Exciter rotor assembly

Claim 2

An exciter rotor assembly (100) for a drive-axle wheel speed sensor for sensing the rotational speeds of a drive axle ring gear (14/30) and of a drive axle differential side gear (48), said assembly characterized by: a generally tubular member (102), said tubular member having first coupling means (110) at one end (108) thereof for engagement with complimentary second coupling means (112) on the side gear for joining said tubular member and said side gear for joint rotation; a first exciter rotor (116) fixed to said tubular member at the other end (114) thereof; and, a second exciter rotor (118) axially fixed to said tubular member axially adjacent said first exciter rotor, said second exciter rotor axially displaced from said first exciter rotor in the direction towards said one end, said second exciter rotor rotatable relative to said tubular member and provided with third coupling means (124/128) for rotationally and axially fixing said second exciter rotor to said ring gear.

Claim 3

The exciter rotor assembly of claim 1 wherein said first coupling means comprises axially extending projections (110) extending from said one end (108) of said tubular member and said second coupling means comprises slots (112) provided in a hub portion (48a) of said side gear for axial receipt of said projections.

Claim 4

The exciter rotor assembly of claim 2 wherein said drive axle (10a) includes a differential carrier (30) fixed for rotation with said ring gear, said third coupling means comprising threaded fasteners (128) extending from said second exciter rotor for threaded receipt in bores (126) provided in said differential carrier.

Claim 5

The exciter rotor assembly of claim 3 wherein said first exciter rotor (116) has a through bore (130) allowing access therethrough from said other end to said threaded fastener.

Claim 6

The exciter rotor assembly of claim 4 wherein said side gear has a hub portion (48a), the outer diameter (104) and inner diameter (106) of said tubular member (102) are generally equal to the outer diameter and inner diameter, respectively, of said hub portion of said side gear.

Claim 7

The exciter rotor assembly of claim 2 wherein said side gear has a hub portion (48a), the outer diameter (104) and inner diameter (106) of said tubular member (102) are generally equal to the outer diameter and inner diameter, respectively, of said hub portion of said side gear.

Claim 8

The exciter rotor assembly of claim 6 wherein said side gear hub and tubular member are piloted in a common support bore for rotation about a common axis of rotation.

Claim 9

The exciter rotor assembly of claim 2 wherein said tubular portion (102) defines a radially outwardly extending shoulder (120) axially interposed between said first and second exciter rotors to maintain the axial separation therebetween, said assembly also including a retaining ring (122) received on the outer diameter surface of said tubular portion for maintaining said second exciter rotor adjacent said shoulder.

Claim 10

The exciter rotor assembly of claim 1 wherein said drive axle (10a) includes a differential carrier (30) fixed for rotation with said ring gear (14), said third coupling means comprising threaded fasteners (128) extending from said second exciter rotor for threaded receipt in bores (126) provided in said differential carrier.

Claim 11

The exciter rotor assembly of claim 9 wherein said first exciter rotor (116) has a through bore (130) allowing access therethrough from said other end to said threaded fasteners.

Claim 12

The exciter rotor assembly of claim 10 wherein said threaded fasteners have a head portion of larger outer diameter than the diameter of said through bore (130) in said first rotor.

Claim 13

The exciter rotor assembly of claim 9 wherein said side gear has a hub portion (48a), the outer diameter (104) and inner diameter (106) of said tubular member (102) are generally equal to the outer diameter and inner diameter, respectively, of said hub portion of said side gear.

Claim 14

The exciter rotor assembly of claim 9 wherein said tubular portion (102) defines a radially outwardly extending shoulder (120) axially interposed between said first and second exciter rotors to maintain the axial separation therebetween, said assembly also including a retaining ring (122) received on the outer diameter surface of said tubular portion for maintaining said second exciter rotor adjacent said shoulder.

Claim 15

The exciter rotor assembly of claim 1 wherein said tubular member is rotatably supported at said one end thereof.

Claim 16

A drive axle assembly (10a) including an in-axle exciter rotor assembly (100) and a speed sensor assembly (140) for sensing the rotational speed of wheels driven by said axle, said axle assembly comprising a housing (26), a driven pinion gear (12), a ring gear (14) driven by the pinion gear, a differential carrier (30) fixed for rotation with the ring gear, a differential assembly (16) driven by the differential carrier and including a first (46) and a second (48) differential side gear, first (20) and second (18) axle shafts rotatable with said first and second side gears, respectively, said wheels driven by said axle shafts, the differential assembly driving said side gears such that rotational velocity of said differential carrier equals the average rotational velocity of said side gears, said assembly characterized in that: one of said side gears (48) has a portion (48a) defining a first outwardly facing surface (50) provided within first connecting means (112), said carrier defines a second outwardly facing surface (52) parallel to and outboard of said first surface, said second outwardly facing surface provided with axially extending threaded bores (126) opening thereto; said exciter rotor assembly comprising a generally tubular member (102) said tubular member having second coupling means (110) at the inboard end (108) thereof for engagement with the first connecting means provided on the side gear portion for joining said tubular member and said side gear for joint rotation; a first exciter rotor (116) fixed to the tubular member at the outboard end (114) thereof; and a second exciter rotor (118) axially fixed to said tubular member axially adjacent said first exciter rotor and inwardly spaced therefrom, said second rotor rotatable relative to said tubular member and provided with threaded members (128) extending inwardly therefrom for threaded receipt in said threaded bores.

Claim 17

A drive axle assembly (10a) including an in-axle exciter rotor assembly (100) and a speed sensor assembly (140) for sensing the rotational speed of wheels driven by said axle, said axle assembly comprising a housing (26), a driven pinion gear (12), a ring gear (14) driven by the pinion gear, a differential carrier (30) fixed for rotation with the ring gear, a differential assembly (16) driven by the differential carrier and including a first (46) and a second (48) differential side gear, first (20) and second (18) axle shafts rotatable with said first and second side gears, respectively, said wheels driven by said axle shafts, the differential assembly driving said side gears such that rotational velocity of said differential carrier equals the average rotational velocity of said side gears, said assembly characterized in that: one of said side gears (48) has a portion (48a) defining a first outwardly facing surface (50) provided within first connecting means (112), said carrier defines a second outwardly facing surface (52) parallel to and outboard of said first surface, said second outwardly facing surface provided with axially extending threaded bores (126) opening thereto; said exciter rotor assembly comprising a generally tubular member (102) said tubular member having second coupling means (110) at the inboard end (108) thereof for engagement with the first connecting means provided on the side gear portion for joining said tubular member and said side gear for joint rotation; a first exciter rotor (116) fixed to the tubular member at the outboard end (114) thereof; and a second exciter rotor (118) axially fixed to said tubular member axially adjacent said first exciter rotor and inwardly spaced therefrom, said second rotor rotatable relative to said tubular member and provided with threaded members (128) extending inwardly therefrom for threaded receipt in said threaded bores.

Claim 18

The drive axle assembly of claim 15 wherein said first connecting means comprise axially extending slots provided in said first surface and said second coupling means comprise axially extending projection extending axially inboardly from the inboard end (108) of said tubular member.

Claim 19

The drive axle assembly of claim 16 wherein said first exciter rotor (116) has a through bore (130) allowing access from the outboard end thereof therethrough to said threaded fasteners provided in said second exciter rotor.

Claim 20

The drive axle assembly of claim 16 wherein said side gear hub portion (48a) defines an inner diameter and an outer diameter, the inner diameter (106) and outer diameter (104) of said tubular member (102) are generally equal to said inner and outer diameter of said hub portion.

Claim 21

The drive axle assembly of claim 13 wherein said tubular portion (102) defines a radially outwardly extending shoulder (120) axially interposed between said first and second exciter rotors and a retaining ring (122) is received in the outer diameter surface of said tubular member to maintain said second exciter rotor adjacent said shoulder means.

Claim 22

The drive axle assembly of claim 16 additionally comprising a speed sensor pickup assembly (140) defining a first and second speed sensor (136 and 138) axially aligned with exciter rotor teeth (132 and 134) provided on said first and second exciter rotors, respectively.

Claim 23

The drive axle assembly of claim 15 wherein said first exciter rotor (116) has a through bore (130) allowing access from the outboard end thereof therethrough to said threaded fasteners provided in said second exciter rotor.

Claim 24

The drive axle assembly of claim 15 wherein said side gear hub portion (48a) defines an inner diameter and an outer diameter, the inner diameter (106) and outer diameter (104) of said tubular member (102) are generally equal to said inner and outer diameter of said hub portion.

Claim 25

The drive axle assembly of claim 15 wherein said tubular portion (102) defines a radially outwardly extending shoulder (120) axially interposed between said first and second exciter rotors and a retaining ring (122) is received in the outer diameter surface of said tubular member to maintain said second exciter rotor adjacent said shoulder means.

Claim 26

The drive axle assembly of claim 15 additionally comprising a speed sensor pickup assembly (140) defining a first and second speed sensor (136 and 138) axially aligned with the exciter rotor teeth (132 and 134) provided on said first and second exciter rotors, respectively.