Abstract: A power booster includes a housing with a rear housing section and a front housing section defining an internal cavity. A housing wall separates the internal cavity into a first chamber and a second chamber with an opening formed in the housing wall, wherein it is desirable to extend a component through the opening. A tube has an end secured in the opening in the housing wall. The tube's end includes a radially directed wall extending from the end of the tube that extends to an axially extending wall positioned concentrically with the tube and terminating with an outwardly turned segment. The axially extending wall is positioned within the opening in the housing wall with a seal positioned between the axially extending wall and the housing wall wherein the distance between the front housing section and the rear housing section is minimized, by extending the component through the tube.

Abstract: A ventilated brake rotor includes two spaced apart annular disks each having an inner diameter and an outer diameter with a locus radius defined radially between the inner diameter and the outer diameter. A series of alternating longer and shorter vanes is distributed around the rotor between the annular disks defining a series of flow passages between each adjacent pair of vanes. Each vane is defined about a curved line with a curvature that is measured from the locus radius, wherein the curved line's curvature is defined by the incoming air flow angle at the flow passage, and wherein the vane profile varies along the curved line so that a non-uniformly curved profile results that maximizes the flow rate through the flow passage. The vane angle and the vane profile result in minimized incidence, viscous and profile flow losses.

Abstract: A clutch includes an input element with an engaged input shaft and clutch plate rotatable in concert. The clutch plate has an annular portion with a clutch plate set of lands and grooves mating with a housing set of lands and grooves to define a shear zone space. A cover is included as part of the housing and engages the body and includes a reservoir. A pump plate is captured between the cover and the body separating out a working chamber generally within the body and includes a pump port. The pump port includes an outer extreme edge that is substantially in line with the outer surface of the clutch plate. A valve port in the pump plate is positioned near the radial outside of the reservoir. A control arm normally closes the valve port and is movable to open the valve port.

Abstract: In a vehicle braking system, integral control and isolation valves are used to individually control the brake line pressure to each wheel brake and to provide pedal isolation for each brake channel. The system is operable on a single fluid or a separated fluid system with an integrated power source. Full proportional anti-lock braking and traction control is provided to each selected wheel independently. The system is applicable as a two, three or four channel base brake system.

Abstract: Reformation of a round tube to a tube with a selected polygonal segment is achieved by supporting the round tube on a mandrel having rounded corners that mate with the tube's inside diameter. The mandrel is otherwise provided in the resultant polygonal shape. The supported tube is subjected to the compressive force of a die having upper and lower die sections that define an elongated polygonal cavity. The planar sides of the cavity are offset relative to the parting line. Preferably, the corners of the cavity adjacent the parting line are wrapped by a leg of the die section. Upon closure of the die sections, the tube material is allocated to a particular quadrant by contact with the die section and the tube is reformed. Excess material that may result from tolerance permitted variations is delivered to the corners of the polygonal tube section maintaining uniform wall thickness across the flat sides of the reformed tube.

Abstract: A passive magnetorheological clutch includes an input member that is constantly driven at engine speed, or some selected proportion thereof. An output member is journaled on the input member so as to be supported thereon in a nonrotating state and to be concentrically rotatable in concert therewith. A space presented between the input and output members contains a quantity of magnetorheological fluid. The space also contains an engagement mechanism including a permanent magnet and a ferromagnetic ring concentrically positioned with an operative gap therebetween, wherein the operative gap's dimension is variable to effect changes in the magnetic field passing between the magnet and the ring. When an actuator effects a reduction in the distance between the magnet and ring, the amount of magnetic field increases in density adjacent the ring. The resultant torque transfer from the input member to the output member is effected across the operative gap and through the magnetorheological fluid.

Abstract: A magnetorheological fluid fan clutch effects modulated rotational motion transmission between a rotatable input shaft carrying an input clutch plate and a housing having a front cover and a rear cover forming a cavity about the input clutch plate wherein a core carried in the front and rear covers operates as output clutch plates. Bearings support the housing on the input shaft through the front and rear covers so that the input clutch plate is rotatable on the input shaft relative to the housing. Magnetorheological fluid is carried in the cavity, through which torque is variably transferred between the input clutch plate and the housing. A coil is positioned radially outside the non-magnetic spacer and carries a variable electrical current to effect a variable magnetic field across the input clutch plate and through the magnetorheological fluid providing modulated torque transmission between the input clutch plate and the core.

Abstract: A solenoid actuated valve includes a first subassembly that carries a coil having its terminal pins attached to a structure such as a circuit board or lead frame. A second subassembly is provided for mating with the first subassembly and carries the valve body. The first subassembly has a solenoid spool including the coil, and a case surrounding the spool. An end plate is suitably locked to the case. A bias spring is provided between the spool and the end of the case. The spool assembly is designed to be freely floating both radially and axially within the coil case and end plate, as restricted by the bias spring. This permits proper location of the coil case to the hydraulic valve body assembly.

Abstract: A clutch includes an input shaft with a clutch plate engaged with the input shaft to rotate in concert therewith. The clutch plate has an annular disk portion with a clutch plate set of lands and grooves. A housing includes a body supported on the input shaft by a bearing with a body set of lands and grooves mating with the clutch plate set of lands and grooves. A cover is included as part of the housing and engages with the body. A pump plate is captured between the cover and the body separating out a working chamber. The pump plate includes an engage port and a pump-out port positioned further radially outward in the pump plate than the engage port. A control arm normally closes the engage port and is rotatable to open the engage port. A slide-block is carried in a pocket of the cover with a spring biasing the slide-block toward engagement with the control arm. The slide-block locks the control arm against rotation when the clutch is inactive.

Abstract: A vehicle braking system that primarily operates as a pure brake-by-wire system, with optional hydraulic actuation. The system includes a set of four electrically actuated drum brakes. At least two of the wheel brakes include hydraulic actuators that operate to apply the wheel brakes independent of electric control. Each of the wheel brakes is normally operated in response to a control signal generated by the vehicle's brake processor. As such, a primary brake-by-wire system is provided at all four vehicle wheels. The rear brakes are proportioned to the front brakes electrically, according to design criteria.

Abstract: A magnetorheological clutch for controllable torque transmission includes a housing defining a cavity with a rotary input element carrying at least one input clutch plate extending radially in the cavity. A rotary output element carrying at least one output clutch plate extends radially into the cavity adjacent the input clutch plate with a gap defined between the input clutch plate and the output clutch plate. A core formed of magnetically permeable material has a pair of side plates extending radially across the housing. A coil effective to establish an electromagnetic field is carried against the core. Magnetorheological fluid is carried in the cavity within the gap and is responsive to the electromagnetic field that is established by the coil through the core so that torque is transferred from the input clutch plate to the output clutch plate through the magnetorheological fluid.

Abstract: A suspension system damper includes a hydraulic rebound cut-off feature without unduly limiting active travel. A spring separates a rebound cut-off piston from the rod guide. The rebound cut-off piston has an oversized center hole. The outer periphery of the rebound cut-off piston is sized for a close slip-fit within the tube with a number of small slots acting as restrictive and tunable flow control features when the system enters a cut-off mode. When the top of the damping piston assembly comes into contact with the rebound cut-off piston, the cut-off mode is entered. Hydraulic flow is cut-off by blocking fluid flow through the center hole. This generates hydraulic loads on the piston rod by virtue of the high pressure generated between the rebound cut-off piston and the rod guide. Fluid is restricted to exiting the rebound cut-off region via the small slots in the outer periphery of the damping piston assembly.

Abstract: An axle sprung motor assembly for driving a locomotive includes a motor selectively driving a rotatable drive gear. A wheelset assembly includes a pair of flanged wheels mounted on an axle with an axle bearing housing rotatably supported on the axle. A set of resilient bushings is carried between the axle bearing housing and the motor housing. The motor assembly is resiliently secured to the wheelset through the interposed resilient bushings. A resilient gear has a hub fixed to the axle and includes a ring gear that engages the drive gear and is mounted to the hub through a set of flex bushings and a set of snubber bushings. Loads transferred from the motor to the wheelset are reduced by relative rotation between the ring gear and the hub that compresses elastomeric material of the flex bushings, with movement limited by the snubber bushings.

Abstract: A slidable brake caliper system includes a retaining pin that is slip fit within a bore of a mounting bracket to slidably retain a caliper relative to the mounting bracket. A resilient cylindrical retaining support in combination with a resilient bushing and boot assembly support the retaining pin slidably within a bore of the mounting bracket. The caliper is clamped onto the retaining pin by a fastener assembly in a manner such that it is slidably retained relative to the mounting bracket to provide a clamping load to a pair of brake pad assemblies that are carried by the mounting bracket and are capable of applying a selective frictional force a rotating element. The caliper suspension system which includes the retaining pin provides a means for pivotably opening the caliper relative to the mounting bracket to replace the pads without complete removal of the retaining pins.

Abstract: An efficient, cost effective eccentric bearing assembly is provided for use in a multiple piston hydraulic pump. The eccentric bearing assembly includes a roller bearing having an annular race. The race includes a groove around its outside perimeter. The groove engagably receives parti-spherical faces of a pair of opposed pistons. The parti-spherical face evenly loads the race and rollers as the race reciprocates with the eccentric. The invention avoids the use of rotating thrust bearings and instead axially supports the piston clip with stationary surfaces. Placement of the parti-spherical face or an optional conical face, at the interface between the pistons and the grooved race maintains the sliding contact point for piston intake strokes near the center of the face.

Abstract: An electromagnetic brake system includes a motor having a rotor with a rotatable disk fixed to the rotor and an electromagnetic brake disposed about the disk to selectively prevent rotation of the rotor. The electromagnetic brake is carried on a resilient element so that it is suspended relative to the disk and isolated from the remainder of the system reducing the propagation of structural and airborne noise generated by actuation of the electromagnetic brake.

Abstract: A control arm adjustment mechanism includes a frame bracket connected to a vehicle frame with a bolt extending through the frame bracket. A cam is keyed to the bolt and has a spiraling eccentric slot with the guide tab extending through the eccentric slot so that rotation of the bolt causes the guide tab to track within the eccentric slot causing a displacement of the bolt and a connected control arm end. A nut is threaded onto the bolt so that when the nut is torqued, the bolt is prevented from sliding. To adjust control arm positioning relative to the frame, the nut is loosened without being completely removed, the bolt is rotated to align a selected indicator mark with the first guide tab and the nut is retorqued.

Abstract: A roll control system with a latchable stabilizer bar actuator includes an anti-roll bar that is mounted to a vehicle's body and includes a pair of ends with one end rigidly connected to the vehicle's chassis and the second end connected to the vehicle's chassis through a hydraulic actuator. The hydraulic actuator includes a single cylindrical tube slidably carrying a piston. The piston separates the tube into first and second chambers. The piston carries a solenoid operated valve that effects latching and de-latching of the actuator for selectively effecting operation of the anti-roll bar.

Abstract: A braking system including a wheel brake with a dual piston caliper assembly provides a brake by wire add-on system with dual level manual override capabilities. A pressure control block associated with the wheel brake directs fluid pressure generated by the master cylinder to the first and the second pistons of the caliper assembly for operation of the braking system in a manual apply mode. An electro-hydraulic modulator generates operating pressure in the brake by wire mode. The electro-hydraulic modulator communicates with the pressure control block so that fluid pressure generated by the electro-hydraulic modulator is transmitted to a single piston of the caliper assembly and is prevented from being communicated to the first piston of the caliper assembly by a solenoid valve assembly positioned in the pressure control block.

Abstract: An energy absorbing device includes an energy absorber element having a plurality of elongated hollow hexagonal cells. The cells are arranged in a block shape with first and second layers interconnected by an intermediate plate. The intermediate plate closes adjacent ends of the first and second layers and forms three-sided pyramidal structures which project into each individual cell of the first and second layers. Each pyramidal structure has an apex located near the center of each cell. The energy absorber element is deformable under impact loading conditions to absorb and dissipate energy. Upon the removal of the impact load the energy absorber element returns to its original shape.