Abstract: A themial insulation method for an internal surface of an injection molding casting die includes forming a thermal insulation blanket on the internal surface using laser cladding. One or more layers of a metal material having suitable thermal emittance and melting point characteristics is applied to the internal surface using laser cladding. Because the impact area of the injected molten metal is subject to greater stress and temperature gradients than the remainder of the surface, laser cladding can be used to apply the thermal insulation blanket only to areas that require additional protection.

Abstract: A method for detecting speed faults in a hybrid powertrain having engine and electric machine speed inputs includes directly sensing the engine and machine speeds and performing comparisons of sensed engine speed with engine speed determined based upon the machine speeds.

Abstract: A center console for a instrument panel includes a housing having a display region and an actuation mechanism associated with the housing. The actuation mechanism permits movement of the housing relative to the instrument panel.

Abstract: A tray has a bottom panel for supporting a battery. An inner panel projects upwardly from the bottom panel to provide an inner locator for the battery. A retainer holds the battery down on the bottom panel. A lock member for the retainer is moveable from an unlocking position to a locking position, and when moved to the locking position forces the retainer inwardly. The retainer has an abutment engageable with the battery to move the battery inwardly against the upright panel when the retainer is moved inwardly. Two fulcrum points in the retainer cause a vertical force to hold the battery in place by a lever effect of the lock member and fulcrum points.

Abstract: A method for testing electric motor shut-off including injecting current into an electric motor, applying at least one of a short or an open to the electric motor for a predetermined length of time, calculating the rate of decay of the current and comparing rate of the decay with a predetermined decay criteria. In one implementation, a predefined sequence of opening and short circuiting the electric motor is used, and the shut-off path tests for the motor three phases can be verified with one test.

Abstract: A front bumper system for a motor vehicle including a body and a front end module includes a beam coupled to the body and an energy absorbing cover coupled to the beam. The front bumper system also includes a grille coupled to the cover and covering at least a portion of the front end module. The grille can define a plurality of openings sized to at least partially restrict objects from contacting the front end module.

Abstract: An electrical switch assembly is provided for an electronically controlled transmission that allows user selection between a plurality of shift schedules for the transmission. The switch assembly provides a signal for selecting among the plurality of shift schedules and has a housing. A first set of electrical contacts are positioned within the housing, and selectively closable to cause the input signal to be indicative of a selection of a first shift schedule. A second set of electrical contacts are positioned within the housing and are selectively closable to cause input signal to be indicative of a selection of a second shift schedule.

Abstract: A coupler for connection of a power source to a vehicle electrical system. The coupler includes a housing arranged to be grasped by an operator, and an actuator arranged to be accessible when the housing is grasped. A plurality of electrically-conductive clasps are arranged on the housing and employ a mechanism to bias the clasps in a closed position for attachment to the vehicle electrical system. A linkage connecting the actuator to the claps is further provided to simultaneously open the clasps when the actuator is activated.

Abstract: A testing apparatus that is used for measuring a vehicle's parasitic loss and overall, loaded efficiency utilizes an external electric drive motor, as an input, connected to the engine crankshaft of the vehicle and dynamometers connected to each driving wheel hub, to measure output at the wheels. Although its wheels with tires are removed, the vehicle remains largely intact and rests upon vehicle supports, which are mounted to a track system under the vehicle. The track system permits the drive motor and dynamometers to adjust and accommodate any vehicle for efficiency analysis. A computer monitors the driving motor input and output at the dynamometers to calculate efficiency.

Abstract: A variable lift deactivateable valvetrain system for an engine is provided. The system includes a camshaft, a rocker shaft, a valve and at least one rocker arm rotateably connected to the rocker shaft and arranged to engage the camshaft. A connecting rocker arm is rotateably connected to the rocker shaft and is in constant engagement with the valve. The connecting rocker arm is arranged to operate in selective engagement with the at least one rocker arm to provide a variable lift deactivateable valvetrain configuration. The system further includes a low lift rocker arm having a low lift pin assembly and a high lift rocker arm having a high lift pin assembly. The low and high lift pin assemblies are arranged to selectively engage the connecting rocker arm responsive to oil pressure selectively directed to the low and high lift pin assemblies.

Abstract: A hybrid powertrain system includes an internal combustion engine operatively connected to a second torque machine to transmit torque to an output member. A method for operating the hybrid powertrain system includes monitoring an operator torque request, determining an output torque command based upon the operator torque request, commanding a transition between an engine-off state and an engine-on state, monitoring an engine crank angle, spinning the engine unfueled, estimating cylinder pressure based upon the engine crank angle during the spinning of the engine, predicting a cylinder pulse torque based upon the cylinder pressure, determining a cancellation torque for the second torque machine based upon the predicted cylinder pulse torque, and controlling motor torque output from the second torque machine based upon the cancellation torque and the output torque command.

Abstract: A hybrid transmission includes a torque machine and an energy storage device connected thereto. The hybrid transmission is operative to transfer power between an input member and an output member and the torque machines in a fixed gear operating range state.

Abstract: Operation of an electro-mechanical transmission includes determining motor torque constraints and battery power constraints. An additional constraint on the electro-mechanical transmission is determined. A preferred output torque is determined that is achievable within the motor torque constraints and based upon the additional constraint and the battery power constraints.

Abstract: A method to control an electro-mechanical transmission mechanically-operatively coupled to an internal combustion engine and first and second electric machines to transmit power to an output member includes determining motor torque constraints and battery power constraints. A preferred output torque to an output member is determined that is achievable within the motor torque constraints and is achievable within a range for a first torque input and is achievable within a range for a second torque input and is based upon the battery power constraints.

Abstract: A method to control a powertrain including a transmission, an engine, and an electric machine includes monitoring a desired transmission shift including an oncoming clutch, monitoring operational parameters of the powertrain, monitoring a maximum electric machine torque capacity, determining a desired output torque profile through the desired transmission shift, determining a maximum electric machine torque capability profile through the desired transmission shift based upon the maximum electric machine torque capacity and the operational parameters, comparing the desired output torque profile to the maximum electric machine torque capability profile, determining a preferred oncoming clutch torque profile through the desired transmission shift based upon the comparing, and executing a clutch assisted shift based upon the preferred oncoming clutch torque profile.

Abstract: A powertrain system includes an engine coupled to a transmission operative in one of a plurality of operating range states to transfer power between the engine and an output member. A method for controlling the powertrain system includes monitoring an operator torque request, monitoring barometric pressure and engine input speed to the transmission, determining an achievable range of input power transferable from the engine to the transmission based upon the barometric pressure and the engine input speed, and determining a preferred operating range state for the transmission and a preferred engine operating point at the preferred operating range state based upon the operator torque request and the achievable range of input power.

Abstract: A method for controlling a powertrain system includes determining a current transmission operating range state and engine state, determining at least one potential transmission operating range state and engine state, providing at least one operator torque request, determining preferability factors associated with the current transmission operating range state and engine state, and potential transmission operating range states and engine states, wherein determining preferability factors associated with potential transmission operating range states includes assigning biasing costs to operator torque requests which reside within a pre-determined range of possible operator torque requests for at least two of the potential transmission operating range states, preferentially weighting the preferability factors for the current transmission operating range state and engine state, and selectively commanding changing the transmission operating range state and engine state based upon stheaid preferability factors and th