Abstract: A viscous clutch (30; 30?) includes a stationary journal bracket (32; 32?) defining a mounting shaft (32-1; 32-1?), an output member (34; 34?) rotatably supported on the mounting shaft about an axis (A), an input member (34; 34?) rotatably supported on the mounting shaft about the axis, and a working chamber (50; 50?) defined between the input member and the output member to selectively transmit torque there between when a shear fluid is present. The mounting shaft extends axially through the viscous clutch from a front face (62; 62?) of the viscous clutch to a rear face (56; 56?) of the viscous clutch, with the rear face defining a mounting surface for mounting the viscous clutch at a mounting location. The front and rear faces are located at opposite sides of the viscous clutch and face in opposite directions.

Abstract: An electromagnetically actuated viscous clutch assembly includes a rotor arranged relative to an axis of rotation, an electromagnetic coil for generating magnetic flux, a housing positioned adjacent to the rotor to create a fluid working chamber therebetween with the housing and the rotor being selectively rotatable relative to one another, an insert extending through the housing and configured to conduct magnetic flux from the electromagnetic coil along a flux path, a valve assembly electromagnetically linked to the insert along the flux path for selectively controlling fluid flow into the working chamber to selectively engage the rotor and the housing, and a plurality of recesses defined in a portion of the housing located at an interior of the flux path to reduce eddy currents.

Abstract: An electromagnetically actuated viscous clutch assembly includes a rotor arranged relative to an axis of rotation, an electromagnetic coil for generating magnetic flux, a housing positioned adjacent to the rotor to create a fluid working chamber therebetween with the housing and the rotor being selectively rotatable relative to one another, an insert extending through the housing and configured to conduct magnetic flux from the electromagnetic coil along a flux path, a valve assembly electromagnetically linked to the insert along the flux path for selectively controlling fluid flow into the working chamber to selectively engage the rotor and the housing, and a plurality of recesses defined in a portion of the housing located at an interior of the flux path to reduce eddy currents.

Abstract: A magnet holder assembly for a clutch includes a magnet holder and first and second permanent magnets. The magnet holder includes a body portion, a first groove defined in the body portion, a second groove defined in the body portion adjacent to the first groove, and a flange extending from the body portion opposite the first groove and extending in a different direction than the first groove. The flange has a connection feature for securing the magnet holder to a rotatable component of the clutch. The first permanent magnet is radially retained by the first groove in the body portion, and the first permanent magnet has a beveled edge configured to mate with the first groove. The second permanent magnet is radially retained by the second groove, and the first permanent magnet and the second permanent magnet have magnetic orientations arranged substantially opposite one another.

Abstract: A viscous clutch assembly (100) includes a rotor (104), a selectively rotatable member (102) surrounding the rotor and defining a working chamber (114) therebetween, a first opening (126A) defined through the rotor (104) between front and rear sides of the rotor (104) and in fluid communication with the working chamber (114) at both the front and rear sides of the rotor (104), a reservoir (112) supported by the rotor (104) and having a second opening (138), a valve assembly (106) supported by the rotor (106) having a cover plate (140) for selectively covering the second opening (138), and a channel (128,130) defined in the rotor (104) between the first opening (126A) and an area adjacent to the second opening (138). The channel (128,130) is in fluid communication with the first opening (126A).

Abstract: A viscous clutch assembly (100) includes a rotational input structure (110), a rotor (104) attached to the rotational input structure (110), a selectively rotatable member (102) surrounding the rotor (104) and rotatably supported by the rotational input structure (110), an electromagnetic coil (108) positioned relative to a driven side of the rotor (104), a valve assembly (106) supported by the rotor (104), and a magnetic flux circuit for controlling the valve assembly (106) with magnetic flux generated by the electromagnetic coil (108). The valve assembly (106) includes a cover plate (140) for regulating flow of a shear fluid. The rotational input structure (110) comprises a material capable of conducting magnetic flux. The magnetic flux circuit is configured to include no more than four air gaps (G1-G4).

Abstract: A fan assembly for directing fluid flow in a hybrid radial and axial direction includes a backplate having an inner diameter portion and a substantially frusto-conical outer diameter portion positioned about a center axis (CL), a plurality of blades extending from the backplate, and an annular fan shroud positioned adjacent to the plurality of blades and configured for co-rotation therewith. The backplate, the plurality of fan blades and the fan shroud form a fan subassembly, and an overall depth of the fan subassembly is approximately 20-35% of an overall fan subassembly diameter (øD1).

Abstract: A valve assembly (106) for an electromagnetically actuated viscous clutch (100) includes a cover plate (140) defining a seating portion configured to selectively cover an opening (138) from a reservoir (112), a flexible mounting plate (142), and an armature (144) that is movable in response to applied magnetic flux to move the cover plate (140) relative to the opening (138) from the reservoir (112). The armature (144) includes a base portion (146) connected to the cover plate (140) and the mounting plate (142), and a finger (148) extending from the base portion (146). The finger (148) and the base portion (146) define a path for conducting magnetic flux.

Abstract: A method of making a fan (20) includes making a subassembly (48) comprising a backplate (22) and a plurality of blades (24) extending from the backplate (22), making a fan shroud (26), positioning the fan shroud (26) adjacent to the blades (24) of the subassembly (48), providing ferromagnetic particles at a first weld location, and directing electromagnetic energy toward the ferromagnetic particles at the first weld location to melt surrounding material and structurally join the fan shroud (26) and at least one of the blades (24).

Abstract: A viscous clutch assembly (100) includes a rotational input structure (110), a rotor (104) attached to the rotational input structure (110), a selectively rotatable member (102) surrounding the rotor (104) and rotatably supported by the rotational input structure (110), an electromagnetic coil (108) positioned relative to a driven side of the rotor (104), a valve assembly (106) supported by the rotor (104), and a magnetic flux circuit for controlling the valve assembly (106) with magnetic flux generated by the electromagnetic coil (108). The valve assembly (106) includes a cover plate (140) for regulating flow of a shear fluid. The rotational input structure (110) comprises a material capable of conducting magnetic flux. The magnetic flux circuit is configured to include no more than four air gaps (G1-G4).

Abstract: A viscous clutch assembly (100) includes a rotor (104), a selectively rotatable member (102) surrounding the rotor and defining a working chamber (114) therebetween, a first opening (126A) defined through the rotor (104) between front and rear sides of the rotor (104) and in fluid communication with the working chamber (114) at both the front and rear sides of the rotor (104), a reservoir (112) supported by the rotor (104) and having a second opening (138), a valve assembly (106) supported by the rotor (106) having a cover plate (140) for selectively covering the second opening (138), and a channel (128,130) defined in the rotor (104) between the first opening (126A) and an area adjacent to the second opening (138). The channel (128,130) is in fluid communication with the first opening (126A).

Abstract: A valve assembly (106) for an electromagnetically actuated viscous clutch (100) includes a cover plate (140) defining a seating portion configured to selectively cover an opening (138) from a reservoir (112), a flexible mounting plate (142), and an armature (144) that is movable in response to applied magnetic flux to move the cover plate (140) relative to the opening (138) from the reservoir (112). The armature (144) includes a base portion (146) connected to the cover plate (140) and the mounting plate (142), and a finger (148) extending from the base portion (146). The finger (148) and the base portion (146) define a path for conducting magnetic flux.

Abstract: A cooling system for a vehicle includes a cooling fan assembly having a cooling fan driven by a brushless DC ring motor, a control/communications system operatively connected to an engine control module (ECM) of the vehicle, a DC-to-DC converter operatively connected to a power source, and a commutation switching segment operatively connected to the DC-to-DC converter and to the control/communications system to provide signals for operating the brushless DC ring motor.

Abstract: A method of operating a cooling fan in a cooling system for a vehicle includes determining a required speed of the cooling fan. First and second signals are provided to a motor controller operatively connected to a motor having a rotatable portion connected to the cooling fan. The first signal coarsely controls a rotational speed of the motor by adjusting a voltage level provided to the motor and the second signal finely controls the rotational speed of the motor by pulse width modulation so that the cooling fan rotates at the required speed.

Abstract: A rotational control apparatus includes a first rotatable assembly and a second rotatable assembly. The first assembly is rotatably mounted to a first support mount. The second assembly is rotatably mounted to the first assembly and is axially moveable relative to the first assembly. The first and second assemblies have respective coaxial surfaces adjacent to and spaced from one another and further have respective axial surfaces that frictionally engage one another when the second assembly is in a first axial position and disengage when the second assembly is in a second axial position. The second assembly is capable of rotation independent of the first assembly when the second assembly is in the second axial position.

Abstract: A dust seal is disposed in a rotational control apparatus for sealing a pressurized chamber, such as a pressure chamber in a pneumatic on/off fan clutch. The dust seal is an annular elastomeric member disposed between first and second members rotating about a first axis. The seal is for sealing against ingress of foreign matter into a pressure chamber that is formed between the first and second members, wherein the first member has an annular extension and the second member has a radially extending surface. The seal comprises a center base section having a first side and a second side, a radially inner upright section and a radially outer upright section. The radially inner upright section extends generally perpendicularly from the first side of the center base section and the radially outer upright section extends from the first side of the center base section at an acute angle relative to the center base section.

Abstract: A cooling system for a vehicle includes a shroud attachable to a fixed portion of the vehicle. A stator assembly for a brushless DC ring motor is attached to at least one mounting support of the shroud. A cooling fan is piloted on the stator assembly, and includes a ring supporting a plurality of fan blades for sweeping an area inside the shroud. A rotor assembly for the brushless DC ring motor is attached to the ring of the cooling fan. The rotor assembly confronts the stator assembly around an outer diameter of the stator assembly. The cooling system is controlled by an electronic controller to rotate the cooling fan to provide appropriate cooling for the vehicle.

Abstract: A cooling system for a vehicle includes a shroud attachable to a fixed portion of the vehicle. A stator assembly for a brushless DC ring motor is attached to at least one mounting support of the shroud. A cooling fan is piloted on the stator assembly, and includes a ring supporting a plurality of fan blades for sweeping an area inside the shroud. A rotor assembly for the brushless DC ring motor is attached to the ring of the cooling fan. The rotor assembly confronts the stator assembly around an outer diameter of the stator assembly. The cooling system is controlled by an electronic controller to rotate the cooling fan to provide appropriate cooling for the vehicle.

Abstract: An eddy current fan drive cooling system is operable in a vehicle having a sheave rotating at a speed related to an engine speed. A driving assembly of the cooling system is attached to the sheave. A plurality of poles are exposed around an outer perimeter of the driving assembly. A plurality of windings are wrapped around the poles. The windings are electrically connected to receive a driving signal to generate a magnetic field around the poles. A driven assembly carrying a cooling fan is provided around the driving assembly. The driven assembly includes a plurality of concentric rings arranged around the exposed poles of the driving assembly. An eddy current torque is produced in the rings in response to magnetic flux passing through the rings from the exposed poles due to the magnetic field around the poles.