Abstract: Cam lobe packs and methods of producing the same. The method uses a tool made up of an insert disposed within a sleeve such that both are responsive to a dynamic magnetic compaction (DMC) pressure source. The insert defines a substantially axisymmetric exterior surface and a cam lobe-shaped interior surface that can receive a compactable material such that upon DMC, the material is formed into the shape of the cam lobe. The sleeve is disposed about the insert and defines a substantially axisymmetric exterior surface such that an axisymmetric compaction imparted to the sleeve by the DMC pressure source forms the desired shaped cam lobe. The tool is configured such that individual tool members corresponding to one or more of the cam lobes can be axially aligned so that an aggregate interior surface is formed that defines an exterior surface profile of a camshaft being formed.

Abstract: A belt tensioner for a starter generator drive is provided. The belt tensioner comprises a carrier having a pivot defining a first pivot axis at a first end and a carrier arm extending from the pivot to terminate in a second end. An idler pulley is rotatably mounted to the carrier for rotation about the first pivot axis and a tensioner pulley is rotatably mounted to the carrier at the second end of the carrier arm for rotation about a second axis. The second axis extends parallel to and is arcuately moveable relative to, the first pivot axis. A tensioner is in communication with the second end of the carrier arm for biasing the carrier arm and the tensioner pulley against a drive belt for tensioning the drive belt engaged by the idler pulley and the tensioner pulley.

Abstract: A camshaft may include a first shaft, a first lobe member, and a second lobe member. The first shaft may include an annular wall defining a first bore. The wall may include a first portion having a first radial outer surface and a second portion having a second radial outer surface that is radially offset relative to the first radial outer surface. The first lobe member may define a second bore having the first portion of the first shaft located therein and frictionally engaged with the first shaft for rotation with the first shaft. The second lobe member may define a third bore having the second portion of the first shaft located therein. The second lobe member may be rotatably disposed on the second portion of the first shaft.

Abstract: An automotive engine component and method of producing the same. The method uses dynamic magnetic compaction to form components, such as camshaft lobes, with non-axisymmetric and related irregular shapes. A die is used that has an interior profile that is substantially similar to the non-axisymmetric exterior of the component to be formed such that first and second materials can be placed into the die prior to compaction. The first material is in powder form and can be placed in the die to make up a first portion of the component being formed, while a second material can be placed in the die to make up a second portion of the component. The second material, which may possess different tribological properties from those of the first material, can be arranged in the die so that upon formation, at least a portion of the component's non-axisymmetric exterior profile is shaped by or includes the second material.

Abstract: A hydraulic control system to provide an oil or pressurized fluid supply to a variable cam phasing system in an engine is provided. The hydraulic control system includes a valve housing attachable to a front cover assembly of the engine; a first valve installed in the housing; and an inlet passage defined by the front cover assembly hydraulically communicating with the first valve in the housing to carry pressurized fluid from a fluid source to the first valve. A first and a second outlet passage defined by the housing hydraulically communicates with the first valve to allow the pressurized fluid to flow to the cam phasing system, thereby variably moving a camshaft assembly operatively connected to the cam phasing system.

Abstract: A camshaft may include a first shaft, a first lobe member, and a second lobe member. The first shaft may include an annular wall defining a first bore. The wall may include a first portion having a first radial outer surface and a second portion having a second radial outer surface that is radially offset relative to the first radial outer surface. The first lobe member may define a second bore having the first portion of the first shaft located therein and frictionally engaged with the first shaft for rotation with the first shaft. The second lobe member may define a third bore having the second portion of the first shaft located therein. The second lobe member may be rotatably disposed on the second portion of the first shaft.

Abstract: A camshaft may include a first shaft, a first lobe member, and a second lobe member. The first shaft may include an annular wall defining a first bore. The wall may include a first portion having a first radial outer surface and a second portion having a second radial outer surface that is radially offset relative to the first radial outer surface. The first lobe member may define a second bore having the first portion of the first shaft located therein and frictionally engaged with the first shaft for rotation with the first shaft. The second lobe member may define a third bore having the second portion of the first shaft located therein. The second lobe member may be rotatably disposed on the second portion of the first shaft.

Abstract: A belt tensioner for a starter generator drive is provided. The belt tensioner comprises a carrier having a pivot defining a first pivot axis at a first end and a carrier arm extending from the pivot to terminate in a second end. An idler pulley is rotatably mounted to the carrier for rotation about the first pivot axis and a tensioner pulley is rotatably mounted to the carrier at the second end of the carrier arm for rotation about a second axis. The second axis extends parallel to and is arcuately moveable relative to, the first pivot axis. A tensioner is in communication with the second end of the carrier arm for biasing the carrier arm and the tensioner pulley against a drive belt for tensioning the drive belt engaged by the idler pulley and the tensioner pulley.

Abstract: An engine assembly may include a cam phaser assembly coupled to a concentric camshaft. The cam phaser assembly may include first and second plate assemblies that have first and second vanes, an oil chamber housing located axially between the first and second plate assemblies, an oil distribution member, and a first fastener. The first and second plates may define first and second fastener passages. The oil chamber housing may define first and second chambers and a first central bore. The first vane may extend into the first chamber and the second vane may extend into the second chamber. The oil distribution member may be located within the central bore of the oil chamber housing and may define a third fastener passage. The first fastener may extend through the first, second, and third fastener passages and couple the cam phaser assembly to an outer shaft of the concentric camshaft.

Abstract: Cam lobe packs and methods of producing the same. The method uses a tool made up of an insert disposed within a sleeve such that both are responsive to a dynamic magnetic compaction (DMC) pressure source. The insert defines a substantially axisymmetric exterior surface and a cam lobe-shaped interior surface that can receive a compactable material such that upon DMC, the material is formed into the shape of the cam lobe. The sleeve is disposed about the insert and defines a substantially axisymmetric exterior surface such that an axisymmetric compaction imparted to the sleeve by the DMC pressure source forms the desired shaped cam lobe. The tool is configured such that individual tool members corresponding to one or more of the cam lobes can be axially aligned so that an aggregate interior surface is formed that defines an exterior surface profile of a camshaft being formed.

Abstract: An automotive engine component and method of producing the same. The method uses dynamic magnetic compaction to form components with non-axisymmetric and related irregular shapes. A die is used that has an interior profile that is substantially similar to the non-axisymmetric exterior of the component to be formed such that first and second materials can be placed into the die prior to compaction. The first material is in powder form and can be placed in the die to make up a first portion of the component being formed, while a second material can be placed in the die to make up a second portion of the component. The second material, which may possess different tribological properties from those of the first material, can be arranged in the die so that upon formation, at least a portion of the component's non-axisymmetric exterior profile is shaped by or includes the second material.

Abstract: A hydraulic control system to provide an oil or pressurized fluid supply to a variable cam phasing system in an engine is provided. The hydraulic control system includes a valve housing attachable to a front cover assembly of the engine; a first valve installed in the housing; and an inlet passage defined by the front cover assembly hydraulically communicating with the first valve in the housing to carry pressurized fluid from a fluid source to the first valve. A first and a second outlet passage defined by the housing hydraulically communicates with the first valve to allow the pressurized fluid to flow to the cam phasing system, thereby variably moving a camshaft assembly operatively connected to the cam phasing system.

Abstract: A camshaft may include a first shaft, a first lobe member, and a second lobe member. The first shaft may include an annular wall defining a first bore. The wall may include a first portion having a first radial outer surface and a second portion having a second radial outer surface that is radially offset relative to the first radial outer surface. The first lobe member may define a second bore having the first portion of the first shaft located therein and frictionally engaged with the first shaft for rotation with the first shaft. The second lobe member may define a third bore having the second portion of the first shaft located therein. The second lobe member may be rotatably disposed on the second portion of the first shaft.

Abstract: An engine assembly may include an engine structure, a crankshaft, a camshaft, a balance shaft, and first and second gears. The crankshaft, camshaft, and balance shaft may each be rotatably supported by the engine structure. The camshaft may be rotationally driven by the crankshaft and the first gear may be coupled to the camshaft. The second gear may be fixed for rotation with the balance shaft and meshingly engaged with and driven by the first gear.

Abstract: An engine assembly may include a cam phaser assembly coupled to a concentric camshaft. The cam phaser assembly may include first and second plate assemblies that have first and second vanes, an oil chamber housing located axially between the first and second plate assemblies, an oil distribution member, and a first fastener. The first and second plates may define first and second fastener passages. The oil chamber housing may define first and second chambers and a first central bore. The first vane may extend into the first chamber and the second vane may extend into the second chamber. The oil distribution member may be located within the central bore of the oil chamber housing and may define a third fastener passage. The first fastener may extend through the first, second, and third fastener passages and couple the cam phaser assembly to an outer shaft of the concentric camshaft.

Abstract: A cooling system has a system bypass to reduce parasitic losses in an internal combustion engine. The system bypass has a diverter valve actuated by a control module to selectively control the amount of coolant flow through the engine without regard to the speed of the water pump. As less coolant is needed to cool the engine, the diverter valve directs more coolant through the bypass to be recirculated to the water pump. The energy absorbed by the water pump is reduced by the reduced coolant flow, which increases the efficiency of the system and reduces engine parasitic losses.