Abstract: A system for selectively consuming and storing electrical energy in a hybrid vehicle. The system includes an electric motor/generator unit having a rotary shaft and an internal combustion engine having a main shaft. A continuously variable transmission mechanically couples the electric motor/generator rotary shaft to the engine main shaft. A control circuit varies the amount of torque of the electric motor/generator unit rotary shaft between a negative and a positive value as a function of the operating condition of the vehicle. The control circuit also controls the transmission to vary the transmission ratio as a function of the engine operating conditions.

Abstract: A fuel system for a direct injection internal combustion engine having a fuel rail and at least one annular cup secured to the fuel rail so that fuel from the fuel rail flows into the cup. A direct injection fuel injector has a portion axially insertable into the fuel cup to a connected position. A recessed channel on the fuel injector registers with a slot in the annular cup when in the connected position so that a U-shaped clip insertable into the cup slots and the fuel injector channels secures the fuel injector and cup together against axial movement.

Abstract: A linear actuator having a housing, a plunger slidably mounted to the housing between an extended and retracted position, and an electric motor drivingly connected to the plunger to move the plunger between its extended and retracted positions. A motor circuit controls the activation of the motor circuit and deactivates the motor circuit whenever the motor current exceeds a threshold value which varies as a function of the supply voltage to the electric motor and/or temperature. A memory storage unit stores the position of the plunger. Whenever the position of the plunger is in a state of transition between its retracted and extended position upon system initialization, the motor control circuit activates the motor to drive the plunger to a preselected extended or retracted position.

Abstract: A method for determining the absolute angle of an angle position sensor over a predetermined rotation range and in which the sensor generates a repeating periodic analog signal across the rotation range. The initial position of the sensor is stored in memory when the sensor is in a predetermined initial angular position. Thereafter, the angular position of the sensor within the rotation range is determined as a function of both the sensor output signal and the stored angular position of the sensor. The current position of the sensor is iteratively stored in memory. Additionally, the sensor output is calibrated by dividing the sensor output into a plurality of arc segments across the rotation range. A polynomial curve fit is then applied to each arc segment to determine the calibration for the sensor and this calibration data is subsequently utilized to provide a signal representative of the absolute angle of the position sensor over the rotation range.

Abstract: A method and apparatus for molding a right angle connector onto a tube end portion. The tube end portion is positioned in a mold cavity; an axially extending core is positioned in the mold cavity with the axis of the core at a right angle to the axis of the tube end portion and with an inboard end of the core positioned proximate the open end of the tube end portion; a molten plastic material is injected into the mold cavity in surrounding relation to the core and the tube end portion; and the core is removed to form a connector fixedly secured to the tube end portion and having a central axial bore communicating with the open end of the tube, extending at a right angle to the central axis of the tube end portion, and conforming to the configuration of the core.

Abstract: A clutch hydraulic actuator system having a vibration damper provided in the system between a master cylinder and a slave cylinder of the system. The damper includes a housing, an elastomeric diaphragm, and a spring steel diaphragm. The upper face of the elastomeric diaphragm is in fluid communication with hydraulic fluid in the system so that the elastomeric diaphragm may deflect in response to low frequency vibrations transmitted through hydraulic fluid in the system to effect damping of the low frequency vibrations. The spring steel diaphragm is positioned in the system generally parallel to and proximate the lower face of the elastomeric diaphragm so as to form a back up for the elastomeric diaphragm so that the elastomeric diaphragm may deform against the spring steel diaphragm in response to intermediate frequency vibrations transmitted through the hydraulic fluid to cause deflection of the spring steel diaphragm to effect damping of the intermediate frequency vibrations.

Abstract: A hydraulic clutch actuator system having a vibration damper in the system including an elastomeric diaphragm and a steel diaphragm. One face of the elastomeric diaphragm is in communication with fluid in the system so that the diaphragm may deflect in response to low frequency system vibrations to effect damping of these vibrations. The steel diaphragm is positioned generally parallel to and proximate the other face of the elastomeric diaphragm so as to form a back-up for the elastomeric diaphragm so that the elastomeric diaphragm may deform against the steel diaphragm in response to high frequency system vibrations to cause deflection of the steel diaphragm to effect damping of the high frequency vibrations. An apertured stop structure above the elastomeric diaphragm functions to limit upward excursions of the elastomeric diaphragm and further functions to maintain communication between the chamber above the elastomeric diaphragm and the damper port to the system.

Abstract: The present invention provides a method and apparatus for identifying and eliminating vibration in a hydraulic clutch actuator. The vibration is identified by using transducers to characterize the vibrational characteristics of a power train of a vehicle. That characterization is used to program a shaker on a test bed to replicate the vibrations on the vehicle in a hydraulic clutch actuator. Different hydraulic dampers may be employed to eliminate the vibration. The preferred apparatus of the present invention includes a two piece hydraulic damper which may be opened as to insert different diaphragms for testing.

Abstract: A master cylinder formed of a forward plastic part snapingly secured to a rearward plastic part. The forward part has a tapered draft angle bore and the rearward part has a purely cylindrical bore aligned with the draft angle bore of the front part and conforming to the diameter of the piston of the cylinder. An annular groove is defined by the parts in surrounding relation to the aligned bores and an annular bearing, having a true cylindrical inner surface corresponding to the diameter of the piston, is positioned in the groove to guide the front end of the piston as the piston moves forwardly into the tapered bore of the forward part.

Abstract: A master cylinder assembly in which the casing defines an annular seal groove defining a forward bore portion forwardly of the annular groove and a rearward bore portion rearwardly of the annular groove. The front end of the piston in the retracted position of the piston is received in the forward bore portion to provide total bearing support for the piston and axial grooves are provided in the forward bore portion to allow recuperative fluid to flow from the associated reservoir and through the axial grooves to the forward bore portion forwardly of the retreating piston.

Abstract: An ignition coil assembly is disclosed for a spark plug of the type used in internal combustion engines. The ignition assembly includes a housing, a tubular and cylindrical primary coil, and a tubular and cylindrical secondary coil. The primary and secondary coils are each wound on their individual bobbins and the bobbins are mounted in the housing such that the primary coil is coaxially positioned inside the secondary coil. The ignition coil assembly further includes a magnetic core having a first portion which extends through the interior of both the primary and secondary coil and a second portion which extends exteriorly of the primary and secondary coils. The first portion of the coil is substantially circular in cross sectional shape thus matching the circular interior of the primary bobbin. In order to construct the primary coil and secondary coil subassembly, the primary bobbin is first positioned on a winding machine and the primary wire is wound on the bobbin.

Abstract: A clutch hydraulic actuator system having a vibration damper provided in the system between a master cylinder and a slave cylinder of the system. The damper includes an elastomeric diaphragm and a spring steel diaphragm. One face of the elastomeric diaphragm is in fluid communication with hydraulic fluid in the system so that the elastomeric diaphragm may deflect in response to low frequency vibrations transmitted through hydraulic fluid in the system to effect damping of the low frequency vibrations. The spring steel diaphragm is positioned in the system generally parallel to and proximate the other face of the elastomeric diaphragm so as to form a backup for the elastomeric diaphragm so that the elastomeric diaphragm may deform against the spring steel diaphragm in response to high frequency vibrations transmitted through the hydraulic fluid to cause deflection of the spring steel diaphragm to effect damping of the high frequency vibrations.

Abstract: A concentric slave cylinder for motor vehicle manual transmissions in which the cylinder housing is fabricated from an inner cylindrical member having a base flange and an outer cylindrical member having a base flange wherein the annular fluid chamber between the outer wall of the inner cylinder and the inner wall of the outer cylinder has a radial dimension of not more than about 4 millimeters.

Abstract: A master cylinder assembly for controlling a motor vehicle clutch including switches for controlling functions such as enabling the starter motor, disabling the cruise control, or signaling the engine computer. The assembly includes an annular seal disposed in an internal groove in the wall of the cylinder sealingly engaging the piston of the cylinder and dividing the cylinder into a pressurized chamber on one side of the seal and an unpressurized chamber open to atmosphere on the other side of the seal.

Abstract: A hydraulic control apparatus having a master cylinder, a slave cylinder, and a conduit connecting the master cylinder to the slave cylinder is constituted as separate modular units interconnected by a quick connect coupling including a female coupler member and a male coupler member. In addition to providing part of the quick connect coupling between the modular units the female coupler member is provided with a bleed system to facilitate removal and addition of hydraulic fluid to the system as required in relation to initial manufacturer and installation and in relation to field maintenance.

Abstract: A seal assembly especially suitable for use as the sealing element in the annular cylindrical bore of a concentric cylinder assembly. The seal assembly includes an annular insert structure of rigid material and an annular seal member of elastomeric material bonded to the insert structure. The annular insert structure has an I-beam cross-sectional configuration including an outer annular flange structure centered on an axis, an inner annular flange structure centered on the axis concentrically within the outer annular flange structure, and annular web structure extending radially between the inner and outer annular flange structures. The web structure coacts with the flange structures to define left and right continuous annular grooves in the left and right faces of the insert structure and defines a plurality of circumferentially spaced holes extending axially through the web structure between the left and right grooves.

Abstract: A damper for use with a hydraulic actuator of the type including a master cylinder and a slave cylinder with a conduit interconnecting the outlet of the master cylinder and the inlet of the slave cylinder. The damper is positioned in the conduit between the master cylinder and the slave cylinder and includes a housing member defining a chamber opening in one face of the housing member and a mounting bracket plate. The mounting bracket plate includes a housing portion corresponding in size and configuration to the one face of the housing member and is positioned against the one face of the housing member to coact with the housing member to seal the chamber. The bracket plate further includes a bracket portion extending outwardly from the housing portion in the form of mounting arms which are utilized to facilitate mounting of the damper to a fixed vehicle structure.

Abstract: A quick connect coupling for use in a hydraulic clutch control system including a hydraulic master cylinder and a hydraulic slave cylinder. One of the coupler members of the quick connect coupling includes a central axial passage defining an inlet at one end of the passage and including a diaphragm positioned at the other end of the passage at right angles to the passage in fluid communication with fluid flowing through the passage. The passage further includes a radial passage portion communicating with the central passage and extending to a fluid port for the coupler member. Hydraulic fluid flowing through the coupler member communicates with an inboard face of the diaphragm so that the diaphragm functions to attenuate pulsations in the hydraulic fluid and preclude transmission of the pulsations rearwardly in the system to the clutch pedal.

Abstract: A pushrod assembly for use in association with a vehicle clutch control system of the type including a slave cylinder having an output member adapted for control of the clutch mechanism of the vehicle, a master cylinder for supplying hydraulic fluid to the slave cylinder, and a clutch control pedal assembly for actuating the master cylinder via the pushrod assembly. The pushrod assembly is connected at a forward end thereof to the master cylinder piston and is adapted for connection at a rearward end thereof to the clutch pedal arm and includes an isolator member of resilient material carried by the pushrod and interposed between the rearward pushrod end and the clutch pedal in a position to be resiliently distorted in response to movement of the control pedal in a release direction relative to the pushrod.

Abstract: A slave cylinder particularly suited for use in a hydraulic clutch release system for a motor vehicle. The cylinder includes a spring boot which serves as both a dust boot and a preload spring device. In one embodiment of the invention, the cylinder is an external slave cylinder and the spring boot extends from a rear end of the cylinder body to a rear end of the pushrod and acts to apply a preload force through the pushrod and through the release lever to the release bearing while simultaneously precluding the entry of dust and other contaminants into the interface between the piston and the cylinder bore.