Abstract: A method of accommodating wear in an electrically operated brake assembly includes setting a home position when a brake shoe engages a brake drum. A stepper motor drives the brake shoes into engagement with the drum. Upon engagement of the brake shoes with the drum, the stepper motor slips. Slipping of a stepper motor indicates that a home position has been reached. Upon release of the brake, the brake shoe is moved away from the drum a fixed distance. The fixed distance is an optimal distance between the friction member and the rotating member such that regardless of wear, the distance relationship between the brake shoe and drum is maintained.

Abstract: A force sensor is incorporated into a disc brake, and is operable to sense the point of force application increase during application of the disc brake. The force will increase sharply once the brake pad initially contacts the rotor. The sensor is able to determine the point of this force increase, and provide this information to a control. The control powers an electric motor for providing electric motor adjustment of the position of the piston which drives the brake pad, to compensate for wear. In a preferred embodiment, the sensor includes a protective cover with a thin anvil between the cover and the sensor. The anvil is operable to transmit the force, and limit the force applied, to protect the sensor.

Abstract: A parking brake system pneumatically actuates an air cylinder to mechanically lock a wheel brake in an applied position in response to a parking demand request. The parking brake system includes a dual hand control that has an electronic control element and a pneumatic control element. The electronic control element communicates with an electronic braking system control unit and the pneumatic control element communicates with a parking brake air reservoir. When the dual hand control is moved to a park position, the electronic control element generates an electronic control signal that applies a parking brake force to the wheel brake. The pneumatic control element generates an air signal that is sent to the air cylinder. The air cylinder includes an extendable shaft that supports a lock member. The air signal moves the lock member into engagement with a brake operating member to lock the wheel brake in the applied condition.

Abstract: A vehicle parking brake system pneumatically actuates an air cylinder to mechanically lock a wheel brake in an applied position in response to a parking demand request. The air cylinder includes an extendable shaft that supports a lock member. When a parking demand request is initiated by moving a hand control, an air chamber is pressurized with air from a parking reservoir via a valve assembly to apply the wheel brake. Air pressure is released from the air cylinder and the lock member is moved into engagement with a brake component to lock the wheel brake in the applied condition. The wheel brake remains locked even if pressure is released from the air chamber. When a release command is initiated, the air cylinder is pressurized and the lock member is moved out of engagement with the brake component.

Abstract: A vehicle suspension is provided that includes a frame supporting a pair of laterally spaced apart suspension members pivotally supported on the frame and movable in a vertical direction. Each of a pair of wheel ends is supported respectively on one of the suspension members. A stabilizer bar is supported on the frame laterally between the suspension members. The stabilizer bar includes opposing ends each respectively proximate one of the suspension members. Each of a pair of resilient stabilizer bar links respectively interconnects one of the ends and one of the suspension members and transmits torsional force to the stabilizer bar in response to movement of the suspension members in the vertical direction during roll conditions. The links have first and second deflection rates during the roll condition with the first rate being less than the second deflection rate.

Abstract: A displacement sensor utilizes a Hall effect sensor and a magnet, but has an extended range compared to conventional Hall effect displacement sensors. Relative movement between the sensor and the magnet is defined such that the path of movement is not parallel to an axis between the north and south poles of the magnet. Thus, the total path of movement is greater than in the prior art. One particularly preferred application for this sensor is in a disc brake, and as part of an adjustment mechanism for adjusting the position of the disc brake pistons. The displacement sensor is relatively small, and thus can be accommodated in the crowded environment of the disc brake adjustment mechanism. On the other hand, with the inventive large range displacement sensor, the simple and compact sensor can provide adequate measurement of the displacement of the piston.

Abstract: A vehicle suspension is provided that includes a frame supporting a pair of laterally spaced apart suspension members pivotally supported on the frame and movable in a vertical direction. A pair of wheel ends is each supported respectively on one of the suspension members. A stabilizer bar is supported on the frame laterally between the suspension members. The stabilizer bar includes opposing ends each respectively proximate to one of the suspension members. A pair of resilient stabilizer bar links each respectively interconnect one of the ends and one of the suspension members and transmit torsional force to the stabilizer bar in response to movement of the suspension members in the vertical direction during roll conditions. The links have first and second deflection rates during the roll condition with the first rate being less than the second deflection rate.

Abstract: A simple parking brake includes an electric motor having an internally threaded nut. The internally threaded nut receives an externally threaded shaft. The shaft is pinned to a lever, such that it cannot rotate. The shaft thus moves linearly when the electric motor drives the nut to rotate. As the shaft moves, it drives the brake actuator between a parking position and a release position. A control supplies a pulse to drive the motor in the appropriate direction and for the particular appropriate distance. The pulse length is preferably selected to be longer than that necessary to move the shaft the necessary distance. The motor is preferably sized to stall once the desired park or open position is achieved. In this manner, a simple control is able to control the motor.

Abstract: A variable rate bushing passively controls the stiffness of a stabilizer bar. During normal vehicle operation, the stabilizer bar is compliant. As twist increase, the resistance increases. In one embodiment, the variable rate bushing includes at least one void which compresses as the vehicle turns. As the stabilizer bar axially twists, the void compresses and the rate of the bushing increases, reducing axial twist and increasing stiffness of the stabilizer bar. In one embodiment, the voids are teardrop shaped, arc shaped, or bone shaped. Alternatively, the bushing includes an inner layer of softer material and an outer layer of harder material to control stabilizer bar stiffness. Also, the bushing may include a molded insert made of a hard material inserted into a softer material to control the stiffness of the stabilizer bar.

Abstract: An adaptive suspension system for a motor vehicle varies suspension parameters in response to steering input. The system includes a sensor to measure changes in the power assist steering mechanism that indicate a change in vehicle direction and a shock variable suspension member changed in response to a change in vehicle direction. The sensor measures pressure changes in the power assist steering system such that the suspension system is optimized to accommodate specific vehicle maneuvering. In another embodiment, the variable suspension member is in hydraulic communication with the hydraulic circuit of the power assist steering mechanism such that pressure changes caused by steering input triggers changes in the suspension system to accommodate vehicle maneuvering.

Abstract: A reformer controller is electrically coupled to both a fuel reformer and an engine control unit. The reformer controller is configured to communicate with the engine control unit to monitor an engine load signal between the engine control unit and an internal combustion engine. The reformer controller operates the fuel reformer in response to the engine load signal. A method of operating a fuel reformer is also disclosed.

Abstract: A drive unit assembly for a vehicle wheel includes a rigidly mounted electric motor coupled to the vehicle wheel via a gear drive. The gear drive includes a cycloid or epicycloid gear arrangement that provides significant speed reduction at the wheel.

Abstract: A brake assembly has a caliper with a first brake pad and a second brake pad. The first brake pad is moveable relative to the caliper. A brake actuator moves the first brake pad and has a first threaded member and a second threaded member. The first threaded member has first thread characteristics for moving the brake actuator at a first speed and a first force. The second threaded member has a second thread characteristics for moving the brake actuator at a second speed and a second force. The first speed is greater than the second speed while the first force is lower than the second force.

Abstract: A brake system includes a rotor and a brake pad. An actuator is connected to the brake pad. The actuator includes an energy receptive material that expands when excited to move the brake pad into contact with a braking surface on the rotor. A drive unit moves the energy receptive material between a first position and a second position, where the second position is closer to the rotor than the first position. An energy source energizes the energy receptive material to expand, moving the brake pad into contact with the braking surface. A control unit controls the drive unit and the energy source.

Abstract: A brake actuator assembly includes a sensor mounted to a push rod which is in communication with a transceiver antenna. The sensor provides positional information of the push rod relative to the antenna. A clearance between a friction element and a rotating brake member is determined based on displacement of the push rod and known mechanical relationships within the brake actuator.

Abstract: A system for controlling multiple vehicle includes a twelve volt (12V)/forty-two volt (42V) battery power distribution system that provides direct current. The system converts single phase alternating current to multiple phase alternating current to simultaneously power multiple vehicle systems. A single pulse width modulation generator converts the direct current from the 12V/42V battery power distribution system to alternating current. This provides one power supply path of alternating current, which has a first phase. A splitter device splits the one power supply path of alternating current into three power paths. A lead/lag circuit is used to shift the alternating current of the second path to a second phase different than the first phase of the first power supply path. A second lead/lag circuit for shifts the alternating current of the third path to a third phase different than the first phase or the second phase. This creates a three-phase alternating current power from a single direct current source.

Abstract: A vehicle drive assembly includes an electric motor directly coupled to a rotatable member for driving a wheel, for example, without gear reduction assemblies between the motor output and the driven wheels. A multi-phase, high pulse current stepper motor is used as the motor in one example. A driven wheel is supported by a wheel mounting member in a conventional fashion. A rotatable member associated with the wheel mounting member is directly coupled to an output of the stepper motor. The stepper motor can selectively operate in several modes. A first mode provides driving torque to the vehicle wheels, a second mode provides a braking force and an optional third mode allows the stepper motor to serve as a parking brake.

Abstract: A clutch device for use with a vehicle suspension system to vary the stiffness of a stabilizer bar. A plurality of dampers connected to the clutch body alternate with a plurality of dampers connected to the stabilizer bar. The dampers are coated with a friction material and surrounded by a fluid. When a load is applied on the walls of clutch body, the friction material comes into contact, dampening the rotation action of the stabilizer bar. A sensor senses the parameters of the ride and generates a signal based on these parameters. The signal activates a power source controller which applies the load to the walls.

Abstract: A vehicle drive assembly includes an electric motor directly coupled to a rotatable member for driving a wheel, for example, without gear reduction assemblies between the motor output and the driven wheels. A multi-phase, high pulse current stepper motor is used as the motor in one example. A driven wheel is supported by a wheel mounting member in a conventional fashion. A rotatable member associated with the wheel mounting member is directly coupled to an output of the stepper motor. The stepper motor can selectively operate in several modes. A first mode provides driving torque to the vehicle wheels, a second mode provides a braking force and an optional third mode allows the stepper motor to serve as a parking brake.

Abstract: An electric motor assembly is provided that includes a housing. A rotor is arranged in the housing and is rotatable about an axis. A vehicle wheel is coupled to the rotor. The rotor has an annular profile defining sinusoidal teeth and is generally concentric with the axis. The angle and number of oblique surfaces of the teeth and the diameter of the rotor, in part, define the speed and torque of the rotor. A plurality of electric linear actuators are arranged circumferentially about and generally parallel to the axis. The actuator includes shafts having ends that engage the profile. The shafts are movable between extended and retracted positions to rotate the rotor in a desired direction. A sensor detecting the position of the rotor and a controller may be used to effect the desired rotation.