Abstract: A shift assembly for a two-speed transfer case utilizes a single actuator to drive both the speed range selection mechanism and a modulating friction clutch pack which selectively transfers drive torque from a primary output to a secondary output. The shift assembly includes an actuator which rotates a shift rail and cam having an intermediate helical track and a dwell region at each end. A lost motion assembly operating in conjunction with the helical cam selectively engages and disengages the clutch when the cam follower is in one of the two dwell regions. Thus, the shift assembly provides sequential operation from full clutch engagement in a first speed range, clutch disengagement in the first speed range, de-selection of the first speed range, selection, and de-selection of neutral, selection of a second speed range and, up to full engagement of the clutch in the second speed range.

Abstract: A turbocharger device for an internal combustion engine including two exhaust gas turbochargers, wherein a regulating device for adjustment of the supply of exhaust gas to one of the turbines or to both turbines is provided in the flow stream of the exhaust gas. A common exhaust gas inflow channel for both turbines is preferably provided on the turbine housing of one of the exhaust gas turbochargers, with two exhaust channel segments for supplying exhaust gas to the respective turbines branching off from the exhaust gas inflow channel. The regulating device is provided where the exhaust gas channel segments branch from the exhaust gas inflow channel on the turbine housing.

Abstract: A solenoid control valve having a spool valve disposed within a valve body and an enlarged diameter, axially sealing land. An upper surface of the sealing land seats against an upper valve stop when the spool valve is in a first sealing position and a lower surface of the sealing land seats against a lower valve stop when the spool valve in a second sealing position, to provide sealing pressure in an axial direction relative to the movement of the spool valve. The control valve includes an actuating portion having a coil and an armature. The armature is in direct contact with the spool valve, preferably through a stem that extends through the upper valve stop. When the coil is not energized, a valve spring biases the spool valve to seat against the upper valve stop so that a source pressure is provided at a control port.

Abstract: The cam phaser of the present invention includes an externally mounted DPCS (234) with spool position feedback to control the position of a center mounted spool valve (192) and control the phase angle of the cam mounted phaser. A position sensor (300) is mounted to the spool valve position such that a control loop (400) controls the position of the spool valve (192). A second, outer loop (430) controls the phaser angle. An offset is preferably added to the spool valve position to move the spool valve to its steady state or null position. This null position is required so that the spool (200) can move in to move the phaser in one direction and outward to move the phaser in the other direction. This type of system reduces any frictional or magnetic hysteresis in the system.

Abstract: A rear axle assembly for a primary front wheel drive motor vehicle includes two electromagnetic clutches and a geared differential. A first electromagnetic clutch provides torque to the geared differential which, in turn, provides drive torque to two axles. The geared differential includes a second electromagnetic clutch operably disposed between the differential cage and the output shafts (axles). Activation of the first electromagnetic clutch provides controlled application of torque to the rear differential and activation of the second electromagnetic clutch progressively inhibits differentiation of the geared differential.

Abstract: A variable displacement vane-type fluid pump is provided which permits improved regulation of the pump discharge such that the pump can meet the various requirements of lubrication for internal combustion engines at all speeds with minimized use of power. Of course, the vane pump may also be utilized in a wide range of power transmission and other fluid distribution applications. The vane pump of the invention may also use both hydrostatic and mechanical actuators to control the position of its containment ring or eccentric ring and hence, regulate the output of the pump. According to yet another aspect of the present invention, to prevent inlet flow restriction or cavitation, a valve may be provided to permit some of the pump outlet or discharge flow to bleed into the pump inlet to provide needed velocity energy to the fluid flow into the pump inlet.

Abstract: A flexible metal disk used to mount the fan to the fan drive. The metal disk is a resilient mounting, and as such reduces vibration levels between the fan and fan drive, thereby preventing damage to various components within the cooling system. The flexible metal disk also functions to self align the fan and the fan drive. The flexible metal disk is also durable, and therefore offers improved creep and deterioration resistance as compared with typical elastomeric mountings. In another preferred embodiment, multiple flexible metal disks may be coupled together and used to mount the fan to the fan drive to provide additional damping as compared with single disk systems.

Abstract: A method of controlling the torque transferred across the engaged clutch of a vehicle having a dual clutch transmission to provide predetermined engine acceleration for each gear based on the engine throttle position and subsequent changes of clutch speed that are in response to operatively varying the torque transferred across the engaged clutch as the engine accelerates to a predetermine speed based on the throttle position. The method includes the steps of determining the engine throttle position, determining the currently engaged gear of the transmission, and sensing the speed of the driven member of the engaged clutch. Then, a target engine speed is determined based on the engine throttle position, the currently engaged gear, and the clutch speed. The torque transferred across the engaged clutch is then continuously varied to cause the engine to accelerate toward the target engine speed.

Abstract: A method and apparatus for making a friction clutch plate includes cutting a supply of friction material into a plurality of individual shaped segments. The cut segments are moved in a first horizontal linear direction to a position adjacent a shuttle assembly. At least a first cut segment is engaged by the shuttle assembly which transfers the first cut segment in a second horizontal linear direction which is substantially perpendicular to the first horizontal linear direction. The first cut segment is deposited in a first indexing fixture. The remaining cut segments are sequentially moved in the first horizontal linear direction to the position adjacent the shuttle assembly. At least a second cut segment is engaged by the shuttle assembly and is transferred in a third horizontal linear direction which substantially perpendicular to the first horizontal linear direction.

Abstract: A breather assembly for connection to a protected chamber for use in both positive and negative pressure environments, is described. The breather assembly has a central intake chamber that is protected from the ingress of water or contaminants. The breather assembly provides drain paths for any water or contaminants that may get into the inner chamber.

Abstract: A phaser for an internal combustion engine having at least one camshaft. The phaser has a housing and a rotor. The housing has an outer circumference for accepting a drive force and the rotor connects to a camshaft coaxially located within the housing. The housing and the rotor define at least one vane separating chambers, advance and retard. The vane shifts the relative angular position of the housing and the rotor. The phaser also includes a spool valve comprising a spool slidably mounted within in a bore in the rotor. The spool routes operating fluid from a supply of pressurized fluid to the chambers. At least one passage from the supply to the chambers provides makeup fluid. The passage includes a check valve and a restrictor.

Abstract: A method and apparatus for a supercharger wherein pressurized air originating from the compressor side is fed into its gear box for draining the oil therein due to the reduced size of the gear box. The supercharger includes a gear case encompassing the drive gear and the driven gear. The gear case has at least one oil inlet in the gear case to receive oil, and at least one oil outlet on the gear case. An air passage has a first end connected to the compressor end down stream in relation to the compressor wheel, and a second end connected to the gear box, whereby pressurized air at the compressor end is disposed to be channeled toward the inside of the gear box for draining lubricating fluid therein.

Abstract: A phaser for maintaining an angular relationship between a crank shaft and a cam shaft or among more than one cam shafts is provided. The phaser includes a rotor having a plurality of vanes integral to the rotor and protruding from the rotor body. The plurality of vanes is disposed to oscillate within their respective chambers formed by the rotor and a housing, thereby maintaining the angular relationship. The phaser also includes a shoulder integral to the rotor and interposed between one of the pluralities of vanes and the rotor body, thereby ensuring that the rotor face is always covering a locking pin hole regardless of vane position. The phaser further includes an inlet check valve located within the phaser structure or in very close proximity to the phaser, thereby reducing control fluid leakage.

Abstract: A variable camshaft timing phaser having a locking pin directly influenced by engine oil, which is not impacted by any intervening valves. The locking pin is comprised of a tapered pin, which fits into a tapered recess. The locking pin is biased towards engaging by a spring, and is retracted by oil from the engine oil supply. The locking pin remains disengaged from the tapered recess as long as the oil pump is on.

Abstract: A hydraulic tensioner that decreases the number of components, secures an adequate backlash, and prevents backward movement of a plunger. The hydraulic tensioner includes a hollow plunger having rack teeth formed on a portion of an outer circumferential surface, slidably received in a bore of the housing, where the plunger has an inner space to form a fluid chamber with the bore. A slider housing portion, having an inclined surface, located in the housing, receives a wedge-shaped slider having a ratchet portion adapted to engage with the rack teeth of the plunger and a second side surface. The wedge-shaped slider being slidable along the inclined surface of the slider housing portion in a direction crossing an axial centerline of the plunger. The hydraulic tensioner further includes a first spring biasing the plunger in a protruding direction, and a second spring biasing the slider such that the slider moves along the inclined slide surface of the slider housing portion.

Abstract: In a VCT system, a method uses a controller to automatically determine a state of a phaser based on an identifier. The identifier identifies a filtered signal of the crank shaft and cam shaft and uses the same to identify the phaser state. A reset signal is generated by the identifier to reset the VCT system, specifically to reset a control law whereby the unnecessary information retained by the VCT system is cleared. Therefore, the controller is able to promptly and accurately determine the phaser position and state.

Abstract: An infinitely variable camshaft timing device (phaser) has a control valve located in the rotor. Since the control valve is in the rotor, the camshaft need only provide a single passage for supplying engine oil or hydraulic fluid, and does not need multiple passageways for controlling the phaser, as in the prior art. Two check valves, an advance chamber check valve and a retard chamber check valve, are also located in the rotor. The check valves are located in the control passages for each chamber. The main advantage of putting the check valves in the advance and retard chambers instead of having a single check valve in the supply is to reduce leakage. This design also eliminates high pressure oil flow across the spool valve and improves the response time of the check valve to the torque reversals due to a shorter oil path. In addition, the phaser of the present invention outperforms an oil pressure actuated device and consumes less oil.

Abstract: The difficulty of working with titanium has inhibited the adoption of titanium compressor wheels in automotive air boost devices. The invention provides an economical process for the manufacture of titanium compressor wheels. A hybrid process is disclosed, wherein a forging process is used to produce a near net shape pattern including filled in areas (10, 11) which must be subsequently machined or milled away to produce the net shape compressor wheel. Using the hybrid or two-step process, the technical complexity and time investment in each step is greatly reduced, flaws as associated with the casting technique are eliminated, the process allows itself to be fully automated, the dimensional accuracy of the final product is greater than with conventional techniques, and the strength of the compressor wheel is increased as compared to cast product.

Abstract: An electronically-controlled viscous fan drive having a one-piece accumulator and reservoir located on the top side of the clutch. The accumulator also has a low pressure and high pressure fill hole for allowing movement of viscous fluid from the reservoir to a anti-bleedback chamber and into the operating and working chamber of the coupling during normal operation. A radially balance valve disk having a step up feature coupled to a spring and an actuator electronically controls movement of viscous fluid from the reservoir to the anti-bleedback chamber through the fill holes by energizing or deenergizing the spring based on engine operating conditions. The valve disk may be a one-piece or two-piece design. The accumulator is designed to prevent morning sickness associated with the flow of viscous fluid from the reservoir to the operating chamber during engine off situations.

Abstract: A variable camshaft phase adjustment device (phaser) for an internal combustion engine having at least one camshaft. The phaser has a housing having an outer circumference for accepting a drive force, and a rotor connected to a camshaft coaxially located within the housing. The housing and the rotor are capable of rotation to shift the relative angular position of the camshaft and the crankshaft. The spool valve comprising a spool slidably mounted within a bore in the rotor. In the spool a chamber is present that has an input communicating with the bore the spool is mounted in, an output communicating with the outside, and an air flow restriction. Hydraulic fluid from the input communicating with the bore is prevented from communicating with the outside by the air flow restriction. The air flow restriction is either in the input communicating with the bore or the output communicating with the outside.