Abstract: An electric machine includes a stator assembly and a bus bar assembly. The stator assembly includes a core with windings positioned on the core. The windings include in-slot portions, end turns, and leads. The leads extend from the in-slot portions at one of the ends of the core with ends of the leads extending axially past the end turns. The leads include a first plurality of leads positioned on a first side of the stator opposite a second plurality of leads positioned on a second side of the stator. The bus bar is substantially circular in shape and positioned radially inward from the end turns. The bus bar assembly includes three bus bars, each bus bar connecting at least one of the first plurality of leads to at least one of the second plurality of leads.

Abstract: A spool valve assembly, configured to control the flow of fluid, includes a spool valve, configured to move axially along an axis to control fluid flow, having a spool cavity and a plurality of spool apertures that communicate fluid between the spool cavity and an outside surface of the spool valve; a valve sleeve, in which the spool valve is concentrically positioned, that slidably receives the spool valve; and a valve plug, received within the spool cavity, having at least one plug aperture and a plug cavity, wherein the spool apertures at least partially overlap the plug aperture(s) in a radial direction to permit the flow of fluid between the plug cavity and the outside surface within a defined flow rate variance regardless of the angular position of the valve plug relative to the angular position of the spool valve.

Abstract: A turbocharger includes a turbine housing. The turbine housing includes a turbine inlet wall defining an inlet passage, an exducer shroud wall defining an exducer interior, a turbine outlet wall defining an outlet passage, a wastegate port wall defining a wastegate channel, and a bushing wall coupled to the wastegate port wall and defining a bushing boss extending along a bushing axis, and a valve seat disposed about the wastegate channel. The turbocharger also includes a wastegate assembly. The wastegate assembly includes a valve element engageable with the valve seat. The wastegate port wall is disposed outside of the exducer interior such that the wastegate port wall and the bushing wall are configured to be thermally decoupled from the turbine inlet wall and such that relative displacement between the valve seat and the bushing axis is reduced during operation of the turbocharger.

Abstract: A transfer case is disclosed that includes an input shaft, a primary output shaft, a secondary output shaft, a gear reduction mechanism that selectively couples the input shaft to the primary output shaft in a high range and a low range, a secondary torque transfer mechanism that operates to selectively couple the primary output shaft to the secondary output shaft to engage a four-wheel drive mode, and an actuation mechanism that operates the gear reduction mechanism and the secondary torque transfer mechanism. The actuation mechanism includes a gear plate with an integral target pattern that is rotatable through a plurality of positions corresponding to states of the gear reduction mechanism and the secondary torque transfer, as well as a sensor that is adapted and positioned to read the target pattern to in each of the positions of the gear plate.

Abstract: The invention relates to a turbocharger with a variable turbine geometry, comprising a turbine (1, 2, 5, 6, 7, 8, 9) with a turbine rotor (1) which is rotatably mounted in a turbine housing (2); the turbine (1, 2, 5, 6, 7, 8, 9) comprising a blade bearing ring (5) being arranged about a turbine axis (A); wherein the blade bearing ring (5) supports a number of blade shafts (6); wherein adjustable guide blades (7) are arranged at the blade shafts (6) on a front side of the blade bearing ring (5); wherein blade levers (8) are arranged at the blade shafts (6) on a rear side of the blade bearing ring (5); wherein an adjustment ring (9) is arranged coaxially with the blade bearing ring (5) and engages with the blade levers (8), a rotation of the adjustment ring (9) relative to the blade bearing ring (5) providing for an adjustment of the guide blades (7); wherein the adjustment ring (9) comprises at least one axially protruding bearing stop (10), the bearing stop (10) being provided by deformation of the adjustment

Abstract: A stator assembly (50) includes a stator core (52) defining an outside diameter (OD) and an inside diameter (ID) with longitudinally extending slots (58) formed between the inside diameter and the outside diameter. The stator core (52) defines a core height extending longitudinally from a first end (53) to a second end (55) of the stator core (52). Distributed windings (60) are retained by the stator core (52) and include an in-slot portion (66) positioned in the slots of the stator core (52), a first end turn portion (62) adjacent to the first end (53) of the stator core, and a second end turn portion (64) adjacent to a second end (55) of the stator core. The first end turn portion (62) defines a first end turn height (h1) extending from the first end (53) of the stator core to a vertex (78) of the first end turn portion (62). A ratio of the first end turn height (h1) to the outside diameter (OD) of the stator core is less than or equal to 0.07.

Abstract: A variable camshaft timing system including a first camshaft phaser having an input that is configured to receive rotational force from a crankshaft and an output that is configured to link with a first camshaft of a concentric camshaft assembly to change the angular position of the first camshaft relative to a crankshaft; and a second camshaft phaser having an output that is configured to link with a second camshaft of the concentric camshaft assembly to change the angular position of the second camshaft relative to the crankshaft, wherein the first camshaft is concentrically positioned to the first camshaft and the first camshaft phaser is mechanically linked to the second camshaft phaser to communicate rotational force from the crankshaft to the second camshaft phaser through the first camshaft phaser and the mechanical link.

Abstract: A turbocharger includes a bearing housing containing a motor within an interior portion of the bearing housing. A liquid-cooled power module is secured to an exterior portion of a bearing housing. The power module contains electrical components that power and control speed of the motor, and has an enclosure that includes sealed first and second volumes separated by a common wall. The first volume is a liquid-cooled compartment for removing heat generated from the electrical components, and the second volume is a liquid-free compartment containing the electrical power components. The electrical power components are fixed to the common wall, which is formed of a heat conductive material, and which may include fins extending into the first volume to optimize heat transfer from the common wall into the liquid-cooled compartment. Finally, the liquid-cooled power module communicates with the motor directly through the bearing housing.

Abstract: In an all-wheel drive (AWD) vehicle, torque carrying connections are provided between the powertrain and all four wheels. A multimode clutch module or clutches are provided to selectively disconnect two of the wheels from the powertrain during operating conditions where disconnection improves the performance and efficiency of the AWD vehicle. The multimode clutch module may be installed at various locations of the AWD vehicle, such as within a front or rear differential, between a half axle and a differential or between a half axle and a corresponding wheel, or within a transfer case or power transfer unit.

Abstract: The invention relates to a turbine comprising a turbine housing defining a volute having a substantially annular outlet opening, a turbine wheel, and an adjusting ring, rotatable about the turbine axis, which is arranged in the turbine housing radially between the volute and the turbine wheel, wherein the adjusting ring comprises a flow channel between a radially outer first peripheral opening and a radially inner second peripheral opening, and wherein the outlet opening is fluidically coupled to the turbine wheel by the flow channel. The outlet opening and the first peripheral opening have a path, variable in the axial direction, so that during a rotation of the adjusting ring, the outlet opening and the first peripheral opening are adjusted relative to each other in such a way that an overflow cross section between the outlet opening and the first peripheral opening is variably changeable.

Abstract: An inlet check valve for controlling fluid from a supply into a variable cam timing phaser includes a double flapper check valve assembly with an open position and a closed position, which includes a housing having a body, at least one stopper, a flapper valve comprising at least two flexible flaps received within the housing and aligned with the stopper(s), and a valve seat received within the housing, the valve seat defining openings aligned with the at least two flexible flaps, axially opposite the two stoppers.

Abstract: A turbine arrangement for an exhaust gas turbocharger includes a turbine housing, a turbine wheel that is arranged in the turbine housing and has an axis of rotation, and a variable turbine geometry arrangement (VTG arrangement). The VTG arrangement includes a bearing ring, a disc, multiple vanes rotatably mounted in the bearing ring, and a contour sleeve that is coupled with the disc. The turbine housing comprises an axial stop, against which the contour sleeve stops in order to secure the VTG arrangement in an axial direction within the turbine housing.

Abstract: A vehicle driveline component with a housing, a ring gear of a transmission, and a plurality of spring sets. The housing defines a bore and a plurality of grooves that are spaced circumferentially about the bore. The ring gear includes an internally-toothed ring gear body and a plurality of mounting teeth that project radially from the ring gear body. The first mounting teeth are received into the grooves in the housing. Each of the spring sets has a first spring, which is disposed between a first side of an associated one of the mounting teeth and a first wall of an associated one of the grooves into which the associated one of the mounting teeth is received, and a second spring that is disposed between a second side of the associated one of the mounting teeth and a second wall of the associated one of the grooves.

Abstract: A transfer case with an actuator for operating a two-speed transmission (i.e., range mechanism) and a clutch (i.e., mode mechanism). The actuator employs a motor-driven cam structure that coordinates the movement of a first fork, which is associated with the range mechanism, and a second fork that is associated with the mode mechanism. A resilient coupling is employed to provide compliance between the motor and the cam structure in the event that tooth-on-tooth contact inhibits the range mechanism from changing from a high-range mode and a low range mode or tooth-on-tooth contact inhibits the mode mechanism from changing between a two-wheel drive mode and a four-wheel drive mode. A sensor target and sensor are employed to identify the rotational positioning of the cam structure placement, which is indicative of the modes in which the transmission and the clutch are operating.

Abstract: A compressor with a compressor housing in which a compressor wheel is arranged. The compressor additionally includes a cartridge which is arranged in the compressor housing in the area of a compressor inlet. The cartridge is designed to variably change the cross section of the compressor inlet.

Abstract: A power electronics assembly that controls an electrically-actuated turbocharger includes a printed circuit board (PCB) having a non-conductive substrate supporting one or more electrical components that attach to the non-conductive substrate on one or more sides of the PCB; one or more conductive layers that couple with the non-conductive substrate and conduct electrical current within the PCB; a fluid barrier layer applied to an outer surface of the non-conductive substrate or conductor layer; and a PCB housing, configured to couple with the electrically-actuated turbocharger, having a fluid cavity that communicates liquid from an internal combustion engine (ICE) to the fluid barrier layer separating the liquid and the PCB.

Abstract: A power transmitting component having a first shaft and a pump. The first shaft has a longitudinal bore, a pump mount and a feed conduit. The pump mount has a circumferentially extending surface, a drive portion and a channel that extends circumferentially about the first shaft. The channel is disposed along a longitudinal axis of the first shaft between the drive portion and the circumferentially extending surface. The feed conduit intersects and fluidly couples the longitudinal bore and the channel. The pump has a pump housing, a first rotor and a pump outlet. The pump housing is mounted about the circumferentially extending surface and is disposed circumferentially about the channel. The first rotor is coupled to the drive portion for rotation therewith. The pump outlet is coupled in fluid communication with the channel.

Abstract: A bearing comprising an axial channel formed along a longitudinal axis of the bearing having an inner radius comprising an inner surface and an outer radius comprising an outer surface and at least one dam region formed on the inner surface of the inner radius of the channel wherein the dam region comprises a modified crescent shape between 90 and 180 degrees about the longitudinal axis of the channel.

Abstract: A friction plate includes a core plate defining a bore. The core plate includes an interior core surface defining the bore, an exterior core surface radially spaced from the interior core surface, a first clutch face extending between the interior core surface and the exterior core surface and facing a first direction, and a second clutch face extending between the interior core surface and the exterior core surface and facing a second direction opposite the first direction. The friction plate also includes a friction material disposed on at least one of the first and second clutch faces. The core plate also includes a fluid directing portion. A first plate thickness is defined between the first and second clutch faces. A second plate thickness is defined at the fluid directing portion. The second thickness is greater than the first thickness.

Abstract: A vehicle transfer case is provided having a housing, a primary shaft rotatably mounted within the housing, a secondary shaft selectively driven by the primary shaft, a hub torsionally fixed with the primary shaft, a clutch housing selectively torsionally connected with the hub via a friction pack, an engagement wheel torsionally fixed with respect to the clutch housing and torsionally connected with the secondary shaft via a flexible torsional force member, the friction pack, upon engagement, causing the clutch housing to be selectively connected with the hub, a reservoir system fixed with respect to the housing capturing lubricant energized by result of the operation of the flexible torsional member, the reservoir system delivering splashed lubricant to a reservoir system, and an Archimedes' screw pump delivering lubricant from a sump adjacent to the secondary shaft to the secondary reservoir system.