Abstract: A spark plug electrode with an electrode tip formed on an electrode base using an additive manufacturing process, such as a powder bed fusion technique. The spark plug electrode includes an intermediate layer located between the electrode tip and the electrode base, where the intermediate layer has a coefficient of thermal expansion (CTE) that is between that of the electrode base and the electrode tip and includes a whole area connection. In some examples, the whole area connection is non-uniform in thickness so that it is thicker in one section than it is in another section.

Abstract: A spark plug electrode includes an electrode tip that is attached to or formed on an electrode base so that the electrode tip is directly thermally coupled to a heat dissipating core through an opening in the electrode base. This direct thermal coupling may take place on a side surface of a ground electrode or a center electrode and removes thermal energy away from the electrode tip in order to reduce thermal and/or other stresses. In one example, the electrode tip includes a precious metal-based material, the electrode base includes a nickel-based material, and the heat dissipating core includes a thermally conductive material such a copper-based material. The heat dissipating core may have one or more core extensions that diverge or branch off of a core main body and extend into the opening in the electrode base for better thermal coupling to the electrode tip.

Abstract: A spark plug electrode with an electrode tip formed on an electrode base using an additive manufacturing process, such as a powder bed fusion technique. The spark plug electrode includes an intermediate layer located between the electrode tip and the electrode base, where the intermediate layer has a coefficient of thermal expansion (CTE) that is between that of the electrode base and the electrode tip and includes a whole area connection. In some examples, the whole area connection is non-uniform in thickness so that it is thicker in one section than it is in another section.

Abstract: A spark plug electrode includes an electrode tip that is attached to or formed on an electrode base so that the electrode tip is directly thermally coupled to a heat dissipating core through an opening in the electrode base. This direct thermal coupling may take place on a side surface of a ground electrode or a center electrode and removes thermal energy away from the electrode tip in order to reduce thermal and/or other stresses. The heat dissipating core may have one or more core extensions that diverge or branch off of a core main body and extend into the opening in the electrode base for better thermal coupling to the electrode tip. The electrode tip can be attached to the electrode base via welding or it can be formed on the electrode base using a suitable additive manufacturing process, such as a powder bed fusion technique.

Abstract: A spark plug electrode with an electrode tip formed on an electrode base using an additive manufacturing process, such as a powder bed fusion technique. The spark plug electrode includes an electrode base that at least partially surrounds a heat dissipating core, an electrode tip that is formed on the electrode base and includes a precious metal-based material, and a thermal coupling zone that directly thermally couples the electrode tip to the heat dissipating core. In some examples, the electrode tip is formed on an electrode base that has been cut or severed to expose a portion of the heat dissipating core, such that the electrode tip is formed directly on the heat dissipating core using additive manufacturing.

Abstract: A spark plug electrode with an electrode tip formed on an electrode base using an additive manufacturing process, such as a powder bed fusion technique. The spark plug electrode includes an electrode base that at least partially surrounds a heat dissipating core, an electrode tip that is formed on the electrode base and includes a precious metal-based material, and a thermal coupling zone that directly thermally couples the electrode tip to the heat dissipating core. In some examples, the electrode tip is formed on an electrode base that has been cut or severed to expose a portion of the heat dissipating core, such that the electrode tip is formed directly on the heat dissipating core using additive manufacturing.

Abstract: A spark plug electrode with an electrode tip formed on an electrode base using an additive manufacturing process, such as a powder bed fusion technique. The spark plug electrode includes an electrode base that at least partially surrounds a heat dissipating core, an electrode tip that is formed on the electrode base and includes a precious metal-based material, and a thermal coupling zone that directly thermally couples the electrode tip to the heat dissipating core. In some examples, the electrode tip is formed on an electrode base that has been cut or severed to expose a portion of the heat dissipating core, such that the electrode tip is formed directly on the heat dissipating core using additive manufacturing.

Abstract: A modular control unit (100) is adaptable, in terms of interface functions, for an electric motor selected from a predetermined number i of electric motors, in particular electric motors of the same power class. The control unit (100) has at least two printed circuit boards (L1, L2), selected from a set of N different printed circuit boards (L1, L2, . . . , LN). Interface functions, electrical components, electronic components or control units for the operation of the electric motor are located on the printed circuit boards.

Abstract: A spark plug electrode with an electrode tip formed on an electrode base using an additive manufacturing process, such as a powder bed fusion technique. The spark plug electrode includes an intermediate layer located between the electrode tip and the electrode base, where the intermediate layer has a coefficient of thermal expansion (CTE) that is between that of the electrode base and the electrode tip and includes a whole area connection. In some examples, the whole area connection is non-uniform in thickness so that it is thicker in one section than it is in another section.

Abstract: A spark plug electrode with an electrode tip formed on an electrode base using an additive manufacturing process, such as a powder bed fusion technique. The spark plug electrode includes an electrode base, an electrode tip that is formed on the electrode base and includes a precious metal-based material, and a thermally resilient joint that is located between the electrode base and the electrode tip, wherein the electrode tip and the thermally resilient joint together include a number of laser deposition layers.

Abstract: A protective circuit protects against overheating of the stator windings of an EC motor. The stator windings are connected to a semiconductor output stage which is designed for time-offset control of the stator windings using a driver circuit of a commutation controller. The protective circuit has two redundant sensor circuits, wherein two resistance-dependent sensor elements connected in series are provided in the first sensor circuit and one resistance-dependent sensor element is provided in the second sensor circuit. The first and the second sensor circuits are connected, respectively, to two evaluating circuits separated from each other and cause an interruption of the driver circuit using switch-off means when a system-specific resistance value of the first sensor element or the one sensor element associated with the second sensor circuit is reached.

Abstract: A housing for fluidically connecting an exhaust gas line to an exhaust gas heat exchanger, wherein the main flow channel of the housing extends in the direction of a central axis (X), from an inlet opening to an outlet opening, with an average flow cross section (SQ). In the main flow channel, at least one opening is provided in the housing for a valve shaft, and on the housing, at least one bypass opening formed by a connecting piece is provided between the inlet opening and the outlet opening. The housing is formed by a maximum of two deep-drawn sub-shells made of sheet metal, wherein the connecting piece is formed circumferentially around the bypass axis (Y) for connecting an exhaust gas heat exchanger via the upper shell and/or via the lower shell.

Abstract: A protective circuit protects against overheating of the stator windings of an EC motor. The stator windings are connected to a semiconductor output stage which is designed for time-offset control of the stator windings using a driver circuit of a commutation controller. The protective circuit has two redundant sensor circuits, wherein two resistance-dependent sensor elements connected in series are provided in the first sensor circuit and one resistance-dependent sensor element is provided in the second sensor circuit. The first and the second sensor circuits are connected, respectively, to two evaluating circuits separated from each other and cause an interruption of the driver circuit using switch-off means when a system-specific resistance value of the first sensor element or the one sensor element associated with the second sensor circuit is reached.

Abstract: A housing for fluidically connecting an exhaust gas line to an exhaust gas heat exchanger, wherein the main flow channel of the housing extends in the direction of a central axis (X), from an inlet opening to an outlet opening, with an average flow cross section (SQ). In the main flow channel, at least one opening is provided in the housing for a valve shaft, and on the housing, at least one bypass opening formed by a connecting piece is provided between the inlet opening and the outlet opening. The housing is formed by a maximum of two deep-drawn sub-shells made of sheet metal, wherein the connecting piece is formed circumferentially around the bypass axis (Y) for connecting an exhaust gas heat exchanger via the upper shell and/or via the lower shell.

Abstract: The invention refers to a method for controlling a brushless, electronically commutated electric motor, a main AC voltage being rectified into an intermediate circuit direct voltage and this direct voltage being fed by an intermediate circuit containing an intermediate circuit capacitor to an inverter which is controlled by a motor control means for feeding and commutating the electric motor whereby the intermediate circuit direct voltage is monitored in respect of its voltage level and is compared with a predetermined limiting value and, on reaching or exceeding the limiting value, the intermediate circuit direct voltage is limited to the predetermined limiting value by clocked disconnection and reconnection.

Abstract: In a method and control system for controlling a brushless, electronically commutated electric motor (M), a three-phase source AC voltage (UN) is rectified and fed to a DC link voltage (UZK), which is supplied to an inverter (2) via a slim DC link circuit (6). A motor control unit (10) for PWM pulsing controls the inverter for commutating the electric motor (M) and adjusting the motor speed with a variable duty cycle (A). The duty cycle (A) is influenced by a compensating factor (k) such that the product of the DC link voltage (UZK) and a resulting DC link current (IZK) is kept constant in the link circuit (6). The DC link voltage (UZK) is monitored. When a first threshold value (UZKac.max1) of an AC component (UZKac) is exceeded, the compensating factor (k) is modified to lower the current AC component (UZKac) below the threshold value (UZKac.max1).

Abstract: A control circuit (1) for an electronically commutated, direct current motor (M) without a collector with a semiconductor end stage (2) which is controlled by an electronic commutation control (4) via a driver stage (6) for the time-offset control of the stator coils (U,V,W) of the motor (M) for the purpose of producing a magnetic rotating field for a rotor depending on the rotor rotation position. Two redundant stall protection units (10, 12) monitor the motor (M) during operation for rotation of the rotor, whereby in the case of a determined stall situation, the first stall protection unit (10) deactivates the driver stage (6) and the second stall protection unit (12) shuts off the supply voltage (UVCC) for the driver stage (6).

Abstract: The invention refers to a method for controlling a brushless, electronically commutated electric motor, a main AC voltage being rectified into an intermediate circuit direct voltage and this direct voltage being fed by an intermediate circuit containing an intermediate circuit capacitor to an inverter which is controlled by a motor control means for feeding and commutating the electric motor whereby the intermediate circuit direct voltage is monitored in respect of its voltage level and is compared with a predetermined limiting value and, on reaching or exceeding the limiting value, the intermediate circuit direct voltage is limited to the predetermined limiting value by clocked disconnection and reconnection.

Abstract: The present invention relates to an EC motor assembly (1) having an electronically commutated, permanent magnet-excited DC motor (M) with an upstream commutation electronic unit (2) that is supplied with a DC link voltage (UZK) via a DC link (8). The DC link (8) can be connected directly to a solar cell generator (12) via a first voltage input (10) on one hand, and on the other, to a grid voltage (UM) via a controllable power supply unit (14) and a second voltage input (16). The DC link voltage (UZK) is variably specified based on a respective available photovoltaic voltage (UPV) of the solar cell generator (12). The power supply unit (14) can be regulated with respect to the output voltage thereof to adapt to the respective DC link voltage (UZK).