Abstract: An end plate for a vehicle battery pack is specially designed to span multiple rows of battery cells and to protect the cells if an object strikes the side of the vehicle. The end plate includes a curved front wall, a flat rear wall, and several cantilevered struts perpendicular to the rear walls. The cantilevered struts are dimensioned such that they buckle to absorb energy rather than transmitting force to the battery cells.

Abstract: Methods and systems are provided for vehicle direct injection fuel pump control. In one example, a method may include reducing a flow speed of fuel from a cam-driven direct injection fuel pump for at least half of a total duration of an output stroke of the fuel pump. A cam driving the fuel pump may reduce the flow speed at a first rate during a main portion of the output stroke, and the cam may reduce the flow speed at a second rate during an end ramp portion of the output stroke.

Abstract: Methods and systems are provided for vehicle direct injection fuel pump control. In one example, a method may include reducing a flow speed of fuel from a cam-driven direct injection fuel pump for at least half of a total duration of an output stroke of the fuel pump. A cam driving the fuel pump may reduce the flow speed at a first rate during a main portion of the output stroke, and the cam may reduce the flow speed at a second rate during an end ramp portion of the output stroke.

Abstract: Various systems for controlling coolant flow through a plurality of coolant lines via a wax thermostat are provided. In one embodiment, a thermostat comprises at least one wax motor that mediates coolant flow between two inlet passages and three outlet passages as a function of longitudinal position, the longitudinal position varying in response to changes in coolant temperature.

Abstract: Methods and systems are provided for determining coolant system health. In one example, a method may include predicting degradation in the coolant system based on oscillations of an estimated coolant temperature at an outlet of a radiator. The method may further control an engine based on the estimated coolant temperature.

Abstract: Sensors are provided in reservoirs on internal combustion engines, and other applications, in which the reservoir is subjected to variations in pressure and temperature that cause the reservoir to exert variable forces on the sensor, thereby affecting sensor accuracy. To overcome problems in the prior art, a reservoir and sensor cartridge system are disclosing having: a reservoir with first and second openings, a cap coupled to the first opening, and a sensor cartridge disposed in the second opening. The sensor cartridge includes a sensor disposed in a body, a circumferential indentation formed in an outer surface of the body, a seal disposed in the indentation, and a retention feature provided on the body's outer surface. The circumferential indentation with the seal is axially displaced along the body from the sensor.

Abstract: Methods and systems are provided for regulating coolant flow in a vehicle cooling system during an engine startup event. In one example, a method may include, during an engine startup event, controlling a flowpath of an engine coolant in a vehicle cooling system via a passive valve and an actively regulatable valve, and responsive to an engine coolant temperature below a threshold at the engine startup event, isolating the flowpath of engine coolant to a subsection of the cooling system to enable rapid warming of the engine coolant without stagnating the engine coolant at an engine. In this way, engine coolant may be rapidly warmed at an engine startup event, via coolant flow isolation, rather than coolant flow stagnation, which may decrease uneven heating of engine system components, and which may thus prolong a functional lifetime of the engine system.

Abstract: Sensors are provided in reservoirs on internal combustion engines, and other applications, in which the reservoir is subjected to variations in pressure and temperature that cause the reservoir to exert variable forces on the sensor, thereby affecting sensor accuracy. To overcome problems in the prior art, a reservoir and sensor cartridge system are disclosing having: a reservoir with first and second openings, a cap coupled to the first opening, and a sensor cartridge disposed in the second opening. The sensor cartridge includes a sensor disposed in a body, a circumferential indentation formed in an outer surface of the body, a seal disposed in the indentation, and a retention feature provided on the body's outer surface. The circumferential indentation with the seal is axially displaced along the body from the sensor.

Abstract: A charge air cooler may include inlet and outlet chambers adjacent one another and separated by a baffle defining a bypass passage for airflow therethrough. The charge air cooler may also include heat exchange conduits connected between the inlet and outlet chambers. A valve may be disposed in the bypass passage and configured to selectively redirect at least a portion of the airflow through the bypass passage responsive to a charge air cooler outlet temperature being below a condensation temperature of the airflow.

Abstract: Methods and systems for increasing fuel economy of a vehicle including a SCR catalyst are presented. In one example, an amount of EGR provided to an engine is decreased in response to performance of the SCR being within a predetermined range of performance. The methods and systems may increase vehicle fuel economy while vehicle tailpipe emissions are achieved.

Abstract: Methods and systems are provided for regulating coolant flow in a vehicle cooling system during an engine startup event. In one example, a method may include, during an engine startup event, controlling a flowpath of an engine coolant in a vehicle cooling system via a passive valve and an actively regulatable valve, and responsive to an engine coolant temperature below a threshold at the engine startup event, isolating the flowpath of engine coolant to a subsection of the cooling system to enable rapid warming of the engine coolant without stagnating the engine coolant at an engine. In this way, engine coolant may be rapidly warmed at an engine startup event, via coolant flow isolation, rather than coolant flow stagnation, which may decrease uneven heating of engine system components, and which may thus prolong a functional lifetime of the engine system.

Abstract: Methods and systems are provided for determining coolant system health. In one example, a method may include predicting degradation in the coolant system based on oscillations of an estimated coolant temperature at an outlet of a radiator. The method may further control an engine based on the estimated coolant temperature.

Abstract: Methods and systems are providing for improving engine coolant level estimation to reduce engine overheating. The level of fluid in a coolant overflow reservoir is inferred based on the fluid level in a hollow vertical standpipe fluidically coupled to the reservoir at top and bottom locations. An ultrasonic sensor positioned in a recess at the bottom of the vertical standpipe transmits signals intermittently, receives their echoes upon reflection from the coolant surface, and estimates the fluid level in the standpipe based on echo times.

Abstract: Methods and systems are providing for improving engine coolant level estimation to reduce engine overheating. The level of fluid in a coolant overflow reservoir is inferred based on the fluid level in a hollow vertical standpipe fluidically coupled to the reservoir at top and bottom locations. An ultrasonic sensor positioned in a recess at the bottom of the vertical standpipe transmits signals intermittently, receives their echoes upon reflection from the coolant surface, and estimates the fluid level in the standpipe based on echo times.

Abstract: Various systems for controlling coolant flow through a plurality of coolant lines via a wax thermostat are provided. In one embodiment, a thermostat comprises at least one wax motor that mediates coolant flow between two inlet passages and three outlet passages as a function of longitudinal position, the longitudinal position varying in response to changes in coolant temperature.

Abstract: Methods and systems for adjusting fuel injection of an internal combustion engine are disclosed. In one example, a change in fuel pressure is scheduled when a number of pilot fuel injections provided by a fuel injector to a cylinder transitions from a first number during a first engine cycle to a second number during a second engine cycle. The methods and systems may reduce engine emissions and improve engine noise characteristics.

Abstract: A four-valve per cylinder engine has two intake valves, two exhaust valves and a centrally located fuel injector. Between each adjacent pair of valves is a valve bridge with a point of minimum separation between adjacent valves. In the present disclosure, the glow plug port is defined in the cylinder top at a location outboard of the minimum separation between adjacent and at a depth which is tangent to an edge of a fuel jet emanating the injector. By placing the glow plug farther outboard than found in the prior art, the glow plug contacts the fuel as it comes out of the injector and as it rebounds off a feature of the piston bowl.

Abstract: Methods and systems for increasing fuel economy of a vehicle including a SCR catalyst are presented. In one example, an amount of EGR provided to an engine is decreased in response to performance of the SCR being within a predetermined range of performance. The methods and systems may increase vehicle fuel economy while vehicle tailpipe emissions are achieved.

Abstract: Methods and systems for adjusting fuel injection of an internal combustion engine are disclosed. In one example, a change in fuel pressure is scheduled when a number of pilot fuel injections provided by a fuel injector to a cylinder transitions from a first number during a first engine cycle to a second number during a second engine cycle. The methods and systems may reduce engine emissions and improve engine noise characteristics.

Abstract: A four-valve per cylinder engine has two intake valves, two exhaust valves and a centrally located fuel injector. Between each adjacent pair of valves is a valve bridge with a point of minimum separation between adjacent valves. In the present disclosure, the glow plug port is defined in the cylinder top at a location outboard of the minimum separation between adjacent and at a depth which is tangent to an edge of a fuel jet emanating the injector. By placing the glow plug farther outboard than found in the prior art, the glow plug contacts the fuel as it comes out of the injector and as it rebounds off a feature of the piston bowl.