Abstract: A position sensor system capable of self compensation over wide temperature ranges, air gaps and tilts. Three matched MRs are aligned in the direction of movement of a magnetic target. The middle MR is the position sensor, and the two outer MRs serve as reference sensors which sense the magnetic field at the limits of the position sensing range. The cooperating magnetic target assures that one of the two outer MR elements is always exposed to some maximum magnetic field, BMAX, corresponding to a position XMAX, and the other MR element is always exposed to some minimum magnetic field, BMIN, corresponding to a position XMIN, such that BMIN≦BX≦BMAX, corresponding to XMIN≦X≦XMAX, where BX is the magnetic field measured by the middle MR and varies with the position, X, of the target. The actual position, X, is computed assuming a linear relation between MR resistance in the magnetic field range from BMIN to BMAX and the position, X, of the target.

Abstract: An evaporative control valve for a vehicle, the valve has a valve body for containing a solenoid that manipulates a plunger between an open position and a closed position, the plunger has a valve end and an adjustment end. The valve body also has a receiving area, a first port, as well as a conduit for connecting the first port to the receiving area. A port member is received and engaged within the receiving area and the port member provides a passageway from the receiving area to outside the valve body and the valve end seals the passageway when the plunger is in its closed position. The first port is aligned with and provides access to set the stroke of the solenoid.

Abstract: An ignition coil assembly includes a cylindrical central core having a main axis, a primary winding outwardly of the central core, a secondary winding outwardly of the primary winding, and a case comprising polyimide material. In one embodiment, a secondary winding spool comprises polyimide material. The overall diameter of the ignition coil assembly is reduced relative to conventional designs.

Abstract: A coil assembly includes a spool (102) having an upper flange (104), a medial flange (106) and a lower flange (108). A terminal groove (118) is established between the upper flange (104) and the medial flange (106), and a winding bay (110) is established between the medial flange (106) and the lower flange (108). Ramps (130) are formed in the groove (118) and at least two terminal posts (126), each having a foot (128), are inserted through the upper flange such that each foot (128) is disposed within the groove (118). Each terminal post (126) is movable between a winding position, wherein the foot (128) protrudes outwardly to facilitate engaging a coil wire end (132), and a retracted position, wherein the foot (128) is retracted behind the respective ramp (130).

Abstract: An ignition apparatus includes a magnetic circuit comprising a central core and a side core or shield, and primary and secondary windings. The shield is allowed to electrically float, thereby reducing the capacitance of the secondary winding. A housing is external to and surrounds the shield to inhibit arcing. A silicone boot overlaps a housing/case interface to further suppress arcing.

Abstract: An evaporative control valve for a vehicle. The valve has a valve body for containing a solenoid that manipulates a plunger between an open position and a closed position, the plunger has a valve end and an adjustment end. The valve body also has a receiving area, a first port, as well as a conduit for connecting the first port to the receiving area. A port member is received and engaged within the receiving area and the port member provides a passageway from the receiving area to outside the valve body and the valve end seals the passageway when the plunger is in its closed position. The first port is aligned with and provides access to set the stroke of the solenoid.

Abstract: An apparatus and method for providing enhanced charging efficiency and a reduction in charge system cost when charging segmented batteries. A current switching device routes charging current from a charge source to a selected segment of the battery, while the remaining segments are in a relaxation mode and are not receiving charge current. A segment selection device periodically reconfigures the current switching device to route charging current to another segment of the battery. As a result, each of the series-connected cells of the battery are subject to alternating charging and relaxation periods until the battery has achieved a desired state of charge.

Abstract: A magnetoresistive sensor assembly includes a housing and a permanent magnet disposed within the housing. The sensor also includes two magnetoresistive dies within the housing in close proximity to the magnet. Three leads that are electrically connected to the magnetoresistive dies extend from the housing. The sensor assembly is manufactured using a leadframe formed with plural long slots and plural short slots. The magnet is attached to the leadframe such that the corners of the magnet are visible through the leadframe, and the magnetoresistive dies are attached to the leadframe based on the position of the magnet. As such, greater precision concerning the placement of the magnetoresistive dies relative to the magnet can be achieved.

Abstract: Method and system for estimating rotor position of a switched reluctance machine is provided. The method allows for estimating flux linkage across a respective phase of the machine. The method allows for measuring of magnetization curves at aligned and unaligned positions of the machine. The method further allows for computing magnetization reference data between the aligned and unaligned positions. A storing step allows for storing rotor position data based on the magnetization reference data. The stored rotor position data is indicative of rotor position variation as a function of phase current. A relating step allows to relate the estimated flux linkage to the magnetization reference data to determine, for a respective phase current, correspondence of the estimated flux linkage relative to the magnetization reference data. A retrieving step allows for retrieving stored rotor position data when said correspondence is determined.

Abstract: A self-compensating control circuit for use with a magneto-resistive sensor. The control circuit includes a first stage amplification and offset function that removes a DC component from the input signal and maximizes an AC component of the input signal within the dynamic range of the control circuit. Subsequent stages remove the remaining DC component, if any, and provide suitable additional amplification. A comparator provides a digital output based on the processed input signal and a threshold signal.

Abstract: Battery charging methods and associated chargers which are capable of rapidly charging a battery while subjecting it to reduced levels of overcharging. The methods described are capable of being utilized within numerous battery charging systems for batteries spanning a range of chemistries, such as lead-acid, nickel-based, and lithium-based batteries. Upon detection of the onset-of-overcharge during the charge process, a variable voltage lid is imposed (VLID=&ngr;(&phgr;)+&bgr;log&phgr;+&kgr;&phgr;) which reduces the maximum voltage that may be applied to the battery as a function of charge acceptance which is typically estimated by a calculation based on state-of-charge. Additionally, the voltage lid can be approximated with step-wise voltage lids which are responsive to the level of charge acceptance within the battery.

Abstract: A continuous paste making process for lead acid batteries that includes the steps of mixing water with a lead oxide, reaction an acid with the lead oxide in a mixture to produce lead acid compounds, and forming a paste including interlocking lead acid crystals from the lead acid compounds, where the mixing, reacting, and crystal forming steps occur in an extrusion apparatus. The method also includes the step of extruding the paste from the extrusion apparatus into a grid where the paste is dried to form a battery plate of the lead-acid battery.

Abstract: An anti-extrusion ring for use in conjunction with a vehicle solenoid valve has a plano-concave cross-section. The anti-extrusion ring is used to support a seal that seals the interface between a solenoid valve and a bore within a valve fitting. When the solenoid valve is installed in the valve fitting, a bore-to-ring interference area is formed between the bore and the anti-extrusion ring and a debris capture area is formed above the bore-to-ring interference area. Thus, when the anti-extrusion ring controllably fractures during installation of the solenoid valve with the bore or due to vibration, debris from the ring will be captured in the debris capture area and prevented from entering a fluid system in which the vehicle solenoid valve is used.

Abstract: A side-mount bracket system for locking the sensor position with respect to a side-mount bracket once the air gap is first established by the gauging layer method, wherein the sensor may be removed and then reinstalled without use of any position setting procedure, yet the air gap is automatically precisely reset to its original value. The side-mount bracket system according to the present invention includes a washer and a side-mount bracket having an elongated slot, wherein as the washer is brought into the slot, facial interaction therebetween, eg., teeth inscribing a smooth surface, causes the washer to be positionally fixed with respect to the bracket. Alternatively, the washer may be slidably trapped onto the bracket at the slot, and a tapered bolt having a varying cross-section which causes expansion of the washer as it is threaded home, thereby affixing the washer positionally with respect to the bracket.

Abstract: A hybrid electrical machine having a permanent magnetic rotor field in addition to an electrically excited rotor field is disclosed. The generator rotor (220) has two opposing claw segments (226, 228) mounted at opposite ends of a rotor shaft (222). A third, center claw segment (232) is mounted on the rotor shaft between the first and second claw segments. A first wound field coil (224) is mounted on the rotor shaft between the first and third claw segments, and a second wound field coil (234) is mounted between the second and third claw segments. One or more permanent magnets (230, 231) may be provided about the periphery of the first, second, and/or third claw segments.

Abstract: A steering column differential angle position sensor includes an upper target wheel and a lower target wheel. Each target wheel forms a plurality of similarly shaped slots that are equally spaced radially around the target wheels. Two receiver coils and a excitation coil are coaxially aligned with the target wheels. A hollow housing surrounds the target wheels and the coils. The excitation coil generates an alternating current magnetic field around itself, and this alternating current magnetic field generates eddy current in the target wheels. The receiver coils receive an alternating current signal that is a combination of the alternating current magnetic field generated by the excitation coil and the eddy current. The receiver coils sense changes in the alternating current signal due to differential slot alignment of the target wheels, and hence, the torque on a steering column that is mechanically coupled to the sensor.

Abstract: A spark ignition assembly for use in a spark ignition system of an internal combustion engine, and an assembly method therefor. The spark ignition assembly includes a housing within which a spark plug, ignition coil and connector are housed. The spark plug has an insulator body, a first electrode and a ground electrode at a first end of the insulator body, and a terminal at an oppositely-disposed second end of the insulator body. The ignition coil is electrically connected to the terminal of the spark plug and to the connector, through which an electric voltage is applied to the ignition coil. The housing preferably contains a liquid injection molding (LIM) compound that surrounds the ignition coil and at least portions of the connector and spark plug.

Abstract: A slip ring assembly includes an insulator body with an rotor-facing first side and second, opposing side, and a pair of slip rings. The slip rings are formed to include respective coupling terminals that generally axially extend from the second side of the insulator body. The insulator body further includes a pair of through-bores that are parallel to but radially offset from a main axis of the insulator body, and are configured for routing the rotor winding leads from the rotor-facing side of the insulator body to the second, opposing side. The coupling terminals each comprise a pair of radially inwardly extending legs and a central, axially extending leg. The leads emerge from the through-bores, and are folded over the radially extending legs. The central, axially extending leg is then folded over the lead to mechanically secure the lead end, which is soldered to ensure electrical connectivity.

Abstract: A ferromagnetic particle sensor includes a housing having a first electromagnet and a second electromagnet attached to the interior surface thereof. A mass sensitive surface acoustic wave (SAW) sensor is disposed between the electromagnets. The sensor is submerged in lubricating fluid and as the electromagnets are energized they produce magnetic forces that draw fluid-borne ferromagnetic particles past the SAW sensor. The SAW sensor is used measure the mass of the ferromagnetic particles and determine when the volume of particles in the lubricating fluid increases.

Abstract: Method and system for bi-directionally controlling power flow between two separate direct current power sources in a multi-stage power converter system are provided. The method allows providing at least first and second power converter stages coupled in parallel circuit to one another. The method further allows providing a first switching controller coupled to selectively actuate a pair of switching devices in the first power converter stage, and a second switching controller coupled to selectively actuate a pair of switching devices in the second power converter stage. One of the first and second switching controllers is selected as a master controller, and the other one of the first and second switching controllers is selected as a slave controller. An average voltage measurement is determined at a respective node of each the power converter stages. A compensating signal is generated based on the difference of the average voltage measurements at the respective nodes of each of the power converter stages.