Abstract: An apparatus or assembly for forming injection molded magnets in permanent magnet rotors or laminations for such rotors. The assembly includes a plurality of platens defining an axial boundary of a die cavity and a plurality of support shoes that are radially moveable between a closed position defining a radial boundary of the die cavity, and an open position creating a gap between the rotor core and the plurality of support shoes. The assembly has an injection system for filling at least one of the plurality of voids of the rotor core with a magnetic slurry, and a plurality of alignment magnets configured to magnetically align the magnetic slurry.

Abstract: An apparatus or assembly for forming injection molded magnets in permanent magnet rotors or laminations for such rotors. The assembly includes a plurality of platens defining an axial boundary of a die cavity and a plurality of support shoes that are radially moveable between a closed position defining a radial boundary of the die cavity, and an open position creating a gap between the rotor core and the plurality of support shoes. The assembly has an injection system for filling at least one of the plurality of voids of the rotor core with a magnetic slurry, and a plurality of alignment magnets configured to magnetically align the magnetic slurry.

Abstract: A method and assembly for forming a rotor include forming a rotor core having a plurality of voids and placing the formed rotor core into a die cavity. The method includes moving a plurality of support shoes to define an outer diameter of the die cavity, and injecting at least one of the plurality of voids with a magnetic slurry. At least one permanent magnet is formed from the magnetic slurry by applying pressure to the rotor core and the magnetic slurry within the die cavity and by applying a magnetic field to align the magnetic slurry. After forming the at least one permanent magnet within the rotor core, the plurality of support shoes are retracted and the rotor core removed with the at least one permanent magnet formed therein.

Abstract: A method and assembly for forming a rotor include forming a rotor core having a plurality of voids and placing the formed rotor core into a die cavity. The method includes moving a plurality of support shoes to define an outer diameter of the die cavity, and injecting at least one of the plurality of voids with a magnetic slurry. At least one permanent magnet is formed from the magnetic slurry by applying pressure to the rotor core and the magnetic slurry within the die cavity and by applying a magnetic field to align the magnetic slurry. After forming the at least one permanent magnet within the rotor core, the plurality of support shoes are retracted and the rotor core removed with the at least one permanent magnet formed therein.

Abstract: A vehicle includes a transmission, a motor configured to provide a motor torque to the transmission, and an engine configured to provide an engine torque to the transmission. A torque converter is operably disposed between the transmission and the motor, the engine, or both. The torque converter is configured to at least partially transfer at least one of the motor torque and the engine torque to the transmission in accordance with a plurality of k-factors. The torque converter includes a clutch configured to at least partially engage to change the effective k-factor applied by the torque converter. A control processor is configured to blend the plurality of k-factors and at least partially engage the clutch based on the blended k-factor.

Abstract: A vehicle includes an engine that generates an engine torque and a motor that generates a motor torque. A transmission can receive the engine torque, the motor torque, or both. The transmission includes a first gear set and a second gear set, as well as a first clutch that at least partially engages to transfer torque to the gears in the first gear set and a second clutch that at least partially engages to transfer torque to the gears in the second gear set. A controller can control the engine torque and the motor torque to control a speed of the engine to follow a desired speed profile. The controller can also control the engagement of the first clutch and the second clutch to optimize a desired gear state to minimize system losses.

Abstract: A controller-executable method provides an electric-only (EV) launch mode in a vehicle having an accelerator pedal, an engine, a motor generator unit (MGU), a dual-clutch transmission (DCT), and a belt alternator starter system adapted for selectively rotating the crankshaft using motor torque from the MGU. Execution of the method uses motor torque from the MGU, while the engine is off, to accelerate the crankshaft to above a calibrated launch speed when a threshold minimum force is applied to the pedal. A designated one of the odd- and even-gear clutches of the DCT are controlled until input torque to the DCT equals a calibrated level. The other DCT clutch may be modulated to dampen drivetrain oscillations. The vehicle launches in the EV launch mode via the designated DCT clutch when the crankshaft speed exceeds an input speed of the DCT. The vehicle and controller are also provided.

Abstract: A vehicle includes an engine that generates an engine torque and a motor that generates a motor torque. A transmission can receive the engine torque, the motor torque, or both. The transmission includes a first gear set and a second gear set, as well as a first clutch that at least partially engages to transfer torque to the gears in the first gear set and a second clutch that at least partially engages to transfer torque to the gears in the second gear set. A controller can control the engine torque and the motor torque to control a speed of the engine to follow a desired speed profile. The controller can also control the engagement of the first clutch and the second clutch to optimize a desired gear state to minimize system losses.

Abstract: A vehicle includes a transmission, a motor configured to provide a motor torque to the transmission, and an engine configured to provide an engine torque to the transmission. A torque converter is operably disposed between the transmission and the motor, the engine, or both. The torque converter is configured to at least partially transfer at least one of the motor torque and the engine torque to the transmission in accordance with a plurality of k-factors. The torque converter includes a clutch configured to at least partially engage to change the effective k-factor applied by the torque converter. A control processor is configured to blend the plurality of k-factors and at least partially engage the clutch based on the blended k-factor.

Abstract: A controller-executable method provides an electric-only (EV) launch mode in a vehicle having an accelerator pedal, an engine, a motor generator unit (MGU), a dual-clutch transmission (DCT), and a belt alternator starter system adapted for selectively rotating the crankshaft using motor torque from the MGU. Execution of the method uses motor torque from the MGU, while the engine is off, to accelerate the crankshaft to above a calibrated launch speed when a threshold minimum force is applied to the pedal. A designated one of the odd- and even-gear clutches of the DCT are controlled until input torque to the DCT equals a calibrated level. The other DCT clutch may be modulated to dampen drivetrain oscillations. The vehicle launches in the EV launch mode via the designated DCT clutch when the crankshaft speed exceeds an input speed of the DCT. The vehicle and controller are also provided.