Abstract: An actively cooled nitrous oxide sensor module is provided. The actively cooled nitrous oxide sensor module includes a sensor unit comprising at least one of the nitrous oxide sensor and at least a portion of circuitry associated with the at least one nitrous oxide sensor. The actively cooled nitrous oxide sensor module also includes an active cooling assembly thermally coupled to the sensor unit. The active cooling assembly includes a coolant inlet and a coolant outlet. The active cooling assembly also includes a coolant path disposed between the coolant inlet and the coolant outlet. The active cooling assembly is configured to control a temperature of the sensor unit based, at least in part, on a circulation of a coolant flow therethrough.

Abstract: A marine fuel delivery system and method of construction thereof provides at least one of a fuel filter housing and a fuel vapor separator housing with a lower support cap extending laterally therefrom, with the lower support cap being formed as a single piece of plastic material with the fuel filter housing and/or fuel vapor separator housing. In addition, the system includes a heat shield extending upwardly from the lower support cap. The fuel filter housing and/or fuel vapor separator housing; the lower support cap and the heat shield are constructed as a monolithic piece of thermoset plastic that does not melt when directly exposed to a 650° C. flame for 2½ minutes.

Abstract: An outboard marine engine has vapor vent control apparatus including a fuel inlet in fluid communication with a fuel reservoir of the engine. The fuel inlet is operably attachable to a fuel pin of a fuel connector. When attached, liquid fuel flows to the fuel reservoir and when detached, liquid fuel flow out of the fuel inlet is prevented. A vapor vent passage is configured in fluid communication with the liquid fuel reservoir and an air intake of the engine. A vent pin is disposed in the vapor vent passage. The vent pin moves between a first position upon attaching the fuel connector to the fuel inlet and a second position upon detaching the fuel connector from the fuel inlet. In the first position, the vapor vent passage is open to fuel vapor flow and, when in the second position, the vapor vent passage is closed to fuel vapor flow.

Abstract: A system and method for manufacturing a brushless direct current (BLDC) motor fluid pump is disclosed. The system includes an electromagnetic forming device, an upper fixture, a lower fixture, and a pneumatic or hydraulic cylinder. The electromagnetic forming device has a central cavity. The central cavity has a predefined depth from an outer surface of the electromagnetic forming device. The upper fixture is disposed in the central cavity. The upper fixture has a pump stop surface that contacts the BLDC motor fuel pump, and the pump stop surface is selectively spaced from the outer surface of the electromagnetic forming device. A lower fixture having a central cavity for receiving the housing of the BLDC motor fluid pump is provided. A cylinder is configured to move the lower fixture towards the upper fixture until the pump stop surface of the upper fixture contacts the BLDC motor fluid pump.

Abstract: A BLDC electric motor assembly (24) includes a rotor (42) having a plurality of magnet segments (50) securely retained thereabout by an annular ring (68) which is shrunk in situ in an electromagnetic forming operation. The magnet segments (50) are formed with tongues (62, 64) on their upper and lower ends (56, 58). One tongue (64) seats in a retaining pocket (48) molded on the rotor shaft (40), whereas the other tongue (62) provides a ledge into which the ring (68) seats. After the magnet forming operation, wherein the ring (68) is shrunk, the outer surface of the ring (68) is flush with the outer surfaces (54) of the magnet segments (50).

Abstract: A marine fuel delivery system and method of construction thereof provides at least one of a fuel filter housing and a fuel vapor separator housing with a lower support cap extending laterally therefrom, with the lower support cap being formed as a single piece of plastic material with the fuel filter housing and/or fuel vapor separator housing. In addition, the system includes a heat shield extending upwardly from the lower support cap. The fuel filter housing and/or fuel vapor separator housing; the lower support cap and the heat shield are constructed as a monolithic piece of thermoset plastic that does not melt when directly exposed to a 650° C. flame for 2½ minutes.

Abstract: An outboard marine engine has vapor vent control apparatus including a fuel inlet in fluid communication with a fuel reservoir of the engine. The fuel inlet is operably attachable to a fuel pin of a fuel connector. When attached, liquid fuel flows to the fuel reservoir and when detached, liquid fuel flow out of the fuel inlet is prevented. A vapor vent passage is configured in fluid communication with the liquid fuel reservoir and an air intake of the engine. A vent pin is disposed in the vapor vent passage. The vent pin moves between a first position upon attaching the fuel connector to the fuel inlet and a second position upon detaching the fuel connector from the fuel inlet. In the first position, the vapor vent passage is open to fuel vapor flow and, when in the second position, the vapor vent passage is closed to fuel vapor flow.

Abstract: A fuel supply system for an outboard marine engine includes a vapor separator (28) having a uni-directional vapor vent device (36) for preventing fuel leakage when the engine (12) is tipped on its side. The vapor separator (28) includes an enclosed interior chamber (50) which is filled with liquid fuel by a suction pump. A separate, high pressure pump transfers the liquid fuel from the interior chamber (50) to a fuel injection system (32) of the engine (12). The vapor vent device (36) includes a generally tubular casing having an enclosed top end permeated by an escape passage (84), and a float (94) slidably disposed within the casing (82) for movement toward and away from sealing engagement with the escape passage (84).

Abstract: A fuel vapor separator used in fuel delivery systems of a marine engine for recovery of fuel vapors and to prevent fuel spills when the engine is tilted.

Abstract: A system and method for manufacturing a brushless direct current (BLDC) motor fluid pump is disclosed. The system includes an electromagnetic forming device, an upper fixture, a lower fixture, and a pneumatic or hydraulic cylinder. The electromagnetic forming device has a central cavity. The central cavity has a predefined depth from an outer surface of the electromagnetic forming device. The upper fixture is disposed in the central cavity. The upper fixture has a pump stop surface that contacts the BLDC motor fuel pump, and the pump stop surface is selectively spaced from the outer surface of the electromagnetic forming device. A lower fixture having a central cavity for receiving the housing of the BLDC motor fluid pump is provided. A cylinder is configured to move the lower fixture towards the upper fixture until the pump stop surface of the upper fixture contacts the BLDC motor fluid pump.

Abstract: An oil injection system for two-stroke engines, including a pressure regulator located within an oil reservoir, the pressure regulator selectively returning a portion of pumped oil directly back to the oil reservoir to prevent oil from exiting the reservoir at a higher than desired pressure. The pressure regulator allows a portion of the pumped oil from the oil reservoir to flow through the oil line to a solenoid valve, where the pressure regulator and solenoid valve together meter the flow of oil to a plurality of oil injectors for injection into the engine cylinders. Locating the pressure regulator within the oil reservoir eliminates the need for a return line from the solenoid valve to the oil reservoir, thus simplifying the solenoid design as well as the overall design of the oil injection system.