Abstract: A method of casting an assembly is provided that includes forming a structural insert, over-molding the structural insert with a temporary core, and positioning the over-molded structural insert within a cavity of a casting die. The over-molded structural insert is cast within a part, to form the assembly, and the temporary core is removed. The method may also include a temporary core configured to define an alloy flash trim location or locating features to position the structural insert within the cavity of the casting die. Further, the temporary core may define shared features with the structural insert. The part and structural insert may be dissimilar materials such as a part of an aluminum alloy material and a structural insert of a steel alloy material.

Abstract: A method of casting an assembly is provided that includes forming a structural insert, over-molding the structural insert with a temporary core, and positioning the over-molded structural insert within a cavity of a casting die. The over-molded structural insert is cast within a part, to form the assembly, and the temporary core is removed. The method may also include a temporary core configured to define an alloy flash trim location or locating features to position the structural insert within the cavity of the casting die. Further, the temporary core may define shared features with the structural insert. The part and structural insert may be dissimilar materials such as a part of an aluminum alloy material and a structural insert of a steel alloy material.

Abstract: A engine block cover plate is described having a depression shaped to guide coolant flow around a bend in a coolant circuit, the plate further including a plurality of oil ports. One example method of operation may include guiding a coolant flow around a bend in a cooling circuit within an engine block via the cover plate, the cover plate having coolant and oil ports positioned therein, and adjusting a valve positioned on the cover plate to control a flow of oil through the oil port in response to an engine component temperature. In this way, flow losses may be decreased while enabling improved oil flow control with reduced system complexity.

Abstract: Various bulkhead inserts having a cracked cap are provided. In one example, a cylinder block includes a plurality of cylinder bores, a crankcase disposed below the cylinder block in a vertical direction, and a plurality of inserts, where each adjacent pair of inserts of the plurality of inserts partitions each cylinder bore of the plurality of cylinder bores. Each insert of the plurality of inserts has an upper portion and a cap disposed below the upper portion, the cap cracked from the upper portion and rejoined to the upper portion by one or more fastening devices, the upper having one or more upper bosses, each upper boss having a surface with extruded, circumferentially-extending serrations.

Abstract: Various bulkhead inserts having a cracked cap are provided. In one example, a cylinder block includes a plurality of cylinder bores, a crankcase disposed below the cylinder block in a vertical direction, and a plurality of inserts, where each adjacent pair of inserts of the plurality of inserts partitions each cylinder bore of the plurality of cylinder bores. Each insert of the plurality of inserts has an upper portion and a cap disposed below the upper portion, the cap cracked from the upper portion and rejoined to the upper portion by one or more fastening devices, the upper having one or more upper bosses, each upper boss having a surface with extruded, circumferentially-extending serrations.

Abstract: A engine block cover plate is described having a depression shaped to guide coolant flow around a bend in a coolant circuit, the plate further including a plurality of oil ports. One example method of operation may include guiding a coolant flow around a bend in a cooling circuit within an engine block via the cover plate, the cover plate having coolant and oil ports positioned therein, and adjusting a valve positioned on the cover plate to control a flow of oil through the oil port in response to an engine component temperature. In this way, flow losses may be decreased while enabling improved oil flow control with reduced system complexity.

Abstract: A vacuum source arbitration system is disclosed. In one example, vacuum is supplied to a vacuum reservoir via an ejector during a first condition, and vacuum is supplied to the vacuum reservoir via an engine intake manifold during a second condition. The approach may provide a desired level of vacuum in a reservoir while reducing engine fuel consumption.

Abstract: Systems and methods for delivering oil to an engine are provided herein. According to one embodiment, the oil delivery system includes an oil supply, a feeder passage fluidically coupled to the oil supply and a cylinder head, the feeder passage coupled to a pump and a filter positioned downstream from the pump. The oil delivery system further includes a squirter passage in fluidic communication with a plurality of piston squirters and the feeder passage at a position between the pump and the filter. In this way, less-filtered oil is selectively routed through a cooling circuit to reduce engine warm-up time.

Abstract: An engine with vacuum and coolant pumps is disclosed. In one example, the vacuum and coolant pumps are mechanically coupled together and driven by a single motor. The approach may reduce system cost and complexity.

Abstract: A vacuum source arbitration system is disclosed. In one example, vacuum is supplied to a vacuum reservoir via an ejector during a first condition, and vacuum is supplied to the vacuum reservoir via an engine intake manifold during a second condition. The approach may provide a desired level of vacuum in a reservoir while reducing engine fuel consumption.

Abstract: Systems and methods for delivering oil to an engine are provided herein. According to one embodiment, the oil delivery system includes an oil supply, a feeder passage fluidically coupled to the oil supply and a cylinder head, the feeder passage coupled to a pump and a filter positioned downstream from the pump. The oil delivery system further includes a squirter passage in fluidic communication with a plurality of piston squirters and the feeder passage at a position between the pump and the filter. In this way, less-filtered oil is selectively routed through a cooling circuit to reduce engine warm-up time.

Abstract: An Oldham-style coupling assembly wherein a driving shaft (12) is rotatably coupled to a driven shaft (32) using a reduced-lash flexible coupling assembly. The coupling assembly includes an intermediate coupling plate (38) stationed between the driven (32) and driving (12) shafts. A driven lug (34) associated with the driven shaft (32) has tapered contact faces (36) and engages a driving slot (40) in the center of the coupling plate (38). Likewise, a pair of diametrically opposed half-lugs (18) associated with the driving shaft (12) engage in respective half slots (42) through a similar tapered interface. Springs (28) backing each of the half lugs (18) establish a continuous axial compression force within the coupling plate (38) to urge seating of the tapered interfaces but without frustrating transverse sliding in the respective slots (40, 42), thereby taking up lash from the system. The lugs (18, 34) are oriented perpendicular relative to each other, so as to simulate a traditional Oldham-style coupling.

Abstract: An engine with vacuum and coolant pumps is disclosed. In one example, the vacuum and coolant pumps are mechanically coupled together and driven by a single motor. The approach may reduce system cost and complexity.

Abstract: An Oldham-style coupling assembly wherein a driving shaft (12) is rotatably coupled to a driven shaft (32) using a reduced-lash flexible coupling assembly. The coupling assembly includes an intermediate coupling plate (38) stationed between the driven (32) and driving (12) shafts. A driven lug (34) associated with the driven shaft (32) has tapered contact faces (36) and engages a driving slot (40) in the center of the coupling plate (38). Likewise, a pair of diametrically opposed half-lugs (18) associated with the driving shaft (12) engage in respective half slots (42) through a similar tapered interface. Springs (28) backing each of the half lugs (18) establish a continuous axial compression force within the coupling plate (38) to urge seating of the tapered interfaces but without frustrating transverse sliding in the respective slots (40, 42), thereby taking up lash from the system. The lugs (18, 34) are oriented perpendicular relative to each other, so as to simulate a traditional Oldham-style coupling.