Abstract: A valve assembly for an exhaust gas recirculation (EGR) system which provides emission control, regulates flow of exhaust gases, and is suitable for gasoline or diesel applications. The EGR valve assembly is a latching valve assembly which reduces power consumption (i.e., continuous electric draw) from the battery while the valve is either being held open or closed, and reduces electrical interference inherent with integrated position sensors. The valve assembly includes a latching mechanism controlled by an actuator which allows a valve to latch open or closed. The valve may be a single stage valve or a multi-stage valve, which includes a latching mechanism that allows for intermediate open positions, and uses of only a short, single pulse of voltage, to change the state of the valve. The actuator may also be held energized at full extend, maintaining a maximum valve open position, creating additional flow capability of the valve assembly.

Abstract: A linear actuator includes a stator assembly and a rotor assembly operatively associated with the stator assembly and mounted for rotation with respect to the stator assembly. A shaft is restricted from rotation and is associated with the rotor assembly such that rotation of the rotor assembly causes linear movement of the shaft. A capnut is associated with a distal end of the shaft for movement therewith. A shroud is coupled to the stator assembly and substantially surrounds the capnut. The shroud includes a valve seat, and an inlet communicating with an outlet through a throttle opening adjacent to the valve seat. The shaft and associated capnut are constructed and arranged to move relative to the valve seat to control air flow between the inlet and the outlet.

Abstract: A valve assembly for an exhaust gas recirculation (EGR) system which provides emission control, regulates flow of exhaust gases, and is suitable for gasoline or diesel applications. The EGR valve assembly is a latching valve assembly which reduces power consumption (i.e., continuous electric draw) from the battery while the valve is either being held open or closed, and reduces electrical interference inherent with integrated position sensors. The valve assembly includes a latching mechanism controlled by an actuator which allows a valve to latch open or closed. The valve may be a single stage valve or a multi-stage valve, which includes a latching mechanism that allows for intermediate open positions, and uses of only a short, single pulse of voltage, to change the state of the valve. The actuator may also be held energized at full extend, maintaining a maximum valve open position, creating additional flow capability of the valve assembly.

Abstract: A digital linear actuator (DLA) large port throttle control valve manifold assembly which is suitable for use with various automotive engines. The sidegate capnut is sized such that the full amount of throttle body intake manifold air is controlled to the engine. Apertures are formed as part of the side gate capnut to minimize axial air loading on the capnut, providing a pressure balance. Providing a pressure balance also reduces the axial force required to position the capnut, which in turn reduces size of the actuator needed to position the capnut, thus reducing the overall size of the DLA. The positional control of the DLA along with the internal plenum port(s) window profile provides the desired air flow for each commanded position.

Abstract: A method of measuring flux density and run out to accommodate rotors of different diameters, evaluate intrinsic properties of magnet material and the magnetization process. Circular run out measurement capability is also used to evaluate bearing journal “ovality.” The method includes the use of a scan tool, or a DLA Rotor Flux Density Scan Fixture, which evaluates the electromagnetic field strength (gauss), combined with surface run out and presents the data in a scalable pictorial format. The scan tool includes a probe which measures a magnetic field strength and circular run out of the perimeter of the magnet. Simultaneously, a non-contact measurement sensor is used to measure the rotor surface for subtle variations. The resulting sine wave gauss data and the surface dimension data are manipulated into a scalable “radar” plot. The radar plot correlates magnetic pole field strength and surface circular run out variation to the index position.

Abstract: A linear actuator includes a stator assembly and a rotor assembly operatively associated with the stator assembly and mounted for rotation with respect to the stator assembly. A shaft is restricted from rotation and is associated with the rotor assembly such that rotation of the rotor assembly causes linear movement of the shaft. A capnut is associated with a distal end of the shaft for movement therewith. A shroud is coupled to the stator assembly and substantially surrounds the capnut. The shroud includes a valve seat, and an inlet communicating with an outlet through a throttle opening adjacent to the valve seat. The shaft and associated capnut are constructed and arranged to move relative to the valve seat to control air flow between the inlet and the outlet.

Abstract: A method of measuring flux density and run out to accommodate rotors of different diameters, evaluate intrinsic properties of magnet material and the magnetization process. Circular run out measurement capability is also used to evaluate bearing journal “ovality.” The method includes the use of a scan tool, or a DLA Rotor Flux Density Scan Fixture, which evaluates the electromagnetic field strength (gauss), combined with surface run out and presents the data in a scalable pictorial format. The scan tool includes a probe which measures a magnetic field strength and circular run out of the perimeter of the magnet. Simultaneously, a non-contact measurement sensor is used to measure the rotor surface for subtle variations. The resulting sine wave gauss data and the surface dimension data are manipulated into a scalable “radar” plot. The radar plot correlates magnetic pole field strength and surface circular run out variation to the index position.

Abstract: A linear actuator includes a plastic housing having an integral flange for mounting the actuator. A stator assembly, having windings, is disposed in the plastic housing. A rotor assembly, having a permanent magnet, is mounted for rotation with respect to the stator assembly such that when the windings are energized, a magnetic field is generated to cause rotation of the rotor assembly. A shaft is restricted from rotation and is associated with the rotor assembly such that rotation of the rotor assembly causes linear movement of the shaft. Connector structure houses leads for powering the windings. The plastic housing has an annular end that captures an annular surface of the connector structure to couple the plastic housing to the connector structure.

Abstract: A method of measuring flux density and run out to accommodate rotors of different diameters, evaluate intrinsic properties of magnet material and the magnetization process. Circular run out measurement capability is also used to evaluate bearing journal “ovality.” The method includes the use of a scan tool, or a DLA Rotor Flux Density Scan Fixture, which evaluates the electromagnetic field strength (gauss), combined with surface run out and presents the data in a scalable pictorial format. The scan tool includes a probe which measures a magnetic field strength and circular run out of the perimeter of the magnet. Simultaneously, a non-contact measurement sensor is used to measure the rotor surface for subtle variations. The resulting sine wave gauss data and the surface dimension data are manipulated into a scalable “radar” plot. The radar plot correlates magnetic pole field strength and surface circular run out variation to the index position.

Abstract: A method provides a plastic housing for an actuator. The actuator has a stator assembly coupled to a connector structure and a rotor assembly that rotates with respect to the stator assembly. The method inserts the stator assembly with connector structure connected thereto into an interior of the plastic housing until a surface of the stator assembly engages a surface of the plastic housing, with an annular end of the plastic housing extending beyond an adjacent annular surface of the connector structure. The annular end of the housing is heated and deformed to capture the annular surface of the connector structure, thereby coupling the plastic housing to the connector structure.

Abstract: An integrated H-bridge electrical harness for controlling an actuator, such as a stepper motor, where the harness includes a signal converter in electrical communication with an ECU, a driver in electrical communication with the signal converter, and a plurality of connectors. At least one of the connectors provides a connection with the ECU, and another of the connectors provides a connection with an actuator. The signal converter receives a first type of signal (such as a pulse width modulated signal) from the ECU, and converts the first type of signal to a second type of signal, and the signal converter sends the second type of signal to the driver. The driver sends a third type of signal (such as a double square wave signal) to the actuator to control the actuator.

Abstract: A linear actuator (10) includes a plastic housing (12) having an integral flange (14) for mounting the actuator. A stator assembly (16), having windings (18), is disposed in the plastic housing. A rotor assembly (20), having a permanent magnet (22), is mounted for rotation with respect to the stator assembly such that when the windings are energized, a magnetic field is generated to cause rotation of the rotor assembly. A shaft (32) is restricted from rotation and is associated with the rotor assembly such that rotation of the rotor assembly causes linear movement of the shaft. Connector structure (46) houses leads for powering the windings. The plastic housing has an annular end (48) that captures an annular surface (50) of the connector structure to couple the plastic housing to the connector structure.

Abstract: An idle air control valve (11) for a vehicle includes a stator assembly (12) and a rotor assembly (26) operatively associated with the stator assembly and mounted for rotation with respect to the stator assembly. A shaft (36) is restricted from rotation and is associated with the rotor assembly such that rotation of the rotor assembly causes linear movement of the shaft. A pintle (38) is associated with a distal end of the shaft for linear movement therewith. A journal (28) is associated with the rotor assembly and is constructed and arranged to support and permit rotation of the rotor assembly relative to the stator assembly. Lubricant (30) is provided between a surface of the journal and a surface of the rotor assembly.

Abstract: A system for adjustably positioning foot pedals with respect to a vehicle chassis, such as to improve ergonomics or to appropriately space a vehicle occupant with respect to a vehicle safety system. The system includes first and second electromagnetic actuators, first and second controllers, and a device, which may be a switch disposed on the vehicle chassis, provides a signal to change spacing between the vehicle chassis and the plurality of pedals. The first electromagnetic actuator displaces a first pedal with respect to the vehicle chassis, and the second electromagnetic actuator displaces a second pedal with respect to the vehicle chassis. The first controller operates the first electromagnetic actuator in response to the configuration of the device, and the second controller operates the second electromagnetic actuator in response to the first controller operating the first electromagnetic actuator.

Abstract: An adjustable positioning apparatus, which may be used for a foot-operated control, includes a first member that is movably supported with respect to a base, an adjuster that is supported on the first member, and a second member. The adjuster includes a displacement device, an actuator, and a controller. The displacement device includes a first portion that is coupled to the first member, and includes a second portion that is displaced with respect to the first portion. The actuator displaces the second portion with respect to the first portion, and the controller operates the actuator and determines displacement of the second portion with respect to the first portion. The second member is coupled to the second portion.

Abstract: A motor (10) for a vehicle includes a stator assembly (14) and a rotor assembly (16). Bearing structure (20, 22) support the rotor assembly to permit rotation of the rotor assembly with respect to the stator assembly. A shaft (30) is threadedly engaged with the rotor assembly and is constructed and arranged such that rotation of the rotor assembly causes linear movement of the shaft. A perfluoropolyether (PFPE) based lubricant (38), having an thermal functionality upper temperature limit of over +200° C., lubricates at least the bearing structure.

Abstract: An idle air control valve assembly including a strain relief feature for a plurality of wire terminals that couple the control valve to a remote source. The strain relief feature prevents damage to solder joints attaching the wire leads to the valve assembly. Additional improvements in the idle air control valve assembly include a plurality of axially and radially extending protrusions on a peripheral surface of a valve body that assist in the alignment and retention of the valve body in a throttle body manifold of an internal combustion engine. The protrusions are operable in combination with a plurality of bolt flange tabs to ensure proper radial positioning of the valve body when inserted into the throttle body manifold.

Abstract: An idle air control valve for a vehicle includes a housing (21), a motor (32) disposed in the housing, a shaft (29) associated with the motor, and a bellows assembly (30) including a bellows structure (10) having a first end defining a base (14), a second, opened end (16), and a bellows (18) between the first and second ends. An annular rim member (28) is associated with the second opened end. A pintle (24) has surfaces defining an annular groove (26) therein. The annular rim member (28) is received, in press-fit engagement, in the annular groove (26). The base (14) is in press-fit engagement with a recess (22) in the housing and the pintle (24) is coupled with an end of the shaft, such that the bellows structure together with the pintle surround the shaft and provide a barrier substantially preventing contaminants from entering the motor.

Abstract: An evaporative fuel vapor control system, purge valve and methods are described. The system includes a fuel supply, internal combustion engine, vapor canister, and a purge valve. The purge valve includes a sensor disposed in the body housing of the purge valve and in communication with the flow passage to provide a signal indicative of the magnitude of chemicals in the fuel vapor being provided to the engine. Various methodologies relating the system, purge valve and sensors are described.

Abstract: An idle air control valve (11) for a vehicle includes a stator assembly (12) and a rotor assembly (26) operatively associated with the stator assembly and mounted for rotation with respect to the stator assembly. A shaft (36) is restricted from rotation and is associated with the rotor assembly such that rotation of the rotor assembly causes linear movement of the shaft. A pintle (38) is associated with a distal end of the shaft for linear movement therewith. A journal (28) is associated with the rotor assembly and is constructed and arranged to support and permit rotation of the rotor assembly relative to the stator assembly. Lubricant (30) is provided between a surface of the journal and a surface of the rotor assembly.