Abstract: A system includes an electric motor, at least one pair of high side and low side switches connected to the electric motor, and a microcontroller connected to the high side and low side switches. At least the low side switches have a minimum on-time requirement. The microcontroller controls the switches by outputting a pulse-width modulation (PWM) signal. At least the PWM signal outputted to the low side switch is center-aligned to the off-time. When a request is made to the microcontroller resulting in a low side on-time of zero with a previous duty cycle request that is greater than a predetermined threshold, the microcontroller is constructed and arranged to extend the duty cycle of the low side switch of the at least one pair of switches into the next period to a duration of the required minimum on-time.

Abstract: An electronics device is disclosed, including: a first printed circuit board having a plurality of through-holes; a second printed circuit board having a plurality of through-holes; a housing in which the first and second printed circuit boards are disposed, the first printed circuit board disposed above the second printed circuit board in the housing; and a connector attached to the housing and including a plurality of pins comprising first pins and a plurality of second pins, a length of the first pins being greater than a length of the second pins. Each of the first pins extends through one of the through-holes of the first printed circuit board and one of the through-holes of the second printed circuit board and thereby makes an electrical connection with the first and second printed circuit boards, and each of the second pins only extends through one of the through-holes of the second printed circuit board and thereby makes an electrical connection with the second printed circuit board.

Abstract: A method is provided for powering a 48V electrically heated catalyst of a catalytic converter of a vehicle without using a 48V battery. The method provides a 12V battery. An electrical energy storage device is electrically connected between the electrically heated catalyst and the 12V battery. The electrical energy storage device is charged by the 12V battery so as to store a voltage of 12V that can then be switched to 48V. The electrically heated catalyst is powered with 48V supplied by the charged electrical energy storage device. A system for performing the method is also disclosed.

Abstract: A system for reducing a resonant oscillation on a direct current bus is disclosed. The system includes a battery, a first capacitor connected in parallel with the battery, and an inductor connected in series with the first capacitor. The system also includes a first element connected in series with the inductor, a second element connected in parallel with the inductor and the first element, and a second capacitor connected in series with the first element. The system also includes an electric machine connected to the second capacitor. During a re-generation mode for charging the battery, a re-generation current flows from the electric machine to the battery, passing through the first element and the inductor and bypassing the second element. Additionally, during a motor mode, a motor current flows from the battery to the electric machine, passing through the second element and bypassing the first element and the inductor.

Abstract: A valve controller and method for controlling a valve having a solenoid are disclosed, including receiving a least one input signal, detecting a first edge of the at least one signal and in response to the detection activating the valve. Activating the valve includes activating the valve in a rise-to-peak phase during which the valve is opened, a hold phase following the rise-to-peak phase during which the valve remains open and a current level of the valve is less than a current level of the valve during the rise-to-peak phase, and an ending-of-activation phase following the hold phase during which current ripple in the valve is less than the current ripple in the valve during the hold phase.

Abstract: A valve assembly for a fluid pump includes a valve body; a fluid inlet and a fluid outlet defined in the valve body; a valve seat; and an inlet disk disposed in the valve body having an inner portion, an outer portion fixed within the valve body, and a plurality of legs connected between the inner portion and the outer portion so that the inner portion is movable between a first position against the valve seat and a second position spaced apart from the valve seat. The connection between the legs, the inner portion and the outer portion provides a spring bias force to the inner portion against movement of the inner portion from the first position. The plurality of legs, the inner portion and the outer portion are configured such that the spring bias force is asymmetric as applied to the inner portion of the inlet disk.

Abstract: A control unit, controller and non-transitory machine-readable medium for detecting a closing time of an injector valve are disclosed. The control unit is configured to receive a valve current profile of the injector valve, process the valve current profile using at least a slope discriminator, and determine a stuck status and a closing time (if applicable) of the injector valve based on an output of the slope discriminator.

Abstract: A coolant flow control module, having a first outer housing, a first rotor located in the first outer housing, a second outer housing adjacent the first outer housing, and a second rotor disposed in the second outer housing. The second rotor is engaged with the first rotor such that the first rotor and second rotor rotate in unison. An actuator is connected to the first rotor, a first plurality of ports is integrally formed as part of the first outer housing, and a second plurality of ports is integrally formed as part of the second outer housing. The actuator rotates the first rotor and second rotor to at least one of a plurality of configurations such that fluid is able to flow through the first plurality of ports and the first rotor, and fluid is able to flow through the second plurality of ports and the second rotor.

Abstract: A printed circuit board is disclosed. The printed circuit board includes: a substrate layer; a copper layer disposed on the substrate layer; and an organic solderability preservative (OSP) layer disposed on the copper layer. The OSP layer defines one or more laser treated OSP surfaces.

Abstract: A fluid injector includes a valve assembly constructed and arranged to control flow of fluid from an inlet to an outlet of the injector. A metal housing surrounds at least a portion of the valve assembly. A plastic body is molded over at least a portion of the housing. A distal end of the body defines an integral stepped portion extending from the body. A carrier surrounds at least the distal end of the body. A seal member is in contact with at least the stepped portion and a surface of the carrier to prevent liquid from entering a space between the housing and the body.

Abstract: A side feed inlet port for an injector, which makes use of stamped parts to form a compact, high strength three-piece inlet port at a significantly reduced cost. By using an inner sleeve and an outer sleeve, injector sealing is accomplished using the interior sleeve, creating a sealing point, while allowing for inlet conduit attachment to the outer sleeve at, above, or below the sealing point of the DEF injector. The construction of the inlet port is such that there is proper sealing between the inner sleeve and one or more seals, while allowing for the connection between the inlet conduit and the outer sleeve to reduce the overall height of the inlet port, and therefore, the injector. The position of the inlet conduit may be altered without affecting the sealing connection between the inner sleeve and the seal(s), such that the desirable overall height may be achieved.

Abstract: A reductant dosing unit is disclosed, including a fluid injector having a fluid inlet and a fluid outlet. A flange is disposed proximal to the fluid outlet of the fluid injector and configured to secure to a boss associated with an exhaust path of an internal combustion engine. The flange has a largely flat body portion with a through-bore in fluid communication with the fluid outlet of the fluid injector. The flange further includes an extension which extends from the body portion toward the fluid injector and which is connected to thereto. A thermal isolator is disposed between the fluid outlet of the fluid injector and the flange. The connection between the extension of the flange and the fluid injector includes a hermetic seal, preventing exhaust gases in the exhaust path from passing between the flange extension and the fluid injector. The thermal isolator is only used as a support and thermal isolator.

Abstract: An engine control unit (ECU) includes a housing; a cover sealingly engaged with the housing so as to define an interior space; a circuit board disposed in the interior space; and a fastener coupling together the circuit board, the housing and the cover, the fastener serving to limit an amount of deflection of the housing relative to the housing. The circuit board and the cover are constructed and arranged to define an airflow path from an outer surface of the cover to the interior space. The airflow path allows for a leak test to be performed on the ECU, wherein upon an affirmative determination that results of the leak test shows no leaks in the ECU, sealant seals the airflow path.

Abstract: A spring retention system for securing a motor in a desired position. The spring retention system includes a captive feature, which includes a plurality of recesses formed as a motor support spring having a circular opening, which are engaged with a motor bearing housing. The spring retention system reduces motor displacement in multiple directions when the motor is exposed to vibrations, which reduces the cantilever bending on the motor shaft and the motor housing, also improving motor pinion run out. The spring retention system also includes a formed opening feature, which allows for the spring retention system to fit with motor bearings having different sizes. The spring retention system also includes a plurality of spring leg retention features formed as part of the motor support spring, which support the motor bearing housing on an axis, and the module housing supports the motor support spring.

Abstract: A protection device for a vehicle electrical system, including a battery pack having at least one contactor. A microcontroller generates a test pulse at a pulse output thereof and a sense input terminal. The microcontroller has at least one output coupled to the control terminal of the at least one contactor. A first capacitor has a terminal coupled to a first terminal of the at least one contactor; a second capacitor having a terminal coupled to a second terminal of the at least one contactor; and circuitry coupled between the microcontroller and the first and second capacitors. The circuitry reflects the test pulse to the sense input terminal if each contactor is open when the microcontroller applies a contactor opening voltage to the contactor control terminal, and presents a signal different from the reflected test pulse to the sense input terminal of the microcontroller if any contactor is welded shut.

Abstract: An electronics device is disclosed, including: a first printed circuit board having a plurality of through-holes; a second printed circuit board having a plurality of through-holes; a housing in which the first and second printed circuit boards are disposed, the first printed circuit board disposed above the second printed circuit board in the housing; and a connector attached to the housing and including a plurality of pins comprising first pins and a plurality of second pins, a length of the first pins being greater than a length of the second pins. Each of the first pins extends through one of the through-holes of the first printed circuit board and one of the through-holes of the second printed circuit board and thereby makes an electrical connection with the first and second printed circuit boards, and each of the second pins only extends through one of the through-holes of the second printed circuit board and thereby makes an electrical connection with the second printed circuit board.

Abstract: A pressure sensor assembly, which includes a support substrate, circuitry mounted to the support substrate, at least one conductor mounted to the support substrate and in electrical communication with the circuitry, and at least one vertically conductive path connected to and in electrical communication with the at least one conductor. The pressure sensor assembly also includes a diaphragm, at least one sealing glass section connected to the diaphragm and the support substrate, and at least one lateral conductive feed-through mounted to the diaphragm. At least one conductive joint is connected to the vertically conductive path and the lateral conductive feed-through, and the conductive joint provides electrical communication between the vertically conductive path and the lateral conductive feed-through.

Abstract: A heat shield for a reductant delivery unit (RDU), the RDU including a fluid injector with a fluid inlet and a fluid outlet, and a clamp flange for attachment to a mounting boss of a vehicle exhaust pipe. The heat shield includes a first portion which is attached to the fluid injector so as to at least partly cover the fluid outlet thereof. The first portion serves as a thermal barrier for the fluid injector and a mechanical barrier for preventing particles in the vehicle exhaust pipe from contacting the fluid injector when the RDU is attached to the vehicle exhaust pipe. The heat shield further includes a second portion which extends radially outwardly from the first portion for sealing the attachment between the clamp flange and the mounting boss of the vehicle exhaust pipe when the RDU is attached thereto.

Abstract: A system for reducing a resonant oscillation on a direct current bus is disclosed. The system includes a battery, a first capacitor connected in parallel with the battery, and an inductor connected in series with the first capacitor. The system also includes a first element connected in series with the inductor, a second element connected in parallel with the inductor and the first element, and a second capacitor connected in series with the first element. The system also includes an electric machine connected to the second capacitor. During a re-generation mode for charging the battery, a re-generation current o flows from the electric machine to the battery, passing through the first element and the inductor and bypassing the second element. Additionally, during a motor mode, a motor current flows from the battery to the electric machine, passing through the second element and bypassing the first element and the inductor.

Abstract: A shroud configured to connect a leadframe to a battery system for a hybrid motor vehicle is provided. The shroud is removably attachable to the leadframe. The shroud has at least one shroud alignment feature, the shroud being removably attached to the leadframe in a predetermined orientation wherein the shroud alignment feature is aligned with a complimentary leadframe alignment feature. The shroud may include a hollow cylindrical portion and at least one connecting feature configured to attach the shroud to the leadframe. The shroud may be provided as part of a connector system that includes the leadframe. In this case, the leadframe is configured to provide an electrical and mechanical connection between a power inverter and the battery system of the electric motor. The leadframe includes at least one leadframe alignment feature that is aligned with the shroud alignment feature.