Abstract: An electric machine including a rotor operably coupled with a stator having a plurality of stator windings. Each stator winding defines has a plurality of axially extending segments disposed within the stator slots and a plurality of end turn segments. At least one first axially extending segment defining a first cross sectional area and at least two second axially extending segments defining a smaller second cross sectional area are disposed in each of the stator slots. At least one of the plurality of end turn segments conductively couples a single first axially extending segment in a first one of the plurality of slots to at least two second axially extending segments in a second one of the plurality of slots. In some embodiments, the larger first axially extending segments are all disposed radially outwardly of the smaller second axially extending segments. The windings may be formed using hairpin conductors.

Abstract: A turbocharger (18) includes a shaft (20), a mixed flow turbine wheel (40) including a wheel hub (44) and blades having tips (42), and a heat shield (11). The heat shield (11) has a side wall, an end (19), and a contoured front edge (13) that connects the sidewall (16) and the end (19). The front edge (13) of the heat shield (11) defines a slope that forms an imaginary line that is angled relative to the sidewall (16) and the end (19), and intersects an axis of rotation of the shaft (20). The heat shield (11) resides at a position that is between a bearing housing (22) of the turbocharger (18) and the turbine wheel (40), and axially inward relative to an axially-facing surface of a turbine volute (24), and between the bearing housing (22) and the turbine wheel (40).

Abstract: An active transfer case for a motor vehicle may comprise a clutch assembly configured to rotatably couple a primary output shaft to an input sprocket when engaged. The clutch assembly may include a clutch pack having a plurality of clutch plates, and a clutch hub having a clutch hub center defined between an inner ring and an outer ring. The outer ring of the clutch hub may have a hub aperture placing the clutch hub center in fluid communication with the clutch plates. The active transfer case may further comprise a retainer slidingly inserted in the clutch hub center between the inner ring and the outer ring. The retainer may include a retainer aperture that aligns with the hub aperture of the clutch hub when the clutch assembly is engaged to permit a flow of a lubricant fluid from the clutch hub center to the clutch plates.

Abstract: A laser cutting device (100) is configured to etch an inner surface of a journal bearing (18). The laser cutting device (100) includes a laser (102); a beam directing tool (130) that receives a beam (108) emitted from the laser (102) and selectively changes the direction of travel of the beam (108); a fixture (170) that supports the journal bearing (18) in a desired position relative to the beam directing tool (130); an actuator (148) connected to one of the beam directing tool (130) and the fixture (170), the actuator (148) providing relative movement between the beam directing tool (130) and the fixture (170); and a controller (180) that controls the intensity and duration of the beam (108) emitted from the laser (102); and the actuator (148), whereby material can be removed from a surface of the journal bearing (18) to a precise width and depth, and in any pattern.

Abstract: A compressor wheel assembly for a forced induction device includes an impeller member and a plate member. The impeller member is formed of a polymer material, and includes a hub portion and a plurality of blades extending from an outer surface of the hub portion. The hub portion includes an outer peripheral portion formed therewith. The plate member is connected to the outer peripheral portion of the impeller member to be rotationally fixed thereto. The plate member being formed of a metal material.

Abstract: A method for producing a coil of a compressor (1) which can be electrically driven, a coil which is produced in accordance with this method, and a stator and a compressor which can be electrically driven. The production process for the coil includes the steps of: producing (100) a first winding (101) of the coil (12), producing (200) a second winding (102) of the coil (12), and compacting (300) the first winding (101) and the second winding (102) by virtue of an external action of force. A cross-sectional area (111, 112, 111?, 112?) of a wire of the first winding (101) and of the second winding (102) is deformed.

Abstract: A charging device for an internal combustion engine with rotor cooling has a shaft, a compressor wheel mounted on the shaft, a stator housing and a stator. The stator is arranged in the stator housing. The charging device additionally has a rotor arranged rotatably fixed on the shaft The rotor is surrounded by the stator. A first fan device is arranged for common rotation with the shaft in order to generate a circulating air flow in the stator housing for cooling the rotor.

Abstract: The present invention relates to a double clutch device (2) with a first clutch (18) for selective torque transmission between a clutch input side (26) and a first clutch output side (28) and a second clutch (20) for selective torque transmission between the clutch input side (26) and a second clutch output side (30), wherein an actuating force (78) counter to the reset force (102) of a first spring device (100) may be applied to the first clutch (18) via a first force transmission element (76) and an actuating force (82) counter to the reset force (116) of a second spring device (114) may be applied to second clutch (20) via a second force transmission element (80). The first spring device (100) extends through at least one recess (104) in the second force transmission element (80).

Abstract: A boost control device for a turbocharger, assembled at room temperature, may not be geometrically optimal at turbocharger operating temperature. The geometric deviation in the boost control device introduced by the heating of the turbocharger to operating temperature, or during welding of the boost control device, is corrected by producing a first turbocharger at room temperature, determining the geometry of the deviation at operating temperature, producing a distance element that will introduce an equal and opposite deviation, introducing the equal and opposite deviation via the distance element in second and subsequent turbochargers, whereby thermal deviation and corrective deviation offset so that the turbocharger is geometrically accurate at operating temperature.

Abstract: A product comprising: an axle shaft and an input shaft, wherein the axle shaft is coaxial with the input shaft; a clutch operatively connected to the axle shaft and the input shaft constructed and arranged to selectively couple and decouple the input shaft and the axle shaft; an actuator operatively connected to the clutch to drive the clutch; and a synchronizer operatively connected to the clutch to synchronize the coupling of the input shaft and the axle shaft.

Abstract: Described is a pressure measuring glow plug with a housing, a glow pin, which projects out of the housing and can be displaced in its longitudinal direction relative to the housing against a restoring force. A sensor acquires the position of the glow pin or a pressure acting on the glow pin, and a center pole is arranged in the housing and electrically connected to the glow pin via a contact spring. This disclosure provides that the contact spring is a U-shaped, bent metal strip, which in a middle section has a reduced width, and broadens from the middle section toward its two ends.

Abstract: A charging apparatus (20) for a combustion engine, having a compressor (1) which has a compressor housing (2) in which a compressor wheel (3) is arranged, the compressor wheel being mounted on one end (4) of a rotor shaft (5), and which has a compressor housing rear wall (6); and having an electric motor (7) which has a stator winding (12) which surrounds a magnet (11), which is arranged on the rotor shaft (5), on the outside. The stator winding (12) is an iron-free stator winding, and the electric motor (7) is a brushless DC motor.

Abstract: Described is a glow plug having a casing and a ceramic glow pin protruding out of the casing. The glow pin has a tapered end section inside the casing. A metal protective tube protrudes out of the casing and surrounds the glow pin. The protective tube has a widened end section inside the casing. A center electrode is arranged in the casing and electrically connected to the glow pin. The glow plug includes an annular or sleeve-shaped contact element through which the glow pin projects and to which the tapered end section of the glow pin is soldered. The contact element is at least partly surrounded by the widened end section of the protective tube.

Abstract: A filter band assembly for a solenoid-actuated valve includes a filter band adapted to be disposed about a valve body of the solenoid-actuated valve. The filter band has a first end at one end and a second end at another end. The filter band assembly also includes a separate bracket affixed to one of the first end and the second end and adapted to support the one of the first end and the second end on the valve body to allow the first end and the second end to be joined together in a closed position.

Abstract: A thermal fuse for an electrical circuit is described, with a contact arm by way of which two electrical conductors are electrically conductively connected to each other, wherein the connection of the contact arm to at least one of the two conductors is a soldered joint, which loses its strength when a activation temperature of the fuse is reached. In accordance with this disclosure a permanent magnet is provided, which generates a magnetic force, which lifts the contact arm from at least one of the two conductors as soon as the soldered joint loses its strength.

Abstract: A ball stud (12) with a relatively short grip length, adapted for use with a turbocharger, having a flexible flange (18) extending from a center of the ball stud (12). The flexible flange (18) is between a ball section (14) and a first shaft portion (20) adjacent to the flexible flange (18) and preferably a narrower threaded shaft portion (22) extending further from the ball section (14). The first shaft portion (20) may be tapered to fit in a complementary aperture (32) of a plate (30). The flexible flange (18) preferably includes a narrow circumference (24) adjacent to a center of the ball stud (12) with a circumferential lip (26) adapted to engage a plate (30). The flexible flange (18) allows subtle flex for thermal expansion and essentially changes a spring rate of the ball stud (12) to emulate a longer fastener.

Abstract: A compressor wheel (1) of a compressor (6A) of an exhaust-gas turbocharger (6), having a hub (2); and having a multiplicity of non-recessed blades (3) which are arranged on the hub (2) and which have in each case a blade leading edge (3A) and a blade trailing edge (3B). The blade leading edges (3A) define an inlet area (A1) which is the area swept by the blade leading edges (3A) as the compressor wheel (1) rotates. The blade trailing edges (3B) define an outlet area (A2) which is the area swept by the blade trailing edges (3B) as the compressor wheel (1) rotates. The ratio A2/A1 is >60%.

Abstract: A turbocharger (10) has an improved wastegate valve assembly (45) wherein a port-controlling valve body (44) includes flow formations which serve to reduce exhaust gas flow in non-optimal directions transverse to an optimal flow direction in the direction of a wastegate passage (26). These flow formations serve to optimize or maximize the flow of exhaust gas in the optimal or primary flow direction as the exhaust gas flow turns through a turn angle (47) from an inlet direction (29) to the optimal flow direction.

Abstract: A two-stage valve assembly for a turbocharger includes a movable primary valve adapted to open and close a valve seat of the turbocharger. The primary valve has at least one opening extending axially therethrough. The two-stage valve assembly also includes a movable secondary valve coupled to the primary valve to open and close the at least one opening of the primary valve. The two-stage valve assembly further includes a spring disposed between the primary valve and the secondary valve to seat the secondary valve against the primary valve. The secondary valve is adapted to be coupled to a valve arm of the turbocharger such that relative small movement of the valve arm causes the secondary valve to move and open the opening to allow some exhaust gas of the turbocharger to escape through the at least one opening without moving the primary valve relative to the valve seat.

Abstract: A turbocharger (1) with variable turbine geometry (VTG) having a guide grate (18) which surrounds a turbine wheel (4) radially at the outside, which has an adjusting ring (5) operatively connected to the guide blades (7) via associated blade levers (20) which are fastened to blade shafts (8) at one of the ends thereof. Each blade lever (20) has a lever head (23) which can be placed in engagement with an associated engagement recess (24), which has a base wall (26), of the adjusting ring (5), and which has a stop (25) at least for setting the minimum throughflow through the nozzle cross sections formed by the guide blades (7). The stop is a first support point (25) on the base wall (26), wherein, in the minimum throughflow position, the lever head (23) makes contact, via a wall surface (27) facing toward the base wall (26), with said first support point.