Abstract: Presented are torque converters with integrated engine disconnect devices, methods for making/using such torque converters, and electric-drive vehicles equipped with such torque converters. A torque converter (TC) assembly includes a TC housing that drivingly connects to an engine output member. A TC output member projects from the TC housing and drivingly connects to a transmission input member. A turbine with a bladed turbine shell is mounted on the TC output member and rotatable within the TC's internal fluid chamber. An impeller with a bladed impeller shell is juxtaposed with the turbine and rotatable within the fluid chamber. An engine disconnect device, which is disposed within the fluid chamber between the impeller shell and TC housing, drivingly couples the impeller to and, when desired, drivingly decouples the impeller from the TC housing and engine output member to thereby transfer torque and prevent torque transfer, respectively, between the engine and transmission.

Abstract: A method of stopping an engine crankshaft includes selecting a target angular position at which the engine crankshaft is to be stopped and detecting an actual angular position of the engine crankshaft and a rotational speed of the engine crankshaft. A stopping torque in calculated based on the actual angular position of the engine crankshaft and the rotational speed of the engine crankshaft. The stopping torque is applied to the engine crankshaft via a motor/generator operably connected to the engine crankshaft. The engine crankshaft is stopped at the target angular position via the application of the stopping torque.

Abstract: An electric starter system is disclosed for use with an engine having a flywheel. The electric starter system includes a pinion gear and a solenoid device coupled to the pinion gear. The solenoid device is movable between a pre-engaged position when the pinion gear is moved into engagement with the flywheel and a disengaged position when the pinion gear is disengaged from the flywheel. A brushless starter motor is selectively connectable to the flywheel of the engine via the pinion gear during a requested engine start event. A latch mechanism is selectively engageable with the solenoid device. The latch mechanism is moveable between a latched position in which the solenoid device is mechanically held in the pre-engaged position and an unlatched position in which the solenoid device is released for movement to the disengaged position.

Abstract: An electric starter system is disclosed for use with an engine having a flywheel. The electric starter system includes a pinion gear and a solenoid device coupled to the pinion gear. The solenoid device is movable between a pre-engaged position when the pinion gear is moved into engagement with the flywheel and a disengaged position when the pinion gear is disengaged from the flywheel. A brushless starter motor is selectively connectable to the flywheel of the engine via the pinion gear during a requested engine start event. A latch mechanism is selectively engageable with the solenoid device. The latch mechanism is moveable between a latched position in which the solenoid device is mechanically held in the pre-engaged position and an unlatched position in which the solenoid device is released for movement to the disengaged position.

Abstract: A hybrid powertrain system includes an electric machine, a torque converter, a transmission, a hydraulic pump, and a controller, and it is arranged to transfer mechanical power to a driveline. The torque converter includes a clutch, a pump, and a turbine, and the electric machine is rotatably coupled to the hydraulic pump and to the torque converter pump. The hydraulic pump is fluidly connected to the transmission, and the controller is operably connected to the electric machine and the torque converter clutch. The controller is executable to determine an operator command, and control the electric machine to spin the hydraulic pump in a speed control mode and control the torque converter clutch in an open state. Upon achieving a desired minimum pump speed, the torque converter clutch is applied in a slip state and the electric machine is controlled in response to the operator command.

Abstract: Presented are clutch-type engine disconnect devices, methods for making/using such disconnect devices, and motor vehicles equipped with such disconnect devices. An engine disconnect device includes a notch plate, which has multiple notches and attaches to a torque converter, and a pocket plate, which has multiple pockets and attaches to an engine's crankshaft. A pawl is movably mounted within each notch; these pawls selectively engage the notches with the pockets. A notch plate insert is nested within each notch, supporting thereon one of the pawls. A selector plate interposed between the pocket and notch plates moves from a first position, to shift the pawls out of engagement with the pockets, and a second position, to move the notch plate inserts within the notches and allow the pawls to engage the notches with the pockets to thereby lock the notch plate to the pocket plate to rotate in unison with each other.

Abstract: Presented are dual-clutch engine disconnect devices, methods for making/using such disconnect devices, and motor vehicles equipped with such disconnect devices. An engine disconnect device for a vehicle includes a first one-way clutch (OWC) with concentric inner and outer races and torque elements interposed between and transferring torque across these races in a first direction. The first outer race rigidly attaches to a damper plate for common rotation therewith, and the first inner race rigidly attaches to a pump cover of a torque converter for common rotation therewith. A second OWC, which concentrically aligns within the first OWC, includes concentric inner and outer races with torque elements interposed between and transferring torque across these races in a second direction. The second outer race is splined to the first inner race for common rotation with the pump cover. The second inner race rigidly attaches to the damper plate for common rotation therewith.

Abstract: A powertrain system includes a flex plate, a transmission input shaft, a torque coupling, a one-way clutch, and a damper assembly. The flex plate is configured to be connected to a crankshaft of an engine. The torque coupling connects the transmission input shaft to the flex plate while allowing slip between the transmission input shaft and the flex plate. The one-way clutch is configured to couple the flex plate to the torque coupling. The damper assembly couples the flex plate to the one-way clutch and is configured to inhibit vibration transmission from the flex plate to the one-way clutch.

Abstract: A fault diagnostic system includes: memory including a fault model, the fault model including: a plurality of failure modes of a vehicle; and symptoms respectively associated with each of the failure modes; an updating module configured to: based on a data set, determine a new failure mode that is not already included in the fault model and new symptoms indicative of the occurrence of the new failure mode; modify the fault model by: adding the new failure mode to the fault model; and adding the new symptoms to the fault model in association with the new failure mode; and re-save the fault model in the memory.

Abstract: A method of stopping an engine crankshaft includes selecting a target angular position at which the engine crankshaft is to be stopped and detecting an actual angular position of the engine crankshaft and a rotational speed of the engine crankshaft. A stopping torque in calculated based on the actual angular position of the engine crankshaft and the rotational speed of the engine crankshaft. The stopping torque is applied to the engine crankshaft via a motor/generator operably connected to the engine crankshaft. The engine crankshaft is stopped at the target angular position via the application of the stopping torque.

Abstract: An engine starter system includes a starter including a multi-phase brushless electric motor and an electronic commutator assembly. A controller includes an instruction set that is executable in response to a command to execute an engine starting event. Operation includes determining a desired starting profile, controlling the starter to engage a rotatable member of the engine, and monitoring the rotational speed of the electric motor via a rotor position sensing circuit. The starter inverter is dynamically controlled to control the electric motor to spin the rotatable member of the internal combustion engine responsive to the desired starting profile, including dynamically controlling the starter inverter to control the electric motor to control the spin of the engine responsive to the desired starting profile to prevent occurrence of an engine speed flare event during the engine starting event.

Abstract: Presented are clutch-type engine disconnect devices, methods for making/using such disconnect devices, and motor vehicles equipped with such disconnect devices. An engine disconnect device includes a notch plate, which has multiple notches and attaches to a torque converter, and a pocket plate, which has multiple pockets and attaches to an engine's crankshaft. A pawl is movably mounted within each notch; these pawls selectively engage the notches with the pockets. A notch plate insert is nested within each notch, supporting thereon one of the pawls. A selector plate interposed between the pocket and notch plates moves from a first position, to shift the pawls out of engagement with the pockets, and a second position, to move the notch plate inserts within the notches and allow the pawls to engage the notches with the pockets to thereby lock the notch plate to the pocket plate to rotate in unison with each other.

Abstract: Presented are dual-clutch engine disconnect devices, methods for making/using such disconnect devices, and motor vehicles equipped with such disconnect devices. An engine disconnect device for a vehicle includes a first one-way clutch (OWC) with concentric inner and outer races and torque elements interposed between and transferring torque across these races in a first direction. The first outer race rigidly attaches to a damper plate for common rotation therewith, and the first inner race rigidly attaches to a pump cover of a torque converter for common rotation therewith. A second OWC, which concentrically aligns within the first OWC, includes concentric inner and outer races with torque elements interposed between and transferring torque across these races in a second direction. The second outer race is splined to the first inner race for common rotation with the pump cover. The second inner race rigidly attaches to the damper plate for common rotation therewith.

Abstract: Presented are wedge-type engine disconnect devices, methods for making/using such disconnect devices, and motor vehicles equipped with such disconnect devices. An engine disconnect device includes an outer race that attaches to a torque converter's pump cover. The outer race's inner diameter (ID) surface has circumferentially spaced grooves. An inner race is concentrically aligned within the outer race and attaches to an engine's output shaft. The inner race's outer diameter (OD) surface has circumferentially spaced pockets. A wedge plate interposed between the inner and outer races has multiple circumferentially spaced ramps. Each ramp slidably mounts within one groove and one pocket. The wedge plate moves between an engaged position, whereat the ramps wedge between the ID and OD surfaces to thereby transfer torque between the inner and outer races, and a disengaged position, whereat the ramps unwedge to thereby free the inner race to rotate with respect to the outer race.

Abstract: An electric starter system is used with an engine. The starter system may include a solenoid device coupled to a pinion gear, a brushless starter motor connectable to the engine via the pinion gear during a requested engine start event, and a controller. In response to the start event, when the engine speed is less than a threshold speed, the controller delivers a control current to the solenoid device at a peak current level sufficient for translating the pinion gear into contact with the flywheel. The control current is reduced to a holding current level less than the peak current level after the pinion gear is engaged with the flywheel. Motor torque is commanded from the starter motor, through the pinion gear, and to the flywheel while maintaining the holding current level, and held for a duration sufficient for starting the engine.

Abstract: A method of diagnosing a propulsion system implements a top-down hierarchical examination procedure, in which the propulsion system is analyzed as a whole to determine if the propulsion system is healthy. Data from a first set of vehicle sensors is compared to a system-healthy data cluster to determine if the propulsion system is healthy or unhealthy. If the propulsion system is unhealthy, then a plurality of subsystems of the propulsion system are each analyzed at a first examination level using selective data from the sensors to identify one of the subsystems as an unhealthy subsystem. A plurality of component systems of the unhealthy subsystem are then analyzed at a second examination level using other selective data from the sensors to identify one of the component systems of the unhealthy subsystem as an unhealthy component system.

Abstract: A geartrain for a powertrain system is disposed to transfer mechanical power between an internal combustion engine, an electric machine and a driveline. The geartrain includes a flywheel, a torque converter, an off-axis mechanical connection and a transmission gearbox. The off-axis mechanical connection includes a first element rotatably coupled to a second element. The flywheel is coupled to a crankshaft of the internal combustion engine. The torque converter includes a pump, a turbine and a pump hub, and the transmission gearbox includes an input member. The pump of the torque converter is coupled to the flywheel, and the pump hub is coupled to the first element of the off-axis mechanical connection. The second element of the off-axis mechanical connection is coupled to a rotor of the electric machine, and the turbine of the torque converter is coupled to the input member of the transmission gearbox.

Abstract: Hybrid vehicles and methods of operating the same are disclosed. Example methods may include providing a powertrain for the vehicle, which includes an internal combustion engine configured to provide rotational power to a rotatable input of a transmission by way of a starting device, and an electric motor-generator comprising a rotor configured to selectively provide rotational power to the rotatable input. The method may further include selectively disconnecting the engine from the rotatable input using a disconnect device separate from the starting device, thereby allowing the rotatable input of the transmission to be driven at a speed faster than an output speed of the engine.

Abstract: A method of controlled stopping an internal combustion engine having a stop-start mode and starter assembly includes detecting when the stop-start mode is active. The method also includes monitoring current rotational speed and position of the engine. The method additionally includes determining when the current rotational position is within a predetermined range of a target stop rotational position and the current rotational speed is less than a threshold rotational speed, and afterward energizing the starter assembly to engage the engine. The method also includes establishing a time delay following energizing the starter assembly to confirm engagement of the starter assembly with the engine. Furthermore, the method includes applying a torque by the starter assembly to stop the engine at the target stop position. A vehicle powertrain employing the engine equipped with the stop-start mode, the starter assembly, and an electronic controller configured to execute the method is also provided.

Abstract: A powertrain system includes a flex plate, a transmission input shaft, a torque coupling, a one-way clutch, and a damper assembly. The flex plate is configured to be connected to a crankshaft of an engine. The torque coupling connects the transmission input shaft to the flex plate while allowing slip between the transmission input shaft and the flex plate. The one-way clutch is configured to couple the flex plate to the torque coupling. The damper assembly couples the flex plate to the one-way clutch and is configured to inhibit vibration transmission from the flex plate to the one-way clutch.