Abstract: A crimping apparatus and methods are provided that apply a press force and a part of the press force is separately applied as a core crimp force for crimping a terminal to a wire conductor. A die assembly includes a die defining a cavity that includes an independently moveable core plate and a ram assembly includes a ram in force connection with a load pin and a core plate. When the ram applies the press force, the core crimp force will be separately applied from the ram through the load pin and core plate to produce a core crimp portion that connects the wire conductor to the terminal. The applied core crimp force is subsequently transferred from the core crimp portion to the core plate to the load pin and into the ram.

Abstract: A ganged electrical connection system includes an arrangement having a spring including a plurality of engagement portions. A plurality of first connectors is receivably coupled in a plurality of receptacles in the arrangement and a plurality of second connectors is matable to the coupled first connectors along mating axes. The plurality of coupled first connectors have floatable movement in the plurality of receptacles. The floatable movement is in at least an axial direction in relation to the plurality of receptacles and the axial positional mating tolerance variation of each second connector in the plurality of second connectors in relation to each first connector in the plurality of coupled first connectors that manifests at each receptacle in the plurality of receptacles is assimilated by each respective spring engagement portion when the plurality of second connectors mate to the plurality of coupled first connectors.

Abstract: A terminal is used in an electrical connector and receives a matable contact member. The terminal has a receptacle contact section has a bottom wall, an upper wall, and a primary and a secondary spring beam, or member. The primary member extends from a bottom wall and is bent back into the receptacle contact section. The primary member has an upper surface facing the upper wall and a lower surface opposite the upper surface. The primary member includes a free end that is spaced from the upper wall a distance less than a thickness of the matable contact member. The secondary member is formed from the bottom wall that extends into the contact section and includes a free end disposed beneath the lower surface of the primary member in an overlapping, spaced relationship thereto remote from the free end of the primary member.

Abstract: A ganged electrical connection system includes a plurality of first connectors matable to a plurality of second connectors along mating axes, and a connector position assurance (CPA) member. The CPA member includes a plurality of tabs and a plurality of release fingers. The plurality of first connectors include a plurality of lock arms and the plurality of second connectors include a plurality of inclined ramps. The plurality of tabs receive the plurality of lock arms and the plurality of inclined ramps deflectingly engage said plurality of release fingers to allow movement of the CPA member in to a position of the CPA member, that when disposed in the position, keeps the plurality of second connectors from unmating from the plurality of coupled first connectors. Methods of fabricating an electrical connection system and a ganged electrical connection system that include the CPA member are also presented.

Abstract: A camshaft phaser includes a housing with a harmonic gear drive unit disposed therein. The harmonic gear drive unit includes a circular spline and a dynamic spline, a flexspline disposed radially within the circular spline and the dynamic spline, a wave generator disposed radially within the flexspline, and a rotational actuator connectable to the wave generator. One of the circular spline and the dynamic spline is fixed to the housing. A hub is rotatably disposed radially within the housing and attachable to the camshaft and fixed to the other of the circular spline and the dynamic spline. A first arcuate input stop member is rotatable with one of the circular spline and the dynamic spline and is received within a first arcuate output opening defined by at least a first arcuate output stop member rotatable with the other of the circular spline and the dynamic spline.

Abstract: A method of manufacturing a metal housing (14) includes providing a first passage (10) through the metal housing (14) and providing a second passage (12) through the metal housing (14), wherein the second passage (12) includes a region of intersection (20) which intersects the first passage (10) to define an opening (22, 122, 222) into the first passage (10). The method further includes subjecting the metal housing (14) to a heat treatment process to carburise an internal surface of the first and/or second passage (10, 12) and, subsequent to the carburization process, applying a hard stage electrochemical machining process to the carburised internal surface of the first and/or second passage (10, 12) to improve surface finish. Another aspect of the invention includes providing a second passage (12) through the metal housing (14) by means of a tool (46), such as an electrochemical machining electrode, having an active region without rotational symmetry about its axis (Y-Y).

Abstract: In a dual intake valve arrangement for an internal combustion engine, a variable valve lift system controls two intake valves for one or more engine cylinders. In each cylinder, one of the intake valves includes an associated two-step actuation device, and the other includes an associated valve deactivation device. To improve in-cylinder air flow turbulence, one valve may be operated in a high-lift or low-lift state while the other valve may be deactivated.

Abstract: A thermal fuse integrated into an electrical circuit powering a heater element having a positive temperature coefficient includes at least one terminal in electrical connection with the heater element thereby connecting the heater element to a power source, and a solder jacket that mechanically retains the electrical connection between the terminal and heater element, wherein a biasing load is applied to the terminal when retained by the solder jacket, and wherein the terminal breaks connection with the heater element under the force of the bias when the solder jacket melts should the heater element overheat. By selecting the solder material forming the solder jacket according to its melt temperature, a temperature specific overheat protection for a heated fuel injector can be provided. Since the injector's metering circuit is separate from the thermal fuse circuit, the fuel injector remains operational even after the heater circuit is opened.

Abstract: A spark plug coil assembly has a primary core bearing primary windings and a secondary winding spool around which secondary windings are wound and in which the primary core is received. A case receives the spool with core. The entire case can be made of composite Iron to function as a magnetic return path for the core, or a composite Iron shield can be overmolded to an otherwise plastic case.

Abstract: A fuel injector is provided with a fuel inlet, a fuel outlet, and a fuel passage for communicating fuel from the inlet to the outlet. A valve and valve seat assembly is provided for selectively preventing and permitting fuel to pass from the fuel inlet to the fuel outlet. The valve seat is defined by a tubular body and a valve seat that traverses an inside wall surface of the tubular body. An upstream face of the valve seat is downstream of an upstream end of the tubular body and a downstream face of the valve seat is upstream of a downstream end of the tubular body. At least one passage is provided through the tubular body beginning downstream of the downstream face of the valve seat and upstream of the downstream end of the tubular body. A cover may be disposed at the downstream end of the tubular body.

Abstract: A method for determining an optimal combustion interval during start-up of a hydrocarbon catalytic reformer under various conditions of temperature, fuel type, and combustion fuel flow rate. An initial catalyst temperature is measured and an algorithm is used to calculate a rate of heating of the catalyst by combustion based upon heat content of the fuel, selected fuel flow rate, and heat capacity and mass of the catalyst and reformer passages. From the initial temperature and the heating gradient, an optimal combustion interval is inferred through the algorithm and used to terminate combustion, initiate a combustion quench interval, and change over the fuel flow rate and mixture from combustion to reforming.

Abstract: A mechanism for compensating systematic uni-directional torque bias imposed on a bi-directional drive actuator shaft, comprising a pallet disposed on an arm for rotation with the actuator shaft. A bucket tappet is engaged by the pallet and contains a helical compression spring. As the actuator shaft rotates and compresses the spring, the load on the pallet increases linearly but the length of the lever arm changes non-linearly at a rate different from the force applied to the pallet. This results in a non-linear torque about the actuator shaft. The torque can be the same at the compression spring preload state as it is at the full load state or it can be biased to be unsymmetrical based on the layout and size of the components and the stroke of the actuator shaft.

Abstract: An electrical distribution center assembly includes a housing having a connector shroud. The shroud defines a shroud cavity adapted for receiving a mating electrical connector body. A blade stabilizer is formed integral with the shroud in a first position within the shroud cavity. The blade stabilizer has blade apertures formed therein. Bladed terminals extend from the housing into the blade apertures. In this position, the blade stabilizer protects the terminal blades from being bent away from a terminal axis. The blade stabilizer is movable to a second position to enable female terminals of the mating electrical connector to electrically connect to the blade terminals.

Abstract: A method and apparatus for reducing the percentage of nitrogen dioxide and nitrogen monoxide in an exhaust gas stream of an internal combustion engine, comprising the steps of injecting a hydrocarbon compound and optionally hydrogen into the exhaust gas stream; passing the exhaust gas through a first catalyst for selective reduction of a portion of the nitrogen oxides to nitrogen, ammonia, and N-containing species; passing the exhaust gas through a second catalyst for selective reduction of a portion of the nitrogen oxides with ammonia to molecular nitrogen; sensing ammonia concentration in the exhaust gas stream after passage through either or both of the first and second catalysts; and controlling by a controller in a feedback loop the injecting to an amount of hydrocarbon that will produce a predetermined concentration of ammonia and nitrogen oxides at the sensor that will lead to high NOx conversion.

Abstract: A method for enshrouding an actuator for use in a fuel injector, comprising the steps of providing an actuator having a body section, a first end piece and a second end piece; providing a shroud having first and second ends; applying a sealant material to at least one portion of an exterior surface of the end pieces, and/or to at least one part of the shroud; and enshrouding the actuator with the shroud, such that the sealant material provides an intermediate layer between the end pieces and the shroud and forms a fluid-tight seal between them.

Abstract: A coupling is provided for attaching an evaporative emission device having a housing to a mounting surface of a motor vehicle. The coupling includes a pair of tracks fixed the mounting surface and a pair of matching rails fixed to the housing. The rails are sized to slide within the tracks until reaching a predetermined seated position within the rails. An aperture is fixed to the mounting surface and includes a shoulder with a manufacturing tolerance defined about a nominal location at the predetermined seated position. A resilient latch is formed on the housing and located so as to snap into the aperture at the predetermined seated position. The latch includes a inclined engaging surface to engage the shoulder over the entire tolerance range of the shoulder.

Abstract: A fuel cell stack is disclosed including a non-fuel cell cassette having temperature sensing elements disposed therein. The temperature sensing elements are disposed in one or more void spaces in the non-fuel cell cassette, which void spaces are connected to openings in the side of the non-fuel cell cassette for lead wires to communicate information from the temperature sensing elements to components outside of the fuel cell stack.

Abstract: A diagnostic method and system is described for diagnosing an operating condition of a conductive particulate matter sensor. The sensor has a substrate and two electrodes on the substrate adapted to collect particulate matter between the electrodes, thereby establishing an electrically conductive path through collected particulate matter between the electrodes that can be detected by measuring electrical resistance between the electrodes, Relect. The diagnosis is performed by detecting whether water vapor condensate may be present between the electrodes and if it is, then measuring resistance between the electrodes while subjecting the sensor to conditions sufficient to evaporate any water vapor condensate and diagnosing a validation that the sensor is in proper operating condition if resistance increases in a manner consistent with evaporation of condensate.

Abstract: A particulate matter sensor is provided for sensing particulate matter present in exhaust gases in a conduit. The particulate matter sensor includes a sensing element with a sensing face which extends into the exhaust conduit and provides a signal indicative of the amount of particulate matter detected in the exhaust conduit. An inner shield is provided to surround the sensing face and includes an inner shield inlet for admitting exhaust gases therein to be sensed. An outer shield surrounds a portion of the inner shield and defines an outer shield chamber extending axially beyond the inner shield. The outer shield has an outer shield inlet passage to receive exhaust gasses from the conduit. Exhaust gases enter the inner shield from the outer shield chamber through the inner shield inlet.

Abstract: A tappet suitable for use with a fluid pump includes a side wall portion and an end face which define an internal chamber of the tappet, the end face having a drive surface for co-operating with a drive arrangement, in use, and a plurality of vents through the end face for allowing fluid flow between the internal chamber and an area outside the tappet. A plurality of longitudinal grooves are formed in an internal surface of the side wall portion, the grooves communicating with respective the vents to form a flow path for fluid into the internal chamber.