Abstract: A method of tuning a vehicle includes measuring a plurality of inlet and outlet frequency responses at the inlet and outlet ports, respectively. The inlet and outlet responses each include an amplitude response and phase response. The method also includes determining inlet and outlet transfer functions that include amplitude and phase responses. An interior noise spectrum is determined and the engine air in/out system is modified based on the interior noise spectrum to result in a different interior noise spectrum.

Abstract: A method for initializing an actuator valve (12) and controlling the valve (12) using current command control (100) or voltage control including an estimate of back emf (200). A series of low voltage pulses (304) is applied to one of the solenoid coils (20, 24) in the actuator valve (12) according to the natural frequency of the armature (16) movement in the actuator valve (12). The current command control system calculates a desired force (Fem) and divides the force into closing and opening components Fem—c, Fem—o, for calculating a desired current command Ic_cmd, Io_cmd, for each of the solenoid coils. The back emf control system divides the current signal into close and open components, Io, Ic, that are individually processed and combined with a back emf estimate for each of the open and close solenoids, ec, eo. The result is a desired voltage command, vc*, vo*, for each of the solenoids that is communicated to the power stage (34) in order to operate the armature (16) as desired.

Abstract: An electrical machine comprising a rotor (26) mounted on a shaft (29) for rotation therewith and defining an axis of rotation, and a stator (54) disposed coaxially with and in opposition to the rotor (26). The electrical machine further comprises a housing (22, 24) enclosing the stator (54) and the rotor (26), the housing (22, 24) having a first axial end with a wall with an inner surface and an outer surface and a second axial end with a wall with an inner surface and an outer surface. The electrical machine also includes a first cooling tube (80′) having a first end and a second end and an embedded portion thereof embedded between the first inner surface and the first outer surface. The first end and the second end of the first cooling tube have a port therebetween directly fluidically coupling the first end to the second end.

Abstract: A variable displacement pump 28 having an electronically modulated solenoid relief valve 100 for controlling fluid flow into the pump 28. An engine control module coupled to the electronic relief valve 100 monitors vehicle speed and steering wheel turning rate change directs the solenoid relief valve 100 to adjust the pressure of fluid displacing a movable cam ring 44 within the pump 28 to provide for greater fluid flow when evasive maneuvers may be required and lesser fluid flow when low steering efforts are needed, thus resulting in energy and fuel savings.

Abstract: A method for controlling a throttle of an electronic throttle control-equipped engine. The method includes the steps of providing a desired throttle position derived from the driver demand and vehicle system requests. The method generates first and second throttle positions by interpolating the desired throttle position within the resolution of the throttle position controller. A duty cycle is also generated as a function of the desired throttle position and system resolution. The resulting conditioned throttle position command having the first throttle position for a first time period and the second throttle position for a second time period is communicated to the throttle controller. The ratio of the time periods corresponds to the duty cycle such that the average throttle position command is approximately equal to the desired throttle position. In this way, the control method can achieve a desired throttle position of higher resolution than the throttle position sensing system.

Abstract: A circuit 17 for interfacing with a sensor 18 having a sensor input current and a modulated sensor current signal corresponding to a sensed condition. A control module 20 is coupled to the sensor 18 and receives the sensor current signal. The control module 20 converts the sensor current signal to a modulated signal having a pulse width with a duration corresponding to the sensed condition. The control module 20 counts a time corresponding to the pulse width. The time corresponds to the sensed condition.

Abstract: An electronic throttle control mechanism having a housing and cover member with a throttle valve, gear mechanism, motor, and failsafe mechanism. The housing, cover member and other components are made of a plastic composite material. A spring member positioned between the housing and sector gear member which is attached to the throttle valve shaft, biases the throttle valve plate member toward the closed position. A spring-biased plunger member biases the throttle plate member from its closed position to a default or “limp-home” position. A metal reinforcing plate is molded into the cover member in order to keep the gears in alignment and maintain proper gear positioning during high temperature fluctuations.

Abstract: A system for disabling display illumination includes an electronic device, such as a radio, navigation system or entertainment device having a graphical display that may be covered with a door for enhancing vehicle interior appearance. To allow the graphical display to be read during night time driving conditions, the graphical display includes some form of graphical back lighting. A transceiver is coupled to the electronic device and generates an infrared signal for inter-module communication. When the door is closed, this infrared signal is reflected back to the electronic device indicating that the door is closed. Using this reflected signal, the graphical back lighting may be disabled to eliminate light leaks and reduce heat buildup.

Abstract: A method and system for distributing electrical energy from an integrated starter-alternator during a deceleration or overrun vehicle condition to an electrically heated catalyst in order to maintain the temperature of the electrically heated catalyst within an operating temperature range during the deceleration or overrun vehicle condition.

Abstract: An electronic throttle control system including a throttle valve for adjusting the amount of air drawn into the engine is disclosed. A throttle valve is controlled by a throttle position feedback controller which suspends an integration element when position error absolute value is greater than a threshold, or when the position rate absolute value is greater than another threshold. The integration element includes an integration increment such that generation of the integration increment begins by a determination made of the position error between the throttle position and the position command. Once a determination of the sign of position error is made, a gain is applied to the position error. Also, a gain is applied to the sign of position error. The integration element of the throttle position feedback controller then operates with the position error and the sign of position error. The throttle valve then reacts in response to the throttle position feedback controller.

Abstract: An engine output control method for a vehicle having a drive by wire engine system responsive to a desired engine torque signal. The method comprises the steps of generating a driver demanded acceleration value corresponding to an accelerator pedal position input, and generating a gear value as a function of a vehicle speed value and the driver demanded acceleration value. The method also derives a driveline torque demand comprising an inertial model torque value of the vehicle driveline corresponding to the driver demanded acceleration and the gear value, and a dynamic transmission model torque value for the gear value. The resulting torque demand is then passed through an inverse torque converter model to generate a demanded engine torque. The resulting demanded engine torque value is then used to control the engine output. In this way, the present method accounts for the transmission and driveline dynamics in an acceleration-based engine control scheme.

Abstract: A brush holder assembly (12) for a rotating electrical machine such as an alternator (10) has a cavity (56) therein. The cavity (56) is defined by a first wall (60), a second wall (62), a third wall (64), and a fourth wall (66). The cavity (56) is sized to receive a brush (42) of the rotating electrical machine. One of the walls (60), (62), (64), and (66) comprise a first drafted surface. A positioning rib (70) is provided on at least the drafted surface to position the brush (42) substantially parallel to the longitudinal axis (58) of the cavity (56).

Abstract: A method and apparatus for controlling engine temperature in a closed circuit cooling system 12 of an automobile 10 having an electric water pump 34, a flow control valve 42, and electric fan 40. A powertrain control module 20 electrically coupled to the electric water pump 34, flow control valve 42 and electric fan 40 interprets inputs from various sensors to adjust the pumping speed of an electric water pump 34, adjust the rotational speed of an electric fan 40, and/or adjust the flow rate through a flow control valve 42 to the radiator 46 according to a look up table as a function of fuel economy, emissions, thermal management and electrical load management.

Abstract: A method of increasing lateral stiffness in fiberglass composite leaf springs used in suspension systems. The increase in lateral stiffness is accomplished by introducing two carbon fiber inserts to the longitudinal side regions of a fiberglass composite spring. The amount of volume of carbon fiber inserts is preferably between 10-20% by volume of the total volume of the spring and is a function of the strain characteristics required within the suspension system. The composite leaf spring secures the weight advantages of fiberglass springs as compared with traditional steel leaf springs and improves lateral stiffness that promotes improved handling as well as increased efficiency in the packaging of suspension and fuel storage systems. These new composite springs can be molded from layering preprag tape containing fiberglass, carbon fiber and resin, or from a 3D weaving process.

Abstract: A cartridge-style pump [10] for a vehicle power steering system can be assembled, tested and shipped independently of an associated pump housing [37]. The pump [10] includes an upper plate [12], a cam plate [16] having a bore [20] formed therein for receipt of a rotor [18], and a lower plate [14]. A plurality of alignment pins [22] are pressed into the lower plate [14] with the cam plate [16] and the upper plate [12] placed onto the alignment pins [22] to locate the plates in their proper position. A plurality of retaining clips [32] are placed onto a respective alignment pin [22] to hold the pump [10] together.

Abstract: A fuel delivery module for an automotive fuel delivery system includes a reservoir and a fuel pump. The fuel pump delivers fuel from the tank to the reservoir via a fuel tank inlet and reservoir outlet and from the reservoir to the engine via a reservoir inlet and engine outlet. The reservoir is formed with a plurality of contaminant traps for collecting contaminants contained in the fuel as the fuel is pumped through the reservoir such that the contaminants settle unto said contaminant traps thereby reducing the amount of contaminants entering the reservoir inlet.

Abstract: A fuel system pressure valve includes is interposed in a fuel line between a fuel pump and a fuel rail for controlling fuel flow from the pump to the rail and from the rail to the pump. The valve includes a valve housing having a pair of half sections to form a valve chamber. A check valve is mounted in the chamber and is operable to allow fuel flow from the pump to the fuel line upon the fuel pump delivering a predetermined fuel pressure to the fuel line. A pressure relief valve is mounted within the chamber parallel to the check valve and is operable to allow fuel in the fuel line to flow through the housing to the fuel pump upon fuel pressure in the fuel line exceeding a predetermined relief pressure. In addition, a parasitic flow orifice is mounted in fluid communication with the valve chamber and allows fuel in the valve chamber to flow through the orifice to a fuel tank when valve chamber pressure is below a predetermined valve chamber pressure.

Abstract: An apparatus and method of for measuring fluid levels in a fluid tank (30) utilizing a no moving parts fluid level sensor (20). The apparatus comprises a hollow sensing tube (24) sealed to a pressure sensor (22). The pressure sensor (22) measures air column pressure as a function of hydrostatic pressure within the fluid tanks (30). By modifying the design of the hollow sensing tube (24) to incorporate at least 30% of the volume at its bottom end, the accuracy of the fluid level measurements may be increased by decreasing the meniscus level (34) deviation in the hollow sensing tube (24). Further, by adding a flexible diaphragm (62) to the bottom end that does not allow fluid to enter the hollow sensing tube (24), the accuracy of the fluid level measurements may be further increased by eliminating the meniscus level (34) altogether.

Abstract: An engine output control method for a vehicle having a drive by wire engine system responsive to a desired engine speed signal. The method comprises the steps of generating a driver demanded engine speed value corresponding to an operator input and generating a speed control system engine speed value corresponding to a predetermined speed value to permit vehicle operation at a constant speed by a speed control system. The method arbitrates between the driver demanded engine speed value and the speed control system engine speed value to derive a first desired engine speed value. This value is limited by a vehicle speed limit value, engine speed limit value, and transmission speed limit value to generate a second desired engine speed value. The engine is then controlled as a function of the second desired engine speed value and an actual engine speed value.

Abstract: An electronic throttle control mechanism having a housing and cover member with a throttle valve, gear mechanism, motor, and failsafe mechanism. The housing, cover member and other components are made of a plastic composite material. A spring member positioned between the housing and sector gear member which is attached to the throttle valve shaft, biases the throttle valve plate member toward the closed position. A spring-biased plunger member biases the throttle plate member from its closed position to a default or “limp-home” position. Several of the components, such as the motor holder, electrical connectors and housing for the throttle position sensor (TPS), are molded together into the cover member to form an integrated modular assembly. This reduces the cost and weight and improves the reliability and overall size of the mechanism.