Gm Global Technolgoy Operations, Inc.

Frederick J Rozario

William Conrad Albertson

Joseph E Robbins

Shekhar G Wakade

Glenn E Clever

Mike M Mc Donald

Alan William Hayman

David R Staley

James Joseph Mazzola, Iii

James B Hicks

Mark Stabinsky

Stephen R Kornblum

Ko-Jen Wu

Qi Ma

Rodney E Baker

Vimesh M Patel

Gary J Patterson

Jeremy T Demarest

William A Berry

Terry Wayne Black

Dominique T Lester

James E Hetzner

Allen G Sheppard

Dennis Kitching

Jason E Morehead

Carlos A Ponce

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.

Method of making component shapes having non-round exterior shapes

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.

Concentric camshaft with varying wall geometry and method of assembly

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.

Camshaft lobe and method of making same

An automotive engine valve stem, engine valve and method of producing both. The valve includes a head and a stem joined to the head. Lightweight, high-temperature materials, such as titanium-based materials may be used to make up at least a the majority of the valve. These materials are combined with fabrication techniques that may vary between the head and the stem, where at least a part of the valve is made by dynamic magnetic compaction. While a majority of the stem may be made from a titanium-based powder material, its tip may be made of a high strength hardened material, such as a steel alloy. The valve head may be made by single press and sintering, double press and sintering, forging and machining, forging and sintering, and dynamic magnetic compaction and sintering.

Method of making titanium-based automotive engine valves

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.

Hydraulic control system for engine cam phasing

A control system comprising a spark knock detection module that detects a spark knock in an engine of a hybrid vehicle, and a torque control module that selectively regulates an engine torque output and an electric machine torque output based on the spark knock. A method comprising detecting a spark knock in an engine of a hybrid vehicle, and selectively regulating an engine torque output and an electric machine torque output based on the spark knock.

Extending variable displacement operation through spark knock control

A valve train for use in an engine is provided. The valve train includes a rocker arm assembly having a valve side arm and a cam side arm. A valve is coupled to the engine and is in contact with the valve side arm. A pushrod is reciprocatable by a camshaft and is in contact with the cam side arm. An overload feature is located on at least one of the rocker arm assembly or the pushrod. The overload feature has a reduced cross-sectional area calibrated to activate at a predefined load.

Valve train with overload features

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.

Twin cam phaser for dual independent cam phasing

An apparatus for providing pressurized fuel for an engine includes an engine starting apparatus including an electric motor operative to crank the engine and a fuel pump operatively coupled to the electric motor.

Fuel pressure boost method and apparatus

A process for powder metal mold casting of three-dimensional parts is disclosed wherein a casting of complex parts is facilitated.

Powder metal mold casting for three dimensional parts

A rocker assembly for a valve train having a first valve, a second valve, and a pushrod is provided. The rocker assembly includes a rocker having a first arm in contact with the first valve, a second arm in contact with the second valve, and a third arm in contact with the pushrod, the first arm having a bore formed therethrough. An adjustable swivel foot includes a first portion having threads and a second portion, the adjustable swivel foot coupled to the first arm such that the first portion extends through the bore of the first arm and the second portion is engageable with the first valve, and a threaded member is included that is engaged with the threads of the first portion of the adjustable swivel foot, the threaded member operable to position the second portion relative to the rocker.

Rocker assembly with adjustable swivel foot

A windage tray apparatus is provided and is configured to be mountable within a crankcase at least partially defined by an engine block of an internal combustion engine. The crankcase has a first bay and a non-adjacent second bay. The internal combustion engine has a crankshaft rotatably supported within the crankcase. The windage tray includes a tray member and a passage at least partially defined by said tray member and in communication with the first bay and the non-adjacent second bay. The passage is operable to allow gas transfer between the first bay and the non-adjacent second bay to reduce the motoring friction of the internal combustion engine. An internal combustion engine incorporating the disclosed windage tray apparatus is also provided.

Windage tray

An internal combustion engine having a cylinder block defining a plurality of cylinders at least half of which are selectively deactivatable by a plurality of switching hydraulic lifters. A source of pressurized oil is provided. Additionally, at least one solenoid-actuated hydraulic control valve operates to selectively communicate pressurized oil from the source of pressurized oil to actuate the plurality of switching hydraulic lifters thereby deactivating the selectively deactivatable cylinders. The number of the solenoid-actuated hydraulic control valves is fewer than the number of selectively deactivatable cylinders.

Cylinder deactivation apparatus

An engine control module includes a valve control module that disables intake and exhaust valves corresponding to a cylinder that includes a mass of intake air. An engine cycle module determines a number of engine cycles that occurred while the cylinder is disabled. An air estimation module determines a remaining mass of air in the cylinder based on the number of engine cycles.

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Fenton, MI, United States of America

Frederick J Rozario