Borgwarner Inc.

Borg-warner Automotive Gmbh

Joshua L Roby

Theodore A Malott

Thomas Buchholz

John Shutty

Stephen Bohan

Thermal management systems for vehicle engines which include hybrid fan drives with viscous clutches and electronic motors, particularly brushless DC motors (BLDC). One embodiment incorporates a pulley driven, electronically controlled viscous clutch mechanism and an internal rotor BLDC motor. Another embodiment includes an engine crank mounted electronically controlled viscous clutch mechanism with a tethered electric motor, particularly a BLDC motor. A further embodiment is an engine block mounted electronically controlled viscous clutch mechanism with an integrated external rotor BLDC motor.

Hybrid fan drive with electric motor

Pulley assemblies for vehicle accessories, such as a water pump. The pulley assembly which can be connected to a related housing member, such as a clutch housing member, includes a pulley member directly driven by the accessory belt of a vehicle engine and a separate pair of bearing members. A preferred use of the pulley assembly is with a hybrid coolant pump with two modes of operation, an electric motor operation, and a mechanical pulley-driven operation. A friction clutch assembly can be positioned inside the housing member and can include a softening spring which minimizes parasitic clutch power consumption.

Multi-mode cooling pump

A friction clutch assembly, preferably for a hybrid cooling pump. The friction clutch assembly includes a friction lining carrier member, a friction lining member, a compression spring member, a clutch carrier member and a flux plate member. A solenoid can be utilized to control the compression of the spring member. The friction clutch assembly has a preferred use in a hybrid coolant pump with two modes of operation, an electric motor operation, and a mechanical pulley-driven operation. The friction clutch assembly can be positioned inside a motor housing. The softening compression spring can minimize parasitic clutch power consumption.

Friction clutch assemblies

A hybrid accessory drive system having two operational modes, a mechanical mode and an electric mode. The accessory is typically a cooling fan. A continuously variable mechanical belt drive mechanism drives the accessory as one mode of operation. An electric motor along with a planetary roller screw mechanism which converts rotary motion to axial motion is used to change the sheave position and thus the drive ratio. Upon disengagement of the mechanical drive mode, the electric motor can be used to drive the accessory in a second mode.

Hybrid fan drive with CVT and electric motor

An electronic coolant valve mechanism with an integral actuator mechanism. The coolant valve mechanism utilizes an electric motor and a planetary roller mechanism integrated into a valve body to translate and operate a valve member in a linear direction. A manifold can include a plurality of coolant valve mechanism operating independently by a control system.

Electronic coolant valve with integral actuator mechanism

Methods and systems for controlling the operation of a dual mode engine accessory, such as a dual mode cooling pump. The dual mode device has two modes of operation, an electric motor operation and a mechanical pulley-driven operation. A friction clutch mechanism controlled by the control system is utilized to switch between the two modes of operation. The speed of the electrical motor can be changed to be substantially the same as, or changed in the direction of, the speed of the mechanical pulley-driven system.

Control methods for dual mode cooling pump

Hydraulic fan drive system with sensor feed-back. A sensor positioned in the central shaft of the fan drive assembly provides speed feedback signals and eliminates the need for routing the sensor wires.

Fan drive system with sensor feedback

Hydraulic fan drive system with oil flow system. A modular valve mechanism is provided with coaxial oil passages to circulating lubrication oil through the clutch and to and from a heat exchanger.

Fan drive system with lubrication flow system

A fan drive system is provided that is hydraulically controlled having an electrical failure mode wherein midrange operation of the fan drive system is maintained. Accordingly, in the failure mode, a fan drive system hydraulic relief valve is not closed thereby ensuring a degree of operation of the fan drive system even during periods of electrical failure.

Electro-hydraulic pressure control fan drive system with electrical failure mode operation

A continuously variable belt drive system including a driving pulley assembly, a driven pulley assembly, and a V-shaped belt engaged to transfer rotary power therebetween is disclosed herein. The driving pulley assembly includes an idler pulley portion. As the belt speed decreases, the belt migrates downward within the driving pulley assembly until it falls within the idler pulley portions, thereby isolating the belt from the rotation of the driving pulley assembly. The driving pulley assembly also includes a belt tensioning mechanism that maintains proper belt tension at all speeds and drive ratios. The tensioning mechanism relies upon a pivotably mounted centrifugal weight arm to provide tensioning as a function of speed. A compression spring provides axial pressure to maintain belt tension over all drive ratios. The spring, acts against a curved cam edge on a pivoting lever arm, which arm transfers an axial force to the rear sheave of the driven pulley assembly.

Continuously variable belt drive system

A continuously variable belt drive system includes a driving pulley assembly, a driven pulley assembly and a V-shaped belt engaged to transfer rotary power therebetween. The driven pulley assembly includes a ratio adjustment mechanism that adjusts the position of a rear sheave relative to a forward sheave. The adjustment mechanism includes a motor and a worm gear mechanism that rotates an actuation screw. Rotation of the actuation screw is reacted by a split nut that translates the screw rotates along the axis of the driven pulley assembly. In one feature, the driven pulley assembly includes a fail-safe mechanism that operates when power is supplied to the motor to hold the split nut together. In another aspect of the invention, the driving pulley assembly includes a belt tensioning mechanism that maintains proper belt tension at all speeds and drive ratios.

A belt-type continuously variable transfer system ( ) includes a driving pulley assembly ( ), a driven pulley assembly ( ) and a V-shaped belt ( ) engaged to transfer rotary power therebetween. The driven pulley assembly ( ) can include a ratio adjustment mechanism ( ) that adjusts the position of a rear sheave ( ) relative to a forward sheave ( ). The adjustment mechanism ( ) includes a motor ( ) and a worm gear mechanism ( ) that rotates an actuation screw ( ). Rotation of the actuation screw ( ) is reacted by a split nut ( ) so that as the screw ( ) rotates is translated along the axis (B) of the driven pulley assembly ( ). Translation of the actuation screw ( ) exerts pressure against the rear sheave ( ) to push it toward the forward sheave ( ), thereby altering the drive ratio of the pulley assembly. In one feature, the driven pulley assembly ( ) includes a fail-safe mechanism ( ) that operates when power is supplied to the motor ( ) to hold the split nut ( ) together. Once power is disrupted, the fail-safe mechanism ( ) allows the components ( ) of the split nut ( ) to be separated, disrupting the threaded engagement with the actuation screw ( ). At this point, the actuation screw ( ) is driven forward by a compression spring ( ), thereby driving the rear sheave ( ) forward to a predetermined drive ratio position. In another aspect of the invention, the driving pulley assembly ( ) includes an idler pulley portion ( ) radially inboard from the normal driving sheave surface ( ).

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Battle Creek, MI, United States of America

Joshua L Roby