Abstract: A method for lapping the gears of a gear set as well as a gear lapping system. The gear set generally includes a first gear in meshed engagement with a second gear, each of the first and second gears having a plurality of gear teeth each with drive and coast flank surfaces. The method includes the steps of lapping the gear set by rotating the first gear in a first direction while the first gear is in mesh with the second gear. The method further includes sensing the vibrations occurring in the gear mesh during rotation and controlling the step of lapping based on the sensed vibrations. The gear lapping system includes an automated lapping machine that is adapted to lap the gear set including a ring gear and a pinion gear. The automated lapping machine is adapted to lap the gear set by rotating at least one of the ring and pinion gears while in mesh, in the presence of a lapping compound, and while translating the gear mesh back and forth across the gear flank surfaces for a plurality of cycles.

Abstract: A low insertion force snap together automotive coupler for the suspension of a vehicle includes a spherical bearing insert having a first end, a second end, a pocket adapted to engage a ball stud that is integrally formed onto a suspension component, and an axially extending annular flange. The coupler further includes a receiver adapted to receive the spherical bearing insert after the spherical bearing insert has been placed to a ball stud and to engage the flange to secure the spherical bearing insert within the receiver. The pocket within the spherical bearing insert is shaped such that an axial force tending to pull the ball stud out of the pocket will result in a radial force exerted upon the flange, thereby causing additional force to keep the flange engaged within the receiver.

Abstract: A controller 12 has an I/O crossover switching network 14, an optional I/O network expansion 16, a plurality of serial I/O shifters 18, a clock generator 20 and I/O control logic 22. The I/O crossover-switching network 14 is also referred to as an I/O multiplexer. Serial data may be transferred between a serial I/O shifter and an external device by way of a dedicated serial data pin (SDATA) 24 or an optional alternate pathway 26 which uses one of a plurality of parallel pins 28. The optional alternate pathway 26 can be used when pins 28 are unavailable or to reduce the number of pins on the device 12. The controller is shown to communicate with an external device 30 also having parallel pins 32. While a single device 30 is shown, the external device 30 can be any number of a plurality of devices having serial and parallel signal pathways that is controlled by the microprocessor 10 of the present invention.

Abstract: A monopole low frequency test woofer (10) has a rigid mounting plate (12) with an acoustical opening (14), a monopole driver (16) with a high mass cone and low resonance mounted on the mounting plate with the basket (13) of the driver fitting about the opening, and a rear tub (20) attached to the mounting plate forming a sealed enclosure about the driver. An inductor (18) is also in connected in series with the monopole driver inside the enclosure. The sealed enclosure has an electrical connector (26) for making connection to an external circuit. The difference in outputs between the test woofer and standard optimized speaker represents the loss in baffling due to the vehicle environment being less than ideal.

Abstract: A method of aligning a sensor device attached to an automobile includes the steps of positioning a first detection object relative to the automobile and generating a plurality of beams at the sensor device. A beam crossing point common to first and second adjacent beams is selected, and the sensor alignment is verified by determining whether the beam crossing point is coincident with the first detection object.

Abstract: A pump includes a pump casing and an impeller. The pump casing has an axis and comprises a cover having a face surface and a body positioned about the axis. A channel is defined in the face surface of the cover. An inlet opening extends through the cover and is coupled to the channel. The channel has a first section and a second section. The first section extends from the inlet opening and is continually sloped relative to the face surface of the cover. The first section has a length of about 40 to about 90 degrees, as measured circumferentially on the face surface of the cover about the axis. The first section includes an inlet ramp, a main ramp, and a secondary ramp, with the secondary ramp being positioned between the main ramp and the inlet ramp, and the inlet ramp being positioned adjacent the inlet opening. Each ramp has at least one depth and at least one slope.

Abstract: A system for providing a key-based access to data stored on a vehicle allows the vehicle to be a critical link as a platform for mobile computing while preserving data security. Multiple hierarchies of key codes allow all users to have access to all vehicle functions but different memory partitions for storing data. The partitions may be used for storing user specific data including passwords, preference settings, and driving log data. The data may be encrypted by the key code to be secure even if the memory system is removed from the vehicle or the vehicle is stolen.

Abstract: A vehicle regenerative-type fuel pump which reduces the possible accumulation and effects of contamination relative to impellers with outer ring members. The outlet port on the pump cover member is enlarged and the C-shaped grove is positioned radially outwardly, which causes an increased outlet area and fluid flow around and through the impeller and through the outlet port.

Abstract: A control system (12) for an automotive vehicle includes a wheel speed sensor (18) generating a rotational speed signal and a controller (14) coupled to the wheel speed sensor. The controller determines a vehicle speed, calculates wheel slip based upon the vehicle speed and the rotational speed, calculates a predicted future wheel slip based upon the vehicle speed and the rotational speed, estimates a normal force on the wheel, calculates a modified brake torque signal in response to the wheel slip, the predicted future wheel slip and the normal force, and actuates the wheel brake in response to the modified brake torque signal.

Abstract: A method and system for providing vehicle control to a driver utilizes an accelerator pedal position and other various inputs. A powertrain control module uses the accelerator pedal position and the other various inputs to give the driver a combination of speed and torque control. In operating a vehicle at speeds ranging from zero to forty-five miles per hour, the powertrain controller provides the driver with torque control by mapping pedal position to electronic throttle angle according to a plurality of predetermined acceleration functions. In operating the vehicle at speeds greater than forty-five miles per hour, the powertrain controller provides the driver with speed control by mapping the electronic throttle angle according to a plurality of predetermined speed functions. Upon receiving other various inputs, the powertrain controller switches control from one form to the other.

Abstract: An electronic throttle control system having a housing and cover member with a throttle valve, gear mechanism, motor, and failsafe or default mechanism. 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. In order to reduce contact between the spring member of the default mechanism and the plunger member, the spring member can have an hourglass shape and/or the outer surface of the plunger member can be minimized.

Abstract: A rear wheel suspension system replaces the lower control arms, upper control arms, coil springs, and anti-roll bar assembly in the prior art with a simple composite member. By carefully designing the shape of the beam, the material system and the pivot locations, the ride and roll rates and camber and toe characteristics of the original prior art suspension system can be preserved.

Abstract: A vehicle regenerative-type fuel pump which reduces the possible accumulation and effects of contamination relative to impellers with outer ring members. The outer ring members have non-uniform configurations (slanted, curved, grooved, etc.) which reduce the affects of contamination which can cause wear and roughing of the outer surface resulting in higher torque and reduced pump efficiencies.

Abstract: A method for testing the integrity of an electronic throttle disable function begins by disabling the drive electronics responsible for controlling the throttle motor. The microcontroller doing the plate position control commands full closing voltage from throttle motor drive electronics (while those electronics are disabled). Then the throttle position voltage is recorded. If the disable system is working, the H-driver will output zero volts even though a full motor closing voltage is requested. The throttle position voltage is then compared to a predetermined default throttle position voltage. If there is a significant difference between the two voltages, then failure mode management is engaged.

Abstract: An electronic throttle control system having a housing and cover member with a throttle valve, gear mechanism, motor, and failsafe mechanism. 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 stop shoulder on the sector gear is transverse to the longitudinal axis of the plunger mechanism midway through the default range of travel of the sector gear and plunger member. This reduces stresses on the components and minimizes friction and wear on the gear train mechanism.

Abstract: A fuel injector (10), including a housing (12), an armature assembly (14), an injector needle (16), a needle seat (18), a needle guide (20), and a orifice disc (22) containing one or more orifice metering pathways (24). The needle guide (20) contains a center guide bore (26) and a plurality of filtering passageways (28). The plurality of filtering passageways (28) are used to filter fuel passing through the needle guide (20) and induce swirl in the fuel to improve atomization.

Abstract: An electrical storage device is coupled in parallel to a fuel cell contained within a fuel cell power generation system. The electrical storage device is either a battery pack, a plurality of capacitors, or a plurality of supercapacitors and is capable of electrochemically oxidizing a quantity of reformer gas contained within an anode chamber of the fuel cell during transient load conditions by charging from a preset state of charge towards full capacity. The energy storage device thereby prevents large quantities of unoxidized reformer gas from entering a chamber of a combuster during transient load conditions, unoxidized reformer gas that generates a tremendous amount of heat when burned that can corrode or damage the combuster.

Abstract: A method of reducing hard machining time, and correspondingly increasing hard machining tooling life, of a non plunging type constant velocity joint for use in reduced angle applications. The method comprises forming a recess having a larger formed radius in a portion of the ball track and cage track areas that is non-functional in low angle operations prior to heat treat hardening. The new process results in a significant reduction of approximately forty-five percent in the hard machining of the ball and cage track surfaces.

Abstract: A torque-based method to steer a vehicle equipped with a steer by wire system begins when a driver applies torque to a steering wheel so as to change the direction in which the vehicle travels. Two sensors, a steering wheel angle sensor and a steering wheel torque sensor then generate an angle signal and a torque signal, respectively. In the unlikely event the vehicle steering system is malfunctioning, the steering wheel torque sensor will still generate a torque signal. This torque signal is used in place of the angle signal to generate the reference signal. Once the reference signal is generated, then it can be used to generate the road wheel angle signal, which is in turn used to position the road wheels accordingly.

Abstract: A system (40) for starting an internal combustion engine (12) of an automotive vehicle (10) has a controller (54) coupled to a starter/alternator (42). The engine (12) has a crankshaft (50) and a turbocharger (24). The controller (54) initiates the starting of the engine (12) by rotating the crankshaft (50). The rotating crankshaft (50) displaces an amount of air from the cylinders (14) of the engine (12) to rotate the rotor shaft of the turbocharger (21). The turbocharger (25) thus draws in air, compresses the air and provides the compressed air to the cylinders (14). When the engine is started the initial power is increased due to the compressed air.