Abstract: A rotating machine comprises a housing defining a generally cylindrical bearing pocket and defining an interior and exterior. The machine also includes a bearing retainer having a generally cylindrical sleeve portion retained in the bearing pocket and a bearing having an outer race and an inner race, the outer race affixed within the cylindrical sleeve portion. The machine further has a rotating member mounted on a shaft for rotation therewith, the shaft having a portion affixed within the inner race of the bearing. In one embodiment, the bearing retainer includes anti-rotation keying projections the bearing pocket includes complementary depressions for the keying projections. The keying projections cooperate with the complementary depressions to prevent rotation of the bearing retainer with respect to the bearing pocket. In another embodiment, a cap is affixed to the bearing retainer to substantially prevent contamination from reaching the bearing from the exterior.

Abstract: A battery heating system for the batteries of an electrical vehicle includes a plurality of electrical heaters. The electrical heaters are apportioned into a plurality of groups, the groups coupled to independently-switchable voltage sources. One or more of the electrical heaters may have a parallel/series design for their resistive heater elements, to improve the reliability of those heaters.

Abstract: A giant magnetoresistive assembly includes a first film fabricated of a ferromagnetic material having a first predetermined thickness, a second film fabricated of a non-ferromagnetic material formed to said first film having a second predetermined thickness greater than said first predetermined thickness, and a third film fabricated of a ferromagnetic material formed to the second film having a third predetermined thickness wherein the third predetermined thickness differs from the first predetermined thickness.

Abstract: A rectification circuit comprises a diode full-wave bridge rectifier, a freewheeling current path and a blocking diode coupled between the rectifier and the freewheeling current path to cause freewheeling current of the bridge rectifier to at least partially flow through the freewheeling current path instead of through the diodes of the bridge rectifier. A result is reduced "reverse recovery" power dissipation in the rectifier diodes.

Abstract: In one embodiment of the present invention, an electrical system for a motor vehicle comprises a capacitor, an engine cranking motor coupled to receive motive power from the capacitor, a storage battery and an electrical generator having an electrical power output, the output coupled to provide electrical energy to the capacitor and to the storage battery. The electrical system also includes a resistor which limits current flow from the battery to the engine cranking motor. The electrical system further includes a diode which allows current flow through the diode from the generator to the battery but which blocks current flow through the diode from the battery to the cranking motor.

Abstract: In one embodiment of the present invention, a method for estimating temperature of fuel in a fuel delivery system of a motor vehicle engine includes the step of calculating a fuel temperature estimate in an engine running state as a function of fuel flow rate, engine coolant temperature and intake air temperature.In a second embodiment of the present invention, a method for estimating temperature of fuel in a fuel delivery system of a motor vehicle engine includes the step of calculating a fuel temperature estimate in an engine not running state as a function of a fuel temperature estimate when the engine was last in a running state, time the engine has been in the not running state, engine coolant temperature and intake air temperature.

Abstract: In one embodiment of the present invention, a rotor for an electrical machine comprises a first pole piece and a second pole piece together defining an axis of rotation of the rotor, each pole piece comprising a generally disc-shaped body having a circumference. Each pole piece further has a plurality of angularly-spaced pole fingers extending axially from the circumference of the body of the pole piece. The rotor additionally includes a plurality of permanent magnets, each permanent magnet affixed to a body of a pole piece between two pole fingers of the pole piece.

Abstract: A rotor for an electrical machine according to one embodiment of the present invention includes first and second individual slip rings mounted on a rotor shaft. A first end of the coil wire for the rotor passes through a first axial passage in the first slip ring and is terminated to conductive material on an axial end of that slip ring. The other end of the coil wire passes through a second axial passage in the first slip ring and through an axial passage in the second slip ring and is terminated to conductive material on an axial end of the second slip ring. The second axial passage of the first slip ring is electrically insulated from the conductive material of that slip ring, so the second wire end does not inadvertently short-circuit to the first conductive material. Also, the first and second slip rings are each designed to cooperate in providing a gap therebetween which provides space to accommodate the termination of the first wire end onto the axial end of the first slip ring.

Abstract: A rotor for an electrical machine according to one embodiment of the present invention comprises a shaft defining an axis of rotation of the rotor, and first and second pole pieces affixed to the shaft for rotation therewith and together defining an interior cavity. The rotor additionally includes a slip ring affixed to the shaft for rotation therewith. Further, the rotor comprises a field-generating coil disposed within the interior cavity, the coil comprising a plurality of turns of electrical wire, the electrical wire further having a section extending to and electrically coupled to the slip ring. Also, the rotor has a retainer disposed exterior to the cavity and adjacent the first pole piece, the retainer comprising a radially-extending channel containing a portion of the section of electrical wire.

Abstract: A linear motor armature includes a sealed metal case having a base portion with at least one cooling channel formed therein and having a central chamber. An epoxy block is disposed within the central chamber. A lamination stack is disposed within the epoxy block. A coil assembly is disposed within the lamination stack, and the coil assembly is cooled by means of the cooling channel. Preferably, more than one cooling channel is provided to facilitate bi-directional cooling flow.

Abstract: In one embodiment of the present invention, an electrical machine includes a rotor having a rotor stop axially affixed with respect to a shaft of the rotor. The rotor stop has a surface which is machined after assembly of the rotor. The rotor is then assembled into the electrical machine, with the machined rotor stop surface accurately locating the rotor axially within the electrical machine. The rotor stop surface includes at least one groove to prevent the formation of long, continuous machining chips during the machining operation.

Abstract: In one embodiment of the present invention, a fuel sensor for a motor vehicle includes a pressure transducer integrated into an end cap for a fuel rail of the vehicle's engine. Further, a temperature transducer can also be included. Fuel sensors according to the present invention facilitate improvements in vehicle packaging and cost.

Abstract: In one embodiment of the present invention, a motor vehicle electrical system has a plurality of electronic modules. The electrical power input of each module is coupled to the output of a switching power supply. Further, the electrical power input of each module is switchably coupled to vehicle system voltage. During "key-on", the switchable connection to vehicle system voltage is closed, thereby providing "key-on" power for the modules from system voltage. During "key-off", the switchable connection is opened, thereby providing "key-off" power for the modules from the switching power supply. In a second embodiment of the present invention, a motor vehicle electrical system has at least one electronic module with a normal power input and a "key-off" power input. The normal power input is coupled to vehicle system voltage, and the "key-off" power input is coupled to the output of a switching power supply. Systems embodying the present invention can reduce "key-off" current draw from the vehicle battery.

Abstract: In one embodiment of the present invention a rotor for an electrical machine comprises a shaft having a radially-reduced portion, the shaft defining an axis of rotation of the rotor. The rotor additionally includes a pole piece having a bore, the pole piece mounted on the shaft for rotation therewith about the axis. Further, the rotor comprises a member located about the shaft in the radially reduced portion and interference fit within the bore of the pole piece. In a second embodiment of the present invention, an electrical machine comprises a rotor which further comprises a shaft defining an axis of rotation of the rotor, a pole piece affixed to the shaft for rotation therewith and a rotor stop slip fit onto the shaft and bearing against the pole piece. The rotor stop also bears against another component of the electrical machine to define an axial position of the rotor within the electrical machine.

Abstract: An operating strategy for a hybrid electric vehicle (HEV) manages the flow of energy to both supply the motive demand power of the HEV and maintain the charge of the energy storage system (ESS). A controller operates the main power unit (HPU) and ESS and, using an optimal fuel cost strategy, scans all possible combinations of power from the HPU and ESS that satisfy the motive demand power. The combination with the lowest fuel cost is selected and the ESS is charged, when possible, using marginal charging; but, if the state of charge of the ESS falls below a certain level, fast charging is invoked. A minimum power threshold strategy can be used rather than the fuel cost strategy. The minimum power threshold strategy determines the optimal compromise of HPU operation and ESS operation to maximize fuel economy by using a motive power threshold below which the HPU is not operated except to recharge the ESS.

Abstract: The present invention provides a method for substantially eliminating backlash in drivetrain gears of a vehicle propelled by an electric motor. The method includes detecting whether brakes of the vehicle are applied. The method further comprises only if the brakes are applied, applying a torque from the electric motor to move at least some teeth of the gears into contact with one another. The present invention further provides a system for substantially eliminating backlash in a drivetrain of a motor vehicle. In one embodiment, the system comprises a plurality of wheels and a drivetrain coupled to at least one of said wheels and comprising engaging gears. The embodiment also includes brakes proximate to at least one of the wheels and adapted to selectively apply braking torque to the at least one of the wheels to which the brakes are proximate.

Abstract: An instrument cluster gauge includes a pointer assembly and a gauge movement. The gauge movement has a staff with a constant diameter. The pointer assembly includes a bushing intended to be placed over the staff when the pointer assembly is mounted on the gauge movement. The bushing has a bore having a lead-in portion providing radial clearance with the staff; a main contact portion with a slight interference with the staff; and a clearance portion providing radial clearance with the staff. The geometry just described facilitates the mounting of the pointer assembly on the gauge movement to a predetermined depth rather than to a predetermined force. Further, the assembly force is defined by design and is therefore more consistent than where a pointer assembly is mounted on a gauge movement staff to a target force. Also, the lead-in eases assembly of the pointer assembly onto the staff, facilitating flexible manufacturing. The bushing further has a face with a stippled surface.

Abstract: The present invention provides a rotor for an electrical machine. The rotor comprises first and second pole pieces defining an axis of rotation of the rotor. The first pole piece comprises a body and a plurality of pole fingers extending axially from the body of the first pole piece. The second pole piece comprises a body and a plurality of pole fingers extending axially from the body of the second pole piece, the pole fingers of the second pole piece intermeshed with the pole fingers of the first pole piece. The rotor also comprises a fan affixed for rotation with the first pole piece and the second pole piece, the fan having a plurality of pockets, each pocket containing a permanent magnet.

Abstract: A conventional full wave diode bridge of an alternator is replaced with a full wave controlled rectifier bridge having controlled switches in place of diodes and the rectifier bridge is controlled in response to a third harmonic of the voltage generated by the alternator to synchronize the rectifier bridge with the alternator and to increase output power from the alternator. The alternator includes a rotor having a field winding receiving a field current which is controlled up to a maximum field current for partial control of the output power produced by the alternator. Power produced by the alternator is also controlled by introducing a phase angle between the phase voltages at the three output connections of the stator winding and the third harmonic up to a maximum or optimum phase angle. To increase power output from the alternator, preferably the field current is increased up to a maximum before any phase angle is introduced between the phase voltages and the third harmonic.

Abstract: In one embodiment of the present invention, machining chips (34) left in the slots (31) of an end face commutator (28) of a motor's rotor (20) are removed using a high-pressure water spray. The windings (26) of the rotor (20) are substantially shielded from water spray by the rotor (20) being located within a cavity (42) of a pallet carrying the rotor (20). Any water which gets on the windings (26) is dried by a brief application of heated forced air.