Abstract: An integrated Vehicle Electrical Design and analysis System (VEDS) which is adapted to accommodate data interchanged between multiple vendor-independent Computer Aided Engineering (CAE) tools. The system includes a Vehicle Database (VDB) which is operative as a central repository to store all design, analysis and library information. The VDB is interfaced and data is exchanged with the CAE tools through an interface which is predominantly object-oriented using Common Lisp Object System (CLOS). For each tool, an outbound translator is operative to translate the tool's internal data structures into a standard interchange format. Similarly, for each tool, an inbound translator is operative to translate a standard or tool specific interchange format into the tool's internal data structures. The VDB also includes an inbound and an outbound translator. The inbound translator is operative to load data structures from each of the CAE tools into the VDB.

Abstract: An apparatus for detecting drive line system imbalances in an automotive vehicle includes an angular position and speed sensor located at a preselected position spaced from, but associated with the drive shaft in non-contacting relationship therewith, the sensor generates a signal responsive to the speed and angular position of the drive shaft relative to the preselected reference point. The apparatus also includes at least one vibration sensor located at a preselected position, spaced from, but associated with, the drive line in non-contacting relationship therewith. The vibration sensor detects the drive line vibration and generates a signal responsive thereto. A signal analyzer receives the signals generated by the angular position and speed sensor as well as the vibration sensor and calculates any imbalance in the drive line system and presents counterweight and position parameters for correcting any system imbalance.

Abstract: A method for attaching a surface mount device to a circuit board includes applying a heat curable adhesive to the circuit board, applying solder paste with a predetermined melting temperature to the circuit board, placing the surface mount device on the adhesive, placing the circuit board into an oven where the circuit board is continuously heated to a first temperature until the adhesive is sufficiently cured so that it withstands reflow of the solder paste then to a second temperature to melt the solder paste.

Abstract: A method for improving the reliability of solder joints is disclosed for use in reflow soldering. In the method, a predetermined amount of solder is applied to at least two solder pads on a circuit board and a component having at least two terminals is fixed in relation to the solder pads. The solder is melted so that the component floats to a predetermined height above the solder pads and, when solidified, the solder fillet formed at each terminal holds the component a predetermined height above the circuit board and forms a convex shape.

Abstract: A high efficiency pump having relatively-moving parts constituted of a light weight material and a coating on at least one of the parts to effect essentially zero clearance between the parts where they merge together. The coating is comprised of solid lubricants in a polymer resin matrix stable up to 700.degree. F.

Abstract: A robotic end effector adapted to be mounted at the end of an arm of a program-controlled robot is capable of providing compliance within a vertical plane as well as alignment along a horizontal axis. A method and system utilizing the end effector to pick up flat or curved glass panels from glass racks and place the glass panels into irregularly-shaped wooden crates. Due to the compliance and horizontal alignment provided by the end effector, the system allows essentially perfect piece-to-piece vertical edge-of-glass alignment and side-edge to side-edge alignment during the packaging process so as to eliminate glass etching/scratching and breakage. The end effector includes a base frame on which compliance devices and side-shift alignment devices in the form of linear bearing systems support a number of material handling devices in the form of suction devices. The handling devices are typically material holding/gripping devices.

Abstract: A collection of agglomerated anti-friction grains for plasma deposition, the grains each consisting essentially of (a) H.sub.2 O atomized stainless steel particles, (b) solid lubricant particles consisting of at least one of boron nitride or a eutectic of calcium fluoride and lithium fluoride, and (c) a binder holding said steel and solid lubricant particles together for plasma spraying, said binder being present in an amount of 0.5-4.0% by weight and is vaporizable at the temperature of plasma spraying and does not interfere with the deposited process.

Abstract: A method of preparing and coating cylindrical bore surfaces of an aluminum workpiece that comprises (a) inserting and rotationally reciprocally moving a plurality of honing elements against the bore surface with a pressure of at least 30 psi to effect a pattern of spiral overlapping abrasions on said surface, each element being constituted of multifaceted, irregular-shaped, abrasive particles (i.e., diamond or SiC) having a particle size of 30-1300 micrometers. The particles, when in contact with the surface, plow micro-sized, non-smooth and irregularly spaced grooves in the aluminum workpiece resulting in spiral peaks and valleys along the direction of movement of the particles, whereupon repeated reciprocation and rotation of the elements (i.e.

Abstract: A technique and accompanying apparatus to promote increased yield, improved surface finish and microstructure, and faster cycling time for precision-sand casting process. Aluminum products are cast by: (a) forming a precision sand mold, devoid of risers and/or vents, and a gating system consisting of a gravity feeding sprue and one or more runners effective to carry molten metal from the sprue only to the bottom of the mold cavity; (b) planting a flow modifier in the gating system between the sprue and mold effective to convert the flow into laminar quiescent flow; and (c) filling the gating system with molten aluminum metal at a rate faster than 4 pounds/second as permitted by the laminar flow that more rapidly fills the mold and acts as a heat sink to prevent a drop in temperature of the in-coming molten metal and thereby increase yield as well as minimizing cycle time.

Abstract: A transfer system for delivering molten metal against gravity from a pressurized furnace to a mold, comprising: a ceramic lined refractory metal gatebox adapted to sit on or above the furnace, the gatebox having one or more openings at its top for communicating with the mold and having a plurality of metal transfer openings along its bottom; a stalk tube depending from each of the gatebox bottom openings, each stalk tube being effective to extend into at least the upper region of the molten metal within the furnace; a sealing gasket between the stalk tube and gatebox; imposing a first fluid pressure on the molten metal in the furnace to gradually force the molten metal up through the stalk tubes into the gatebox to substantially fill same, said stalk tubes promoting a convection circulation of metal between molten metal between the furnace and gatebox to retain the temperature of the molten metal in the gatebox at a difference of no greater than 15.degree.-15.degree. F.

Abstract: A vehicle vibration simulator to simulate occupant exposure to vibration in a motor vehicle includes a reaction mass, a seat portion, a seat actuator between the reaction mass and the seat portion for providing at least one degree of vibration freedom, a steering column portion, a steering column actuator between the reaction mass and the steering column portion for providing at least one degree of vibration freedom, a floorpan portion, a floorpan actuator between the reaction mass and the floorpan portion for providing one degree of vibration freedom, the seat actuator, steering column actuator and floorpan actuator being actuated independently and/or simultaneously to simulate occupant exposure to vehicle vibration.

Abstract: A shaped soldering strip for promoting improved soldering joints to or between a tube array comprising: a thin coupon of solder having margins defining openings aligned with the axes of the tubes to be joined; a collar surrounding each margin to define a cup shape integral with the associated margin, such margin forming the bottom of said cup shape and being positioned by the collar for placement in annular contact or at least in micro-close proximity to the external circumference of an aligned tube to limit downward weepage of flux deposited in said cup shape: and bridges connecting said collars to create said coupon that extends over said frontal area and gangs the collars for positioning on the tubes of said array.

Abstract: An apparatus for preparing a surface of a cylinder bore by electrical discharge machining includes a rotatable spindle and at least one electrode operatively connected to a power source and rotatably supported upon the spindle, the electrode being movable radially relative to the surface of the cylinder bore between a first retracted position such that the electrode is positioned within the cylinder bore prior to preparing the surface and at a second position spaced from the first position wherein the electrode is adjacent the surface of the cylinder bore for preparing the surface by electrical discharge machining as the electrode rotates with the spindle.

Abstract: A fast hole drilling EDM electrode and a more efficient apparatus and method for electrical discharge machining using the electrode. The electrode has an electrically conductive body with a leading end or tip and a length of relatively uniform non-circular cross-section that is operatively adapted to provide a dielectric flush path between the electrode body and the hole being machined in the workpiece. At least one dielectric supply bore is formed lengthwise through the body. The one or more supply bores connect a dielectric exit at the leading end of the body with a dielectric entrance located distally therefrom. This electrode is operatively adapted for being rotated during the machining process and for its non-circular cross-section to form a hole with a circular cross-section, when so rotated.

Abstract: A contamination-resistant, temperature-sensing device for sensing the extent of conductive heat flow from a metal surface. A heat transfer member is mounted to one end of a thermally insulative tube. The heat transfer member has two oppositely facing surfaces, one of which engages the metal surface to receive conductive heat flow therefrom, the other of which radiates transferred heat through the tube. A sensor is mounted to the other end of the tube to detect the extent of heat radiated through the tube and hence the extent of conductive heat flow from the metal surface. The sensing device also includes a housing surrounding the tube and the sensor. In addition, the sensing device includes a variable rate coil spring to allow the heat transfer member to bear against the metal surface at a constant contact force. A controller is electrically coupled to the sensor for controlling the extent of conductive heat flow from the metal surface based on the detected heat radiated through the tube.

Abstract: A method and system for estimating and controlling the temperature of an electrically heated catalyst having a heating element disposed in an exhaust passage of an internal combustion engine. Mass air flow into the engine is sensed. A temperature at an inlet of the catalyst is first determined. Next, a steady-state temperature rise of the heating element is determined based on the catalyst inlet temperature. The steady-state temperature rise is converted into an instantaneous temperature rise having a time constant based on the sensed mass air flow. A total catalyst temperature of the catalyst is then determined based on the catalyst inlet temperature and the instantaneous temperature rise. Finally, the heating element of the electrically heated catalyst is controlled based on the total catalyst temperature.

Abstract: A piston and ring assembly operative within a cylindrical bore wall to retain fluid to one side. The piston has a side wall for movement along the cylindrical wall and has one or more spaced grooves in the side wall, each groove defining a pair of interior groove surfaces spaced apart a uniform distance; at least one sealing element presenting a pair of opposed surfaces operating between and along the pair of groove surfaces, the sealing element being capable of engaging the cylindrical wall, the spacing between the opposed surfaces of the sealing element and the pair of interior surfaces of the groove being no greater than ten microns; and a solid film lubricant mixture coating the groove surfaces and the opposed surfaces of the sealing element, whereby surface adhesion of the fluid, present in the spacing, inhibiting migration of such fluid through the spacing and flutter of the sealing element, in said spacing, being essentially eliminated.

Abstract: An apparatus for testing an integrated circuit includes a bond substrate having a location for an integrated circuit. The location on the bond substrate has a plurality of traces around each location. A first fixture holds the bond substrate in a fixed relation to first fixture and holds the integrated circuit in a fixed relation to the first fixture and the bond substrate. A wirebonder forms wirebonds between the traces and the bond pads. An electrical tester provides electrical signals from the traces to the bond pads to verifying the operation of the integrated circuit. A second fixture lifts the bond substrate while the integrated circuit remains held to the first fixture. A vibrator vibrates the first fixture in relation to the second fixture so that the wirebonds are broken at a predetermined location near the bond pad.

Abstract: A method of through-hole drilling of metal workpieces having sufficient ductility to create hinged drill caps, which comprises: while carrying out through-hole drilling with low thrust drill tips, directing a fluid jet stream against the drill exit side of the workpiece with sufficient force to retain and resulting drill cap closed against the exit side until such drill cap is completely annularly severed from the workpiece, the jet stream being oriented substantially coincident with the revolving axis of the drill. The fluid of the jet stream may be a machining liquid coolant, a gas, or a water-based solution. The jet stream has a diameter upon impingement with the workpiece that is less than the diameter of the exit opening created by the drill.

Abstract: Method of depositing an Fe.sub.x O comprising coating onto a light metal substrate by use of wire-arc thermal spraying that propels atomized droplets by use of atomizing gases, comprising: preparing at least one surface of the light metal substrate to present an exposed essentially non-oxidized substrate surface; and thermally spraying melted droplets of a steel feedstock wire onto the prepared surface by use of propellant gases to deposit a composite coating, the gases being controlled as to content to regulate the exposure of the droplets to oxygen so that Fe.sub.x O is substantially the only iron oxide formed during spraying, x being 0.5-1.5.