methods and systems for a clutch cartridge are provided. The clutch cartridge includes, a dog clutch including a clutch ring slidingly engaged with a tube shaft and including a first toothed interface and a second toothed interface, where the dog clutch is designed to selectively engage a first gear and a second gear. The clutch cartridge further includes a first bearing coupled to the tube shaft and the first gear and a second bearing coupled to the tube shaft and the second gear.