Hybrid drive module having a rotor secured to a hub via staking

1. A hybrid drive module, comprising:

a torque converter including:

a cover;

an impeller; and,

a turbine;

a rotor for an electric motor, the rotor including a magnet;

a hub non-rotatably connected to the rotor and the cover and including:

a first circumferential surface; and,

a first plurality of protrusions:

extending radially outward from the first circumferential surface; and,

formed of a material forming the hub; and,

an end plate:

not part of the rotor;

made of a non-magnetic material;

disposed between the first plurality of protrusions and the rotor; and,

engaged with the rotor, wherein:

the first plurality of protrusions restrains the end plate and the rotor, with respect to the hub, in a first axial direction; and,

the end plate blocks movement of the magnet in the first axial direction.

2. The hybrid drive module of claim 1 , wherein the first plurality of protrusions fixes an axial position of the rotor on the hub.

3. The hybrid drive module of claim 1 , wherein:

the material forming the hub, with the exception of the first plurality of protrusions and material adjoining the first plurality of protrusions, has a first number of lattice defects including point defects or imperfections, line defects, or surface defects-grain boundaries, per unit of volume; and,

the material forming the first plurality of protrusions has a second number of lattice defects, including point defects or imperfections, line defects, or surface defects-grain boundaries, per unit of volume greater than the first number of lattice defects per unit of volume.

4. The hybrid drive module of claim 1 , wherein the first plurality of protrusions is in contact with the end plate and urges the end plate into contact with the rotor in a second axial direction, opposite the first axial direction.

5. The hybrid drive module of claim 1 , wherein the hub includes:

a second circumferential surface; and,

a second plurality of protrusions:

extending radially outward from the second circumferential surface; and,

formed of the material forming the hub, the hybrid drive module further comprising:

a resolver rotor engaged with the second circumferential surface, wherein the second plurality of protrusions fixedly secures the resolver rotor to the hub.

6. The hybrid drive module of claim 1 , further comprising:

an input part arranged to receive torque; and,

a disconnect clutch including:

at least one first clutch plate non-rotatably connected to the hub;

an inner carrier non-rotatably connected to the input part;

at least one second clutch plate non-rotatably connected to the inner carrier; and,

a piston plate axially displaceable to open and close the disconnect clutch.

7. A hybrid drive module, comprising:

a torque converter including:

a cover;

an impeller; and,

a turbine;

a rotor for an electric motor;

an end plate;

a hub non-rotatably connected to the rotor and the cover and including:

a first circumferential surface; and,

a first plurality of protrusions:

extending radially outward beyond the first circumferential surface;

formed of the material forming the hub; and,

restraining the rotor, with respect to the hub, in a first axial direction; and,

a spring located between the rotor and the first plurality of protrusions for the hub and urging the rotor in a second axial direction, opposite first axial direction.

8. The hybrid drive module of claim 7 , wherein:

the first plurality of protrusions are in contact with the end plate; and,

the spring reacts against the end plate to urge the rotor in the second axial direction.

9. The hybrid drive module of claim 7 , wherein:

the material forming the hub, with the exception of the first plurality of protrusions and material adjoining the first plurality of protrusions, has a first number of lattice defects, including point defects or imperfections, line defects, or surface defects-grain boundaries, per unit of volume; and,

the material forming the first plurality of protrusions has a second number of lattice defects, including point defects or imperfections, line defects, or surface defects-grain boundaries, per unit of volume greater than the first number of lattice defects per unit of volume.

10. The hybrid drive module of claim 7 , wherein:

the rotor includes at least one magnet;

the end plate is made of a non-magnetic material; and,

the end plate restrains the at least one magnet in the first axial direction.

11. The hybrid drive module of claim 7 , further comprising:

an input part arranged to receive torque; and,

a disconnect clutch including:

at least one first clutch plate non-rotatably connected to the hub;

an inner carrier non-rotatably connected to the input part;

at least one second clutch plate non-rotatably connected to the inner carrier; and,

a piston plate axially displaceable to open and close the disconnect clutch.

12. The hybrid drive module of claim 11 , wherein:

for a first mode:

the disconnect clutch is open to enable independent rotation of the hub and the inner carrier; and,

the rotor is the only source of torque for the torque converter;

for a second mode:

the disconnect clutch is closed to non-rotatably connect the hub and the inner carrier; and,

the input part is the only source of torque for the torque converter; and,

for a third mode:

the disconnect clutch is closed to non-rotatably connect the hub and the inner carrier; and,

the rotor provides torque to the input part via the disconnect clutch.

13. A method of securing components to a hub of a hybrid drive module including a torque converter and a disconnect clutch, comprising:

non-rotatably connecting a rotor for an electric motor to a first circumferential surface of a hub;

placing an end plate on the first circumferential surface;

inserting a spring between the end plate and the rotor;

compressing, using a first punch, the spring between the end plate and the rotor;

urging, with the spring, the rotor in a first axial direction;

deforming, using a second punch, material forming the hub to form a first plurality of protrusions extending radially outward from the first circumferential surface;

contacting the end plate with the first plurality of protrusions; and,

restraining, with the first plurality of protrusions, displacement of the end plate and the rotor, with respect to the hub, in a second axial direction, opposite the first axial direction.

14. The method of claim 13 , further comprising:

engaging a resolver rotor with a second circumferential surface of the hub;

deforming, using the second punch or a third punch, the material forming the hub to form a second plurality of protrusions extending radially outward from the second circumferential surface; and,

fixedly securing the resolver rotor to the hub with the second plurality of protrusions.

15. The method of claim 13 , further comprising:

deforming the material forming the hub such that:

the material forming the hub, with the exception of the first plurality of protrusions and material adjoining the first plurality of protrusions, has a first number of lattice defects including point defects or imperfections, line defects, or surface defects-grain boundaries, per unit of volume; and,

the material forming the first plurality of protrusions has a second number of lattice defects, including point defects or imperfections, line defects, or surface defects-grain boundaries, per unit of volume greater than the first number of lattice defects per unit of volume.

16. The method of claim 13 , further comprising:

non-rotatably connecting the hub and a cover for the torque converter.