Abstract: An electromagnetic actuation system includes an electrical coil, a magnetic core, an armature, a controllable bi-directional drive circuit for selectively driving current through the coil in either of two directions, and a control module providing an actuator command to the drive circuit. Current is driven though the electrical coil in a first direction when an actuation is desired. When the actuation is not desired current is driven through the electrical coil including in a second direction sufficient to reduce residual flux within the actuator below a level passively attained within the actuator at zero coil current.

Abstract: An apparatus for controlling operation of an electromagnetically-activated actuator includes an activation controller that is one of integrated within a connector assembly of the actuator and integrated into a power transmission cable in close proximity to the actuator. The activation controller comprises a control module configured to generate an actuator command signal, and an actuator driver comprising a bi-directional current driver. The actuator driver is configured to receive the actuator command signal from the control module and generate an activation command signal for controlling the direction and amplitude of the current provided to the actuator.

Abstract: An electromagnetic actuation system includes an actuator having an electrical coil, a magnetic core, and an armature. The system further includes a controllable bi-directional drive circuit for selectively driving current through the electrical coil in either of two directions. The control module provides an actuator command to the drive circuit effective to drive current through the electrical coil in a first direction to actuate the armature and in a second direction subsequent to armature actuation to oppose residual flux within the actuator. The control module includes a residual flux feedback control module configured to adapt the actuator command to converge residual flux within the actuator to a preferred flux level.

Abstract: An electromagnetic actuation system includes an actuator having an electrical coil, a magnetic core, and an armature. The system further includes a controllable bi-directional drive circuit for selectively driving current through the electrical coil in either of two directions. The control module provides an actuator command to the drive circuit effective to drive current through the electrical coil in a first direction to actuate the armature and in a second direction subsequent to armature actuation to oppose residual flux within the actuator. The control module includes a feed forward control module configured to adapt the actuator command to converge residual flux within the actuator to a preferred flux level.

Abstract: An apparatus for closed loop operation of a solenoid-activated actuator includes an external control module and a power source which are electrically and operatively coupled to an activation controller of the actuator. The external control module and the power source are located externally to the actuator. The apparatus further includes an activation controller which is integrated within the body of the actuator. The activation controller includes a control module and an actuator driver and is configured to communicate with the external control module and to receive electrical power from the power source. The apparatus additionally includes at least one sensor device which is integrated within the body of the actuator and is electrically and operatively coupled to the activation controller. The at least one sensor device is configured to measure one or more parameters during operation of the actuator and the measured parameters are provided as feedback to the activation controller.

Abstract: An electric machine includes a stator core defining a number of stator slots (S) extending along a longitudinal axis and angularly spaced about the longitudinal axis. The machine includes a rotor assembly rotatable relative to the stator core and defining first and second ends. The rotor assembly includes a plurality of laminations stacked between the first and second ends. Each respective one of the plurality of laminations defines a number of rotor slots (R) positioned along an outer periphery. A stator slot pitch is defined as 360 divided by the number of stator slots (S). A rotor slot pitch is defined as 360 divided by the number of rotor slots (R) in each respective one of the plurality of laminations. The laminations are skewed relative to each other. An optimal rotor skew angle is determined by the greater of the stator slot pitch and rotor slot pitch.

Abstract: A fuel rail assembly of an internal combustion engine includes an axially extending non-round fuel conduit and at least one axially extending stiffening feature integral with said conduit. Integration of the stiffening features in the conduit enables reduction or elimination of the objectionable frequency noise radiated by the fuel rail assembly. By aligning the stiffening features axially relative to the conduit, panels having a relatively small surface area are formed and, thus, the noise radiating surface area is significantly reduced. The axial orientation of the added stiffening features allows the length of the stiffening features to be relatively large, which increases the stiffening effects to provide increased resistance to flexing, thus, reducing the noise radiated by the fuel system of the internal combustion engine.

Abstract: A fuel rail assembly of an internal combustion engine includes an axially extending non-round fuel conduit and at least one axially extending stiffening feature integral with said conduit. Integration of the stiffening features in the conduit enables reduction or elimination of the objectionable frequency noise radiated by the fuel rail assembly. By aligning the stiffening features axially relative to the conduit, panels having a relatively small surface area are formed and, thus, the noise radiating surface area is significantly reduced. The axial orientation of the added stiffening features allows the length of the stiffening features to be relatively large, which increases the stiffening effects to provide increased resistance to flexing, thus, reducing the noise radiated by the fuel system of the internal combustion engine.

Abstract: An apparatus measures relative displacement between a first end and a second end of a shaft. The first and second ends being centered on a shaft axis. The apparatus includes first and second ferromagnetic plates. The first ferromagnetic plate has a first side and a second side and is connected to the first end. The first ferromagnetic plate is centered on the shaft axis and has a plurality of ferromagnetic teeth extending from the first side and in a first direction parallel to the shaft. The second ferromagnetic plate has a first side and a second side and is connected to the second end. The second ferromagnetic plate is centered on the shaft axis. The first and second ferromagnetic plates form a gap. The apparatus further includes a plurality of magnets having a magnetic field and a sensing device. The magnets are coupled to the first side of the second ferromagnetic plate. The sensing device is disposed within the gap for sensing a magnetic flux of the magnetic field.

Abstract: Certain circuit faults in a phase of a multi-pole, switched reluctance, rotary electrical machine are detected; and the machine is selectively operated with a detected circuit fault when the nature of the fault permits continued operation of the phase and the operation of the phase is desirable. The fault may be one of certain short or open circuits in which at least one of the two current controlling electronic switches is operable to control phase current within predetermined limits. In the continued operation when a fault is detected, (1) the phase current is switched off earlier than it would be in the absence of the fault and/or (2) the maximum phase current is reduced compared with that permitted in the absence of the fault; and either or both of these modifications may be a function of motor speed. If the circuit fault adversely affects current control by an electronic switch normally controlling current level, another electronic switch is substituted for current control.

Abstract: In one method for controlling an electric motor, current turn-on and turn-off rotor-position angles for each motor phase are chosen to substantially maximize the absolute value of average motor torque when the motor is operating in two different quadrants of motor torque and motor speed. The first quadrant has positive motor torque and positive motor speed. The second quadrant has negative torque and positive speed. The third quadrant has negative torque and negative speed. The fourth quadrant has positive torque and negative speed. In another method, the motor is operated in at least one of the first and third quadrants and in at least one of the second and fourth quadrants, wherein the absolute value of motor speed is limited when the motor is operating in the first or third quadrants but not in the second or fourth quadrants. In one example, the motor operates a vehicle brake caliper.

Abstract: The subject invention provides an assembly for measuring movement of and a torque applied to a shaft extending between first and second ends and being hollow, specifically for measuring rotation and twisting of the shaft. A permanent magnet is disposed within the shaft for producing a parallel magnetic field emanating radially from the shaft. A sensor mechanism is positioned adjacent the shaft to detect the magnetic flux produced in response to the shaft being moved. The sensor mechanism includes a magnetostrictive (MR) material disposed annularly about the shaft and extends between first and second edges. A flux collector extends beyond the first and second edges of the magnetostrictive material to direct the magnetic flux through a Hall sensor to detect an axial component of the magnetic flux in response to twisting.

Abstract: A target wheel sensor assembly includes a target wheel, a magnet, and two or more sensing elements placed therebetween. The magnet and the sensing elements are configured so that as the target wheel rotates each of the sensing elements outputs a respective asymmetric signal relative to the direction of rotation of the target wheel or an object mechanically connected to the wheel. Each of these asymmetric signals is differentially combined with one another to determine the direction of motion of the target wheel, and, if optionally desired, the position of the target wheel.

Abstract: A magnetic position sensor for measuring a position of a ferromagnetic target over a range. The sensor comprises a magnet at least as long as the range and a sensor array mounted upon a surface of the magnet. The array is at least as long as the range and includes a plurality of sensing elements mounted a fixed distance from the surface of the magnet. The magnet length and the fixed distance have values such that a set of relatively constant values, preferably values of magnetic flux density, is measurable in the sensor array in the absence of the ferromagnetic target. A method of making a position sensor is also disclosed, as is a method of measuring the position of a ferromagnetic target over a range.

Abstract: A magnetic sensor provides an output voltage range having first and second linear slopes. Proper selection of magnetic sensor dimensions enables changes in magnetic flux density upon the passage of at least one tooth and one slot of a target wheel past the magnetic sensor to be represented as a linear magnetic sensor output comprised of at least one linear range whereby linear interpolation of position is possible with appropriate signal processing algorithms.

Abstract: A magnetic sensor has magnetically sensitive element located at a side surface, instead of the bottom surface, of a bias magnet, the magnet being located adjacent a magnetic target wheel, wherein the bias magnet is magnetized parallel to the direction of motion of the teeth/slots of the target wheel. The output may be of a single or double frequency. Sampling of output slope can provide information regarding direction of movement of the target wheel. In a second embodiment the bias magnet is magnetized perpendicular to the movement.

Abstract: A sensor assembly for sensing angular position of an object is provided. The assembly may comprise at least one magneto-sensing magnet having a second axis of rotation. The assembly may further comprise a magnet having a second axis of rotation. At least one of the magnet and the magneto-sensing element are rotatable relative to the other. The respective axes of rotation of the magneto-sensing element and the magnet are non-coincident with respect to one another. The magnet is magnetized along one of the following directions: an axial direction and a radial direction.

Abstract: An apparatus measures relative displacement between a first end and a second end of a shaft. The first and second ends being centered on a shaft axis. The apparatus includes first and second ferromagnetic plates. The first ferromagnetic plate has a first side and a second side and is connected to the first end. The first ferromagnetic plate is centered on the shaft axis and has a plurality of ferromagnetic teeth extending from the first side and in a first direction parallel to the shaft. The second ferromagnetic plate has a first side and a second side and is connected to the second end. The second ferromagnetic plate is centered on the shaft axis. The first and second ferromagnetic plates form a gap. The apparatus further includes a plurality of magnets having a magnetic field and a sensing device. The magnets are coupled to the first side of the second ferromagnetic plate. The sensing device is disposed within the gap for sensing a magnetic flux of the magnetic field.

Abstract: A torque sensing apparatus for picking up a magnetic flux in response to applying a torque to a shaft is disclosed. A magnetostrictive material is disposed on the surface of the shaft and is magnetically polarized. The apparatus includes a first flux collector and a second flux collector spaced from each other and extending annularly around the shaft. A first fluxgate is connected to the first flux collector at one end and to the second flux collector at the other end with a first excitation coil wound about the first fluxgate. A second fluxgate is connected to the first flux collector at one end and to the second flux collector at the other end with a second excitation coil wound about the second fluxgate. A feedback coil is positioned between the shaft and the flux collectors, the fluxgates, and the excitation coils.

Abstract: A magnetic position sensor for measuring a position of a ferromagnetic target over a range. The sensor comprises a magnet at least as long as the range and a sensor array mounted upon a surface of the magnet. The array is at least as long as the range and includes a plurality of sensing elements mounted a fixed distance from the surface of the magnet. The magnet length and the fixed distance have values such that a set of relatively constant values, preferably values of magnetic flux density, is measurable in the sensor array in the absence of the ferromagnetic target. A method of making a position sensor is also disclosed, as is a method of measuring the position of a ferromagnetic target over a range.