Abstract: A control system for controlling energization of a plurality of valves in a vehicle hydraulic system. The control system includes a plurality of sensors for measuring various dynamic conditions and operational aspects of the vehicle, a signal processing circuit coupled to the plurality of sensors for determining a desired energization of the plurality of valves dependent upon measurements by at least a portion of the plurality of sensors, and a driver circuit coupled to the signal processing circuit for generating, responsive to the desired energization of the plurality of valves as determined by the signal processing circuit, a control signal to energize the plurality of valves to the desired energization. The control system receives inputs from the plurality of vehicle sensors. These inputs are processed, and the processed inputs and signals derived from the inputs are forwarded to the driver circuit for use in generating a control signal for operating the vehicle valve system.

Abstract: A method and apparatus for determining likelihood of rollover of a vehicle and/or mitigating rollover of the vehicle is responsive to measured vehicle lateral acceleration and a measured one of vehicle roll rate and vehicle suspension displacements to derive estimates of roll angle and roll rate. First, preliminary, estimates of roll angle and roll rate are derived and used as pseudo-measurements in a dynamic, closed loop observer equation which represents a model of the vehicle in a first roll mode for roll angles small compared to a reference value indicating two wheel lift-off and a second roll mode for roll angles at least near a reference value indicating two wheel lift-off. The observer equation has parameters and gains with values for each mode stored as a function of roll angle index derived from measurements and pseudo-measured values. The observer equation produces second, improved values or roll angle and roll rate together indicating the likelihood of vehicle rollover.

Abstract: A first method for estimating a torque/force exerted by a load against an actuator driven by an electric motor against the load includes measuring motor current of the electric motor and measuring a position/angle or speed/angular speed of the actuator and includes calculating the torque/force exerted by the load against the actuator using at least a difference between a calculated motor torque/force and a calculated actuator-experienced torque/force. A second method includes measuring input voltage of the electric motor instead of measuring motor current. A third method includes measuring both motor current and input voltage. In one example, without limitation, the actuator is an automotive electromechanical brake caliper.

Abstract: A method for welding/brazing a tube to a member. The tube has an axially-extending first portion and has a tube form which extends transversely from the first portion. A filler material is obtained. The tube, the member and the filler material are positioned such that the filler material contacts the tube form and the member. A resistance current path is created through the tube, the filler material and the member which melts at least some of the filler material creating a weld/braze zone which includes at least some of the tube, at least some of the member, and at least some of the filler material.

Abstract: The invention provides a method for controlling a vehicle with a braking system including a modulator pump. A first fluid line can communicate brake fluid from the master cylinder to a brake caliper. An isolation valve including a pressure bypass can be disposed along the fluid line between the master cylinder and the brake caliper. A second fluid line can extend from a first position along the first fluid line between the master cylinder and the isolation valve to a second position along the first fluid line between the isolation valve and the brake caliper. A modulating pump is disposed along the second fluid line to pump fluid to the brake caliper during a controlled brake event. The modulator pump is engaged to pump fluid to the brake caliper until the pressure in the first fluid line reached slightly below the predetermined pressure to prevent the isolation valve from opening in response to excessive pressure.

Abstract: A method of initializing a brake-by-wire system is provided. The method includes connecting multiple braking actuators to a controller to allow for communication between the braking actuators and the controller. The braking actuators are associated with one or more wheels of a vehicle. Subsequent to connecting the multiple braking actuators to a controller, the method includes dynamically assigning a primary identifier to the braking actuators using the controller.

Abstract: A torsion pedal feel emulator assembly for a motor vehicle and a method of operating the same. The assembly includes a pedal member for receiving an applied pedal force. A torsion member is operably attached to the pedal member. A portion of the torsion member is positioned adjacent a reaction surface. The torsion member rotates as a result of the applied pedal force, and a dynamic reaction force is generated against the applied pedal force. A pivot is operably attached to the torsion member and the motor vehicle. The method includes receiving an applied pedal force. A torsion member is rotated as a result of the applied pedal force. A dynamic reaction force is generated against the applied pedal force as a result of the torsion member rotation.

Abstract: A method produces PWM voltage waveforms in a PWM motor controller of a three phase PM DC brushless motor, wherein the motor controller has first, second and third half H-bridge transistor pairs to generate the voltage waveforms to electronically commutate the motor. The first transistor pair is always assigned to the first phase for every commutation state requiring a voltage waveform from the first transistor pair. The second and third transistor pair are similarly assigned. The first method also includes always starting a voltage waveform generated by the first transistor pair substantially at the beginning of the PWM period when a commutation state requires a voltage waveform from the first transistor pair but delaying starting a voltage waveform generated by the second transistor pair by substantially ? of the PWM period and delaying starting a voltage waveform generated by the third transistor pair by substantially ? of the PWM period.

Abstract: A system and a method for transmitting signals having audio data in a vehicle are provided. The system includes a first transceiver configured to receive an analog communication signal having the audio data and to transmit a first FM signal having the audio data in an ISM frequency band in response to the analog communication signal. The first FM signal is transmitted at a first predetermined power level. The system further includes a second transceiver configured to receive the first FM signal and to transmit a second FM signal having the audio data in an FM frequency band in response to the first FM signal. The second FM signal is transmitted at a second predetermined power level less than the first predetermined power level.

Abstract: A method for controlling an electric brake system having a piston moveable by an electric motor is provided. The method includes the steps of storing data for correlating a position of the piston to a braking force applied by the piston, estimating a braking force associated with a specific position of the piston based upon the stored data, generating a control signal based upon the estimated braking force, determining a second braking force associated with the specific position and updating the stored data based upon a difference between the estimated braking force and the second braking force.

Abstract: An apparatus (10) is set forth for measuring a return signal of a magnetostrictive sensor (20) that detects a force, torque, or pressure. The return signal includes noise, a DC resistance (44), an AC resistance and an inductance and the inductance is shifted ninety degrees from the AC resistance. The apparatus (10) includes a sensor filter (22) to remove the noise from the return signal. A sensor filter (22) shifts the return signal and more specifically, the inductance by an additional angle and the sum of the additional angle and the ninety degrees phase shift is defined as the final detection angle. To detect the inductance at the final detection angle, a wave filter (16) and a reference filter (28) shifts a reference signal by the final detection angle to trigger a first demodulator (26) to detect the inductance at the final detection angle. The inductance detected by the first demodulator (26) varies due to temperature.

Abstract: Disclosed is a method for repairing defects in kinetically sprayed surfaces. The typical defects comprise isolated or connected conical shaped holes in the kinetic spray coating. The repair involves thermally spraying a molten material into the defective area to fill in the cone followed by continued kinetic spraying to complete the coating.

Abstract: An apparatus and method for fluid flow measurement are provided. The apparatus includes a first thermistor; a second thermistor; a first deflecting member configured to shield the first thermistor from fluid flowing in a first direction; a second deflecting member configured to shield the second thermistor from fluid flowing in a second direction where the second direction is substantially opposite the first direction; and a circuit in electrical communication with the first thermistor and the second thermistor. The circuit includes a comparator for comparing a first signal from the first thermistor to a second signal from the second thermistor. The comparator provides an output indicative of a direction of fluid flowing past the first thermistor and the second thermistor.

Abstract: An actuator for an electro-mechanical-brake motor assembly includes a housing surrounding a rotatable motor shaft presenting a longitudinal axis. A spring is non-rotatably supported on the housing. A latching device is non-rotatably supported by the housing. The latching device has a plurality of teeth. A latch gear is non-rotatably supported on the rotatable motor shaft and circumscribes the longitudinal axis and presents a plurality of axially facing angled teeth presenting a meshing engagement with the teeth of the latching device. The latching device is axially movable relative to the housing in response to magnetic force generated by the electric coil.

Abstract: The invention provides a multi-disc brake for a vehicle having a knuckle for supporting a wheel of a vehicle and a hub mounted for rotation on the knuckle about a rotation axis. The multi-disc brake also includes a pair of discs mounted for rotation with and sliding movement on the hub along the rotation axis. Each disc includes inboard and outboard engaging surfaces. The multi-disc brake also includes a plurality of brake pad assemblies disposed in alternating arrangement between the discs. The multi-disc brake also includes a caliper disposed for sliding movement relative to the knuckle and having an inboard wall and a bridge portion extending from the inboard wall around the discs and the brake pad assemblies to an outboard wall adjacent to the outboard brake pad assembly.

Abstract: A brake booster apparatus having a housing with oppositely disposed first and second walls. A first connector is disposed in the first wall and a second connector is disposed in the second wall. An elongate hollow member is deformationally engaged to each of the first and second connectors. The various embodiments of the invention include embodiments wherein the hollow member is deformed to engage the hollow member and connectors and embodiments wherein the first and second connectors are deformed to engage the hollow member and connectors. The deformational engagement mechanically attaches and sealingly engages the hollow member with each of the first and second connectors. The hollow member defines a passage through the apparatus from the first wall to the second wall of the housing. A method of manufacturing a brake booster is also disclosed.

Abstract: A processor is responsive to a thermistor temperature (Tth) adjacent a FET and to a drain-to-source voltage (VDS) of the FET. The processor stores the characteristics of the PET and a thermal model of the system hardware and uses a first set of equations to determine the temperature (TJ) at the junction of the PET in a stable region of operation where TJ?Tth is nearly constant. The processor is further responsive to a step change in successive measurements of VDS indicative of a lag of Tth relative to TJ. In this step-change region, the processor then resolves TJ based upon a second set of equations.

Abstract: A tilt sensor system (10) is provided comprising a housing (12), a magnetized region (13) within the housing (12), and a magnetized, articulated pendulum (14) magnetically coupled to the magnetized region (13) for suspending the pendulum (14) within the housing (12). In a particular embodiment, the tilt sensor system (10) is incorporated into a park brake system (50) including a park brake for securing a portion of a vehicle in a static condition, and a control system for actuating the park brake responsive to a tilt measurement from the tilt sensor system. In addition, the tilt sensor system (10) may be incorporated into (or functionally coupled to) other vehicle control systems adapted for receiving tilt-related information from the tilt sensor system for use in performing respective vehicle control functions.

Abstract: Welded structures having a first and a second member formed from sheet metal, tubes, and similar shapes, are economically fabricated through use of a method for joining a second member to a first member having a folded rim extending therefrom. The folded rim defines an air gap within the folded rim. The first and second members are joined together by forcing the folded rim against the second member under sufficient pressure to flatten the folded rim to a point that there remains substantially no air gap inside the folded rim, and resistance welding together the first and second members. The second member and the rim respectively define faying surfaces thereof. The air gap inside the folded rim extends generally parallel to the faying surfaces. The faying surfaces of the rim and second member are forced against one another by applying pressure through the folded rim in a direction generally perpendicular to the faying surfaces.

Abstract: A velocity sensor including a damper assembly having a central axis, a magnet extending parallel to the central axis, the magnet having a magnetic axis radially oriented with the central axis, and a coil extending parallel to the central axis and radially oriented with the central axis, wherein movement of the damper assembly with respect to the magnet induces a voltage in the coil.