Borgwarner Inc.

Daniel Brown

Chad M McCloy

Shawn Blackmur

Franklin R Smith

Roger T Simpson

Mark M Wigsten

Braman C Wing

David B Roth

Christopher J Pluta

Chris D Thomas

John R Smerczak

Michael Close

Anthony J Mattord

Glen Kozeli

Paul A Darsky

Jiju Alexander

Andrew Morris

A torque-limiting coupler for connecting an electric motor to a rotatable input of a vehicle is provided, including: a rigid frame that is configured to be coupled to one of the rotatable input or an output shaft of the electric motor; and an clastic member, configured to engage the other of the rotatable input or the output shaft of the electric motor, that engages the rigid frame such that the elastic member substantially maintains its shape and inhibits angular displacement between the rotatable input and the output shaft when an amount of torque received from the output shaft is below a predetermined torque limit, the elastic member changes shape permitting angular displacement between the rotatable input and the output shaft when an amount of torque received from the output shaft exceeds the predetermined torque limit.

Torque limiting coupler for an electric motor shaft

An electrically-actuated variable camshaft timing (VCT) phaser assembly, comprises a sun gear configured to receive input from an electric motor and one or more planet gears having radially-outwardly-extending gear teeth that engage the sun gear; a first ring gear, having radially-inwardly extending gear teeth that engage the radially-outwardly-extending gear teeth of the sun gear, configured to receive rotational output provided by a crankshaft; a second ring gear, having radially-inwardly extending gear teeth that engage the radially-outwardly-extending gear teeth of the sun gear, configured to couple to a camshaft; one or more planet gear pins that carry the planet gear(s) and engage a planetary gear set to prevent the relative rotation of the planet gear pin(s) relative to the planetary gear set; and one or more springs that bias the planet gear pin(s) and the planetary gear(s) toward the first ring gear and the second ring gear.

Electrically-actuated camshaft phaser with backlash reduction

A method includes determining a value of an operational motor current limit and setting a value of a startup current limit equal to a predetermined value in excess of the value of the operational motor current limit if a set of predetermined conditions is satisfied. The method includes determining that operation of the engine has been interrupted, operating the electric motor of the variable valve timing mechanism with a current having a magnitude that is less than or equal to the startup current limit after determining that operation of the engine has been interrupted, determining that operation of the engine has resumed, and operating the electric motor of the variable valve timing mechanism with a current having a magnitude that is less than or equal to the operational motor current limit after determining that operation of the engine has resumed.

Method for controlling camshaft orientation for improved engine re-starting of an engine having start-stop capability

An electrically-actuated variable camshaft timing (VCT) device, comprising: an input configured to receive rotational force from an electric motor; an output configured to couple with a camshaft of an internal combustion engine; a planet gear having radially outwardly extending gear teeth configured to engage ring gears and a radially-inwardly-facing surface; a planet pin, supporting the planet gear, having an outer surface and an axis of rotation about which the planet gear rotates; and a spring applying force in a substantially axial direction along the axis of rotation that moves the planet gear in a radial direction.

Electrically-actuated camshaft phasers with tapered features

An electrically-actuated variable camshaft timing (VCT) assembly includes a gearbox assembly including an input; an electric motor having a rotor, a stator, and a motor shaft that is coupled with the input of the gearbox assembly, wherein the motor shaft includes etchings, on an outer surface of the motor shaft, that releasably couple the motor shaft to the rotor at a center aperture of the rotor when an amount of torque exerted on the motor shaft via the gearbox assembly is less than or equal to a predetermined torque value, and the etchings are further configured to decouple the motor shaft from the rotor when the amount of torque exerted on the motor shaft is greater than the predetermined torque value.

Torque limited variable camshaft timing assembly

A variable camshaft timing (VCT) assembly for controlling the angular position of concentric camshafts includes an independent VCT device that is configured to couple with a first concentric camshaft and change an angular position of the first concentric camshaft relative to an angular position of a crankshaft; and one or more dependent VCT devices mechanically linking an output of the independent VCT device with a second concentric camshaft, wherein the dependent VCT device(s) change(s) an angular position of the second concentric camshaft relative to the angular position of the first concentric camshaft based on angular movement of the output of the independent VCT device.

Variable camshaft timing assembly

A system and method of controlling an angular position of a camshaft relative to an angular position of a crankshaft includes detecting rotational movement of an electric motor output shaft controlling a camshaft phaser; detecting rotational movement of the crankshaft; determining the relative difference between the rotational movement of the electric motor output shaft and the rotational movement of the crankshaft; and determining whether the angular position of the camshaft relative to the angular position of the crankshaft is advancing, retarding, or remaining constant.

Electric phaser startup control method

A hydraulically operated camshaft phasing mechanism has two lock pins. One of the lock pins engages at an intermediate position and an end lock pin engages near one of the stops at the end of the phaser range of authority. At least one of the locking pins, preferably the end lock pin, when the vane is at an end stop position, is engaged by oil pressure and spring loaded to release when the oil pressure side of the end lock pin is vented.

Variable camshaft timing mechanism with a lock pin engaged by oil pressure

An electrically-controlled eccentric camshaft phaser () that adjusts phase between a camshaft and a crankshaft includes a sprocket (), configured to connect to the crankshaft and rotate about a center axis (x), having a sprocket ring gear (); a camshaft plate () configured to connect to the camshaft and rotate about the center axis (x), having a camshaft ring gear (); an eccentric shaft () that includes a crankshaft eccentric section () and a camshaft eccentric section (); a sprocket bearing () that is received by the crankshaft eccentric section (); a camshaft bearing (), having a different diameter than the sprocket bearing (), that is received by the camshaft eccentric section ().

Eccentric gears with reduced bearing span

A variable camshaft timing device adjusts phase between a camshaft and a crankshaft and includes a first ring gear configured to connect to the camshaft and rotate about a center axis, having a plurality of radially-inwardly facing gear teeth; a second ring gear axially spaced from the first ring gear, configured to receive rotational input from the crankshaft and rotate about the center axis, having a plurality of radially-inwardly facing gear teeth; a planetary gear assembly including one or more planet gears that are configured for rotation by an electric motor and engage the first ring gear and the second ring gear through the planet gear(s); and a cushioned stop configured to transmit energy between the planetary gear assembly and a planetary gear stop attached to a sprocket or a camshaft plate.

EPhaser cushion stop

A split ring planetary drive with at least one travel end stop received in at least one pocket of a first ring gear. The travel end stop is moveable between a first stop position in which as the planetary drive rotates in a direction the travel end stop engages the stop on the planet carrier, preventing further rotation of the split ring planetary drive in the direction, and a second position in which the travel end stop does not engage the stop on the planet carrier. The travel end stop may be a deadbolt, a snap ring or pivoting pawl.

Carrier stop for split ring planetary drive

A variable compression connecting rod system () located in an internal combustion engine () and a method of assembly can include a connecting rod () mountable to a piston pin () having a first longitudinal axis at one end andmountable to a crankpin () having a second longitudinal axis at a second end portion (). A hydraulically actuated eccentric rotor () rotatable about one of the first and second longitudinal axis. The eccentric rotor () including first and second vanes () for driving the rotor between first and second angular positions in response to fluid pressure acting on the first and second vanes. The eccentric rotor() having an eccentric surface area with different radial distances () movable into alignment with a longitudinal axis of the connecting rod () for varying a longitudinal length of the connecting rod () between the first and second longitudinal axis.

Variable compression ratio connecting rod system with rotary actuator

A coupling assembly () and method can include a first rotatable member () and a second rotatable member () defining a cylindrical hub portion having a plurality of springs () interposed between the cylindrical hub portion of the second rotatable member () and the first rotatable member () for transferring rotational torque between the first and second rotatable members. A plurality of load-bearing surfaces () associated with the first rotatable member () are engageable by the plurality of springs () to accommodate radial clearances () between the first rotatable member () and the cylindrical hub portion while providing rotational drive torque from the first rotatable member () to the second rotatable member () through the plurality of springs ().

Electric phaser coupling method

A system () including a phaser (), a motor (), and a controller () for controlling the phase between a camshaft () and a crankshaft () of an engine (). The phaser () is attached to the camshaft (), is in communication with the crankshaft (), and is configured to adjust the phase of the camshaft (). The motor () actuates the phaser () and is operatively attached to and in communication with the phaser () such that rotation of the crankshaft () back-drives the motor () to subsequently generate a signal. The controller () is in electrical communication with the motor (), is responsive to the signal, and uses the signal to determine the rotational speed of the motor () to thereby commutate the motor () and subsequently drive the motor () so as to actuate the phaser () and control the phase of the camshaft ().

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Freeville, NY, United States of America

Daniel Brown