Abstract: A vehicle body compartment lid includes a unitary, one-piece panel. The panel has both an inner panel portion and an outer panel portion, and is bent or folded such that the inner panel portion and the outer panel portion are in juxtaposition with one another. A method of manufacturing a vehicle body compartment lid employing the panel is also provided. The panel is preferably formed using fluid pressure.

Abstract: A magnetorheological damper device is provided having an increased shear interface area per unit volume of device, which enhances the stroking force of the damper.

Abstract: The family of transmissions has a plurality of members that can be utilized in powertrains to provide at least eight forward speed ratios and one reverse speed ratio. The transmission family members include three planetary gear sets having seven torque-transmitting mechanisms and three interconnecting members. The powertrain includes an engine that is selectively connectable to at least one of the planetary gear members and an output member that is continuously connected with another one of the planetary gear members. The seven torque-transmitting mechanisms provide interconnections between various gear members, the input shaft and the transmission housing, and are operated in combinations of two to establish at least eight forward speed ratios and at least one reverse speed ratio.

Abstract: The invention provides a valvetrain configuration in an internal combustion engine in which a plurality of two-step rockers enable the engine poppet valves to switch between two lift profiles. In addition, a lost-motion stationary lash adjuster enables the deactivation of the engine poppet valve. The integration of a two-step rocker with a deactivating stationary lash adjuster yields a better control of the combustion process, under different engine operating conditions than what is achievable with either one of these actuators acting alone. Preferably, the locking and unlocking of the two-step rocker arm and deactivating stationary lash adjuster is controlled by two on/off hydraulic valves in a hydraulic circuit, and a piloted check valve prevents hard landings between stationary and moving components within the stationary hydraulic lash adjuster.

Abstract: A multilayer composite contains a gel coat layer, a laminate layer, and a barrier layer disposed between the gel coat and the laminate layer. The laminate contains from 40–80% by weight paste and from 20–60% by weight reinforcing fibers. The barrier coat also comprises a cured polyester resin, and contains reinforcing fibers shorter than those in the laminate layer. The barrier layer has sufficient flexibility to avoid cracking during demolding and handling. Preferably, the barrier layer exhibits an elongation at break of more than 1%, and more preferably about 2% or more. The resin of the barrier layer can contain up to about 25% by weight of the resin of an isophthalic acid based polyester resin. The composites can be made using an open tool molding process.

Abstract: Parameters specifying properties of the materials used in the lost foam casting process are input at an input step. Numerical methods may be used to simultaneously solve a set of coupled equations relating thermal properties, flow properties, and other physical properties of the metal and foam. A profile number ? and an engulf number E may be evaluated using the values of physical quantities determined during the numerical solution step. Once values for the profile number ? and engulf number E have been determined, these values may be checked to see if they lie within appropriate ranges.

Abstract: A fuel cell comprising a membrane electrode assembly (MEA) that is made up of a membrane sandwiched between first and second electrodes, a contaminant peroxide, damaging to the MEA, and at least one constituent with the contaminant peroxide that prevents, or at least inhibits, decomposition of at least one of the first electrode, the second electrode, the membrane, and any combination thereof.

Abstract: The electrically variable transmission family of the present invention provides low-content, low-cost electrically variable transmission mechanisms including first and second differential gear sets, a battery, two electric machines serving interchangeably as motors or generators, and five selectable torque-transfer devices. The selectable torque transfer devices are engaged singly or in pairs to yield an EVT with a continuously variable range of speeds (including reverse) and four mechanically fixed forward speed ratios. The torque transfer devices and the first and second motor/generators are operable to provide five operating modes in the electrically variable transmission, including battery reverse mode, EVT reverse mode, reverse and forward launch modes, continuously variable transmission range mode, and fixed ratio mode.

Abstract: Turn signal assemblies for motor vehicles that employ shape memory alloy actuators to provide automatic cancellation of turn signals. A controller is in operative communication with the shape memory alloy actuator and is programmed to provide an activation signal to the shape memory alloy.

Abstract: A starting clutch control includes an engine control state and a slip control state. The engine and slip control states include feedforward and driveline damping control terms. The engine state control may further include an engine speed control term. The slip control state further includes a clutch slip control term. Changes to clutch engagement commands are frozen upon throttle tip-in events.

Abstract: An instrument panel beam includes an elongated main member having a bent tubular configuration, and a plurality of structural supports connected to the member. The beam is formed of a lightweight material, such as a magnesium or aluminum alloy. The beam is preferably constructed utilizing a die-cast process, wherein at least a portion of the member is overmolded by each support so as to cooperatively form a soldered region therebetween.

Abstract: A method and system to improve fuel economy of an engine on a vehicle is offered. An electronic throttle control device is commanded to a wide open throttle position during vehicle coast down, thus improving engine breathing and reducing pumping losses, and improving engine efficiency. This includes monitoring operator inputs to: an accelerator device, a braking device, and a cruise control device, and, monitoring throttle position control input from the electronic controller to the electronically controlled throttle mechanism. The electronically controlled throttle mechanism is commanded to a substantially wide-open throttle condition only when the monitored operator inputs to the accelerator device, the braking device, and the cruise control device are each at a null position. A further limitation on the wide-open throttle command includes monitoring other inputs from the electronic controller to the throttle mechanism.

Abstract: A vehicle chassis having substantially all of the mechanical, electrical and structural componentry necessary for a fully functional vehicle, including at least energy conversion system, a steering system and a braking system. The chassis is configured for releasable engagement with a variety of different types or styles of vehicle bodies. Various prior art mechanical control linkages between a driver and controlled systems are replaced with non-mechanical control signal transmission components. Fuel cell technology is also implemented. A system for adjustable, reconfigurable foot pedals is also shown for generating driver input to the by-wire braking systems and energy conversion systems and for providing control and comfort for the driver and/or a passenger.

Abstract: A bayonet collet pickup tool includes a collet chuck having a collet portion including a bore disposed therein. A collet is held in the bore and is operable therein. A bayonet cap is mounted to an outer surface of the collet chuck proximate the bore. The bayonet cap includes a tubular socket concentric with the bore, at least one pair of diametrically opposed linear slots adjacent the socket, and a circular ledge adjacent the socket and perpendicular to the slots. A part including a shaft and at least one pair of diametrically opposed pins projecting from the shaft is receivable in the bayonet cap and the bore. Rotating the collet chuck while the pins are level with the ledge and then closing the collet releasably retains the part in the tool.

Abstract: A forming apparatus and method for minimizing wrinkling in the forming of a three-dimensional component from a two-dimensional blank. The forming apparatus includes vertically opposed sets of tools or binders. A first tool or binder apparatus has first and second sets of opposed sides having contoured binder surfaces. A second tool or binder apparatus is mounted in vertically opposed relation to the first binder apparatus, and includes first and second sets of opposed tool or binder segments that have contoured binder surfaces thereon that are complementary in shape to the respective binder surfaces of the first and second sets of opposed sides of the first binder apparatus. One of the first and second sets of opposed binder segments of the second binder apparatus have substantially similar contours and the other have different contours. One of the first and second sets of opposed binder segments of the second binder apparatus is elevated and movable with respect to the other.

Abstract: A system, method, and apparatus are provided for maintenance opportunity planning in a production line having a plurality of machines and buffers between machines on the production line, with the buffers processing production units between at least two of the machines. The system, method, and apparatus advantageously indicates maximum allowed downtime for a machine, through monitoring the status of the buffers to determine whether the flow of units through the buffers is favorable, monitoring the status of the plurality of machines, and determining which of the plurality of machines may be shut down for a particular period of time while substantially maintaining the favorable flow of units through the buffers. In this way, the inventive system and method saves time and resources by reducing production line downtime and unscheduled overtime.

Abstract: A multistage machining process includes a plurality of stations. Workpiece feature quality is predicted based on decomposition of the machining process into sources of variation, reticulation of the machining process into machining stations and error models that account for significant contributions to feature quality including from categorical sources of variation.

Abstract: A press and tooling apparatus for forming a preheated blank includes a heated upper tool and an opposing heated lower tool mounted within the press for relative closing movement to press the preheated blank there between. A binder ring assembly surrounds the lower tool and is mounted on the press for movement relative to the lower tool so at to bind the preheated blank to the upper tool in air tight sealing relationship in readiness for closure of the tools and application of pressurized gas to force the blank into contact with the upper tools. The binder ring assembly includes an upper ring that is heated so as to prevent the cooling of the preheated blank, and a lower ring that supports the upper ring and is fixedly connected to the upper ring by spaced apart connectors so as to minimize the heat transfer path from the heated upper ring to the lower ring.

Abstract: Active pressure relief valves and methods of use for regulating atmospheric conditions within an interior compartment of a vehicle generally include an active material to effect movement of a flap relative to an opening. The active material has the ability to remember its original at least one attribute such as dimension, shape, and/or flexural modulus, which can subsequently be recalled by applying or removing an external stimulus, as will be discussed in detail herein. Suitable active materials include, without limitation, shape memory alloys, ferromagnetic shape memory alloys, shape memory polymers, piezoelectric materials, electroactive polymers, magnetorheological fluids and elastomers, electrorheological fluids, composites of one or more of the foregoing materials with non-active materials, combinations comprising at least one of the foregoing materials, and the like.

Abstract: A reconfigurable clamp for a flexible manufacturing system comprises a body portion, a plurality of pins slidably engaged within sleeves formed in the body portion, a compression spring attached to each shaft of the plurality of pins, a reservoir comprising a magnetorheological fluid in operative communication with the plurality of pins, and an electromagnet in operative communication with the magnetorheological fluid, wherein the electromagnet selectively increases a yield stress property of the magnetorheological fluid; and a matching pressure foot.