Abstract: A powertrain includes an engine with a crankshaft rotating on a first axis, motor/generator unit (MGU), belted drive system, transmission, actuator assembly, and controller. An MGU rotor shaft rotates about a second axis. The belted drive assembly has a first pulley connected to the crankshaft, a second pulley selectively connected to the rotor shaft, and an endless rotatable drive element that connects the pulleys. The transmission is connected to the flywheel via an input clutch. The actuator assembly has a third axis parallel to the first and second axes, a linear actuator(s), pinion gears translatable along the third axis to selectively engage the first and second gear elements, and overrunning clutches to passively disengage the pinion gears from the first or second gear element. The controller transmits control signals to the MGU and linear actuators to command a control state via translation of the pinion gears.

Abstract: A linear magnetic sensor shield system comprises first and second shield parts. The system may include first and second field sensor assemblies, each having field sensors disposed therein. The first shield part may be disposed adjacent to a first side of the first field sensor assembly, and the second shield part may be disposed adjacent to a second side of the second field sensor assembly. The shield parts may be formed of mu metal or a mu metal and steel composite, by of example. A torque transmitting device is also provided.

Abstract: A powertrain includes a motor-generator and an auxiliary electric system. The powertrain also includes a first energy storage device disposed in a parallel electrical relationship with a motor-generator and an auxiliary electric system. Additionally, the powertrain includes a first switching device selectively transitionable between a first open state to electrically disconnect the first energy storage device from at least one of the motor-generator and the auxiliary electric system, and a first closed state to electrically connect the first energy storage device to at least one of the motor-generator and the auxiliary electric system. The motor-generator and the auxiliary electric system are operable regardless of the first switching device being in the first open and closed states.

Abstract: A powertrain includes a motor-generator and an auxiliary electric system. The powertrain also includes a first energy storage device disposed in a parallel electrical relationship with a motor-generator and an auxiliary electric system. Additionally, the powertrain includes a first switching device selectively transitionable between a first open state to electrically disconnect the first energy storage device from at least one of the motor-generator and the auxiliary electric system, and a first closed state to electrically connect the first energy storage device to at least one of the motor-generator and the auxiliary electric system. The motor-generator and the auxiliary electric system are operable regardless of the first switching device being in the first open and closed states.

Abstract: A vehicle includes a transmission, energy storage system (ESS), power inverter module (PIM), and controller. The PIM includes a boost converter having a bypass switch and a first plurality of switches, and also a power inverter having a second plurality of switches. The controller is programmed to execute a method that enables a DC boost converter of the PIM by opening the bypass switch when a speed and a torque of the electric machine are within a predetermined boost range. The controller bypasses the boost converter by transmitting a second switching signal closing the bypass switch when the speed and torque are not within the predetermined boost range. A voltage input to the power inverter is equal to the DC battery voltage whenever the boost converter is bypassed and exceeds the DC battery voltage whenever the boost converter is enabled.

Abstract: A powertrain includes an engine with a crankshaft rotating on a first axis, motor/generator unit (MGU), belted drive system, transmission, actuator assembly, and controller. An MGU rotor shaft rotates about a second axis. The belted drive assembly has a first pulley connected to the crankshaft, a second pulley selectively connected to the rotor shaft, and an endless rotatable drive element that connects the pulleys. The transmission is connected to the flywheel via an input clutch. The actuator assembly has a third axis parallel to the first and second axes, a linear actuator(s), pinion gears translatable along the third axis to selectively engage the first and second gear elements, and overrunning clutches to passively disengage the pinion gears from the first or second gear element. The controller transmits control signals to the MGU and linear actuators to command a control state via translation of the pinion gears.

Abstract: A powertrain for a vehicle is disclosed. The powertrain includes an engine, a motor-generator and a starter mechanism. The powertrain also includes a first energy storage device disposed in a parallel electrical relationship with a motor-generator and an auxiliary electric system. Additionally, the powertrain includes a first switching device selectively transitionable between a first open state to electrically disconnect the first energy storage device from at least one of the motor-generator and the auxiliary electric system, and a first closed state to electrically connect the first energy storage device to at least one of the motor-generator and the auxiliary electric system. Electrical communication between the motor-generator and the auxiliary electric system is independent of the first switching device being in the first open and closed states.

Abstract: A vehicle includes a transmission, energy storage system (ESS), power inverter module (PIM), and controller. The PIM includes a boost converter having a bypass switch and a first plurality of switches, and also a power inverter having a second plurality of switches. The controller is programmed to execute a method that enables a DC boost converter of the PIM by opening the bypass switch when a speed and a torque of the electric machine are within a predetermined boost range. The controller bypasses the boost converter by transmitting a second switching signal closing the bypass switch when the speed and torque are not within the predetermined boost range. A voltage input to the power inverter is equal to the DC battery voltage whenever the boost converter is bypassed and exceeds the DC battery voltage whenever the boost converter is enabled.

Abstract: A vehicle includes an engine, transmission, auxiliary and high-voltage electrical loads, a drivetrain, and an electrical system. The electrical system, characterized by an absence of a DC-DC converter, includes a full-bridge active rectifier/inverter, a semi-active auxiliary rectifier, an MGU connected to the engine via the drivetrain, and a controller. The controller executes a first operating mode in which the bridge rectifier is disabled and the MGU operates as a motor to restart or assist the engine, and a second operating mode in which the MGU is a generator, with the rectifier/inverter powering the HV-ESS and HV electrical load. The auxiliary rectifier provides an auxiliary DC output voltage to the LV-ESS and auxiliary electrical load. Switches may be positioned between a DC bus connection point and the HV-ESS and LV-ESS, with a switch closed and another opened in the first operating mode, and vice versa in the second operating mode.

Abstract: A vehicle includes an engine, a transmission connected to the engine, an auxiliary electrical load, and an electrical system. The electrical system includes a high-voltage energy storage system (HV-ESS), an auxiliary/low-voltage energy storage system (LV-ESS) connected to the load, a full-bridge active rectifier/inverter, a semi-active auxiliary rectifier, and a motor generator unit (MGU) connected to the HV-ESS via the active rectifier/inverter, and to the LV-ESS via the semi-active auxiliary rectifier. A controller establishes a first operating mode in which the MGU is operated as a motor for restarting or assisting the engine via the active rectifier/inverter, and second operating mode in which the MGU operates as a generator and the semi-active rectifier provides an auxiliary DC output voltage to the LV-ESS and the load. Another vehicle has first and second switches in lieu of the semi-active rectifier, with the active rectifier connected to the HV-ESS and LV-ESS via different switches.

Abstract: A linear magnetic sensor shield system comprises first and second shield parts. The system may include first and second field sensor assemblies, each having field sensors disposed therein. The first shield part may be disposed adjacent to a first side of the first field sensor assembly, and the second shield part may be disposed adjacent to a second side of the second field sensor assembly. The shield parts may be formed of mu metal or a mu metal and steel composite, by of example. A torque transmitting device is also provided.

Abstract: An electric machine is provided that includes a rotor assembly having a rotor core configured to support permanent magnets spaced around the rotor core to define a number of rotor poles. The rotor core has multiple rotor slots arranged as multiple barrier layers at each of the rotor poles. The rotor core is configured so that the electric machine satisfies predetermined operating parameters. In one embodiment, the electric machine is coupled with an engine through a belt drive train and provides cranking (engine starting), regeneration and torque assist modes.

Abstract: An electromagnetic actuation system includes an actuator having an electrical coil, a magnetic core, and an armature. The system further includes a controllable drive circuit for selectively driving current through the electrical coil. A control module provides an actuator command to the drive circuit effective to drive current through the electrical coil to actuate the armature. The control module includes a magnetic force control module configured to adapt the actuator command to converge magnetic force within the actuator to a preferred force level.

Abstract: An electromagnetic actuation system includes an actuator having an electrical coil, a magnetic core, and an armature. The system further includes a controllable bi-directional drive circuit for selectively driving current through the electrical coil in either of two directions. The control module provides an actuator command to the drive circuit effective to drive current through the electrical coil in a first direction to actuate the armature and in a second direction subsequent to armature actuation to oppose residual flux within the actuator. The control module includes a residual flux feedback control module configured to adapt the actuator command to converge residual flux within the actuator to a preferred flux level.

Abstract: An electromagnetic actuator includes an electrical coil and a high permeability magnetic flux path. The magnetic flux path includes a magnetic core, an armature and a flux return structure. The electromagnetic actuator further includes a flux sensor which is integrated within the actuator and is configured to detect a magnetic flux within the high permeability magnetic flux path.

Abstract: An apparatus for closed loop operation of a solenoid-activated actuator includes an external control module and a power source which are electrically and operatively coupled to an activation controller of the actuator. The external control module and the power source are located externally to the actuator. The apparatus further includes an activation controller which is integrated within the body of the actuator. The activation controller includes a control module and an actuator driver and is configured to communicate with the external control module and to receive electrical power from the power source. The apparatus additionally includes at least one sensor device which is integrated within the body of the actuator and is electrically and operatively coupled to the activation controller. The at least one sensor device is configured to measure one or more parameters during operation of the actuator and the measured parameters are provided as feedback to the activation controller.

Abstract: An electromagnetic actuation system includes an electrical coil, a magnetic core, an armature, a controllable bi-directional drive circuit for selectively driving current through the coil in either of two directions, and a control module providing an actuator command to the drive circuit. Current is driven though the electrical coil in a first direction when an actuation is desired. When the actuation is not desired current is driven through the electrical coil including in a second direction sufficient to reduce residual flux within the actuator below a level passively attained within the actuator at zero coil current.

Abstract: An apparatus for controlling operation of an electromagnetically-activated actuator includes an activation controller that is one of integrated within a connector assembly of the actuator and integrated into a power transmission cable in close proximity to the actuator. The activation controller comprises a control module configured to generate an actuator command signal, and an actuator driver comprising a bi-directional current driver. The actuator driver is configured to receive the actuator command signal from the control module and generate an activation command signal for controlling the direction and amplitude of the current provided to the actuator.