Abstract: A method of making a pre-formed tubular member includes the steps of providing a tubular member extending longitudinally and providing a bending assembly having a mandrel with at least one ball and a bending die. The method also includes the steps of positioning the at least one ball inside of the tubular member. The method further includes the steps of bending the tubular member about the bend die to form a bent pre-formed tubular member having at least one curved portion having a recess therein.

Abstract: A hydroform die tube holding assembly and method of using same includes at least one seal unit for sealing an end of a tube. The hydroformed die tube holding assembly also includes a seal unit elevator for attachment to a lower die half to operatively support the at least one seal unit. The hydroformed die tube holding assembly further includes at least one upper gas spring for attachment to an upper die half to engage, the seal unit elevator to drive the seal unit elevator downward prior to the upper die half engaging the tube.

Abstract: A hand brake lever, especially for a motor vehicle, includes at least two tubes (2, 3) telescopically inserted into each other for actuating a locking device (5) of a parking brake. The tubes (2, 3) automatically lock in any pulled-out position and actuation of a device corresponding to the tubes (2, 3) causes the release of the locking device (5).

Abstract: Methods and apparatus are provided for generating route instructions on a turn-by-turn navigation system in a vehicle. Turn instructions can include a turn icon as well as visual and audio prompts. The turn-by-turn navigation system typically includes a dual-use disk changer configured for both audio and Map/POI disk access. Separate Map and POI database disks are typically installed in dedicated slots of the disk changer and are designed to minimize switching time, while audio disks can be installed in the remaining slots. Moreover, audio playback buffering can be employed to enable audio-to-navigation-to-audio disk switching without interrupting audio playback. The turn-by-turn navigation system can generally be produced more economically than a typical premium system with a full complement of costly features, such as a color map display, since the turn-by-turn navigation system can be configured with only those features deemed most useful to a broad-based market segment.

Abstract: A compact air-bump stop (jounceshock) provides improved motor vehicle suspension system accommodation of jounce and rebound than is provided than by a conventional shock absorber, bump cushion and/or air-bump stop. In an independent jounceshock, a primary shell and a secondary shell are reversibly collapsible into each other, and a valved piston demarcates a primary chamber within the primary shell and a secondary chamber within the secondary shell, both of which being filled with a mixture of pressurized gas, preferably nitrogen, and oil. The valving of the valved piston allows for selectively unidirectional, metered movement of the oil therethrough in concert with the direction of movement of the secondary shell with respect to the primary shell. In an integrated jounceshock, a compact air-bump stop is integrated with a shock absorber.

Abstract: A method is provided for distributing a recall notification to an automobile equipped with an in-vehicle communications system. The method comprises the steps of providing a telematics service center with identification information corresponding to the automobile, matching the identification information with the corresponding in-vehicle communications system, and wirelessly transmitting the recall notification to the in-vehicle communications system. A system for distributing a recall notification to a vehicle, and a vehicle equipped with an in-vehicle communications system are also provided to carry out the method.

Abstract: A cup holder assembly includes a housing partially defined by a pair of opposing sidewalls and configured to partially enclose an interior space. At least one support ring pivotably moves along a cam surface of the housing between a use position and a stored position. In the use position, the support ring is substantially outside of the interior space, is perpendicular to the opposing side walls, and can at least partially support a container. In the stored position, the support ring is substantially inside of the interior space parallel and substantially adjacent to the one of the side walls.

Abstract: Methods and apparatus are provided whereby a single person can test exterior lights of a vehicle. The apparatus comprises a controller coupled to the lights for turning light groups ON and OFF in a predetermined sequence in response to a START TEST signal and vehicle safe-status. Vehicle status sensors are provided for reporting to the controller the status of predetermined vehicle elements whose safe status is a prerequisite for testing the lights. A user actuated switch coupled to the controller provides the START TEST signal. Vehicle safe-status desirably includes transmission in PARK and motor OFF. An internal memory coupled to the controller stores data on prior tests and prompts the user that another test is needed. Prompts are also desirably provided to tell the user what changes need to be made to achieve safe-status for the test. Post test, the vehicle desirably returns to its prior state.

Abstract: The present invention concerns a method for cooling a passenger compartment in a hybrid vehicle that operates an engine intermittently during vehicle operation, the hybrid vehicle having an HVAC system including an HVAC duct, a blower adapted to direct a flow of air through the HVAC duct, and an evaporator located within the HVAC duct. The method includes the steps of operating the blower; operating the compressor; allowing a predetermined amount of ice to form on the evaporator during operation of the compressor; turning off the vehicle engine; ceasing operation of the compressor; measuring an indicator corresponding to a remaining amount of the predetermined amount of ice formed on the evaporator; and re-starting the compressor when a predetermined air temp in air duct is reached.

Abstract: Methods and system are provided for an adaptive vehicle locking system. The system includes a plurality of vehicle door locks, each configured to lock and unlock in response to a first signal, a plurality of sensors each configured to sense opening and closing of an associated vehicle door and to send second signals in response to opening and closing of the associated vehicle door, and a lock requester configured to send a third signal. A control module that includes a memory for storing a history of the second signals and a timer adaptively settable in response to the history of the second signals is configured to receive the second signals from the plurality of sensors and the third signal from the lock requester. The control module is also configured to send a first signal to the plurality of vehicle door locks causing the vehicle door locks to lock in response to timing out of the timer following receipt of the third signal.

Abstract: An apparatus is provided for illuminating the interior of an automotive passenger vehicle for ingress and egress. The apparatus comprises a lighting device integrated into the periphery of a sun visor or similar object. The lighting device is typically activated by a remote entry device, a door opening, or by an interior switch. The apparatus is particularly applicable where overhead interior lighting is impractical, such as in convertibles and other types of vehicles with removable tops. The lighting device may be customized for color and intensity, as well as for physical configuration. The apparatus can also be used in lieu of conventional interior roof lighting as a manufacturing cost reduction.

Abstract: A dust testing facility for static dust testing of a motor vehicle, wherein actual road dust is utilized, which dust is fully recirculated and reused, and wherein the dust testing of the motor vehicle suitably approximates a dynamic road dust test of the motor vehicle. The dust testing facility includes a dust testing chamber which receive thereinside a motor vehicle to be tested and is integrated with four major component systems: an air supply system, a dust supply system, a dust spray system interfaced with the dust supply system, and a dust recapture system interfaced with the air supply and dust supply systems. The dust testing chamber preferably includes, for purposes of dust testing of a motor vehicle, a leak detection system selectively interfaced with a motor vehicle being dust tested.

Abstract: Sheet metal forming is a manufacturing process in which flat sheet metal is drawn into a die cavity to form a product shape. Draw-in amount is the single most important stamping index that controls all forming characteristics (strains and stresses), formability failures (splits, wrinkles) and surface quality (distortions) on a panel. Adaptation of a new die set for repetitively stamping sheet metal parts to a part design specification is simplified by using a math-based simulation of the stamping operation under specified engineering stamping conditions for the specified part. The stamping simulations are used to create an engineered draw-in map comparing selected locations on the peripheral edge of the stamped part with corresponding locations on the peripheral edge of its original sheet metal blank.

Abstract: An analog instrument gauge display is provided that comprises a lens having a pointing indicia displayed thereon, a back plate having a pattern thereon, and a drive motor coupled to the lens and configured to rotate the lens and pointing indicia relative to the pattern on the back plate in response to receipt of a signal.

Abstract: A double action punch assembly for a hydroforming die includes a first punch segment having an aperture extending therethrough. The double action punch assembly also includes a movable mounting block disposed in the aperture of the first punch segment. The double action punch assembly further includes a plurality of second punch segments connected to the mounting block. The first punch segment is moved in a first action to pierce a tubular member in a first direction and the second punch segments are moved in a second action to pierce the tubular member in a second direction to produce an opening in the tubular member.

Abstract: A clamp assembly for a hydroforming die includes a stationary lower bed to support a lower die half of the hydroforming die, a stationary upper bed spaced above the lower bed, at least one guide post extending between the lower bed and the upper bed, a movable slide disposed between the upper bed and the lower bed and movable along the at least one guide post to support an upper die half of the hydroforming die, a lifting cylinder operatively connected to the movable slide to move the movable slide and upper die half toward and away relative to the lower die half, at least one link mechanism connected to the upper bed and the movable slide to equalize a force on the hydroforming die, and at least one linkage cylinder operatively connected to the at least one link mechanism to activate the at least one link mechanism to prevent the movable slide and upper die half from moving away from the lower die half to keep the hydroforming die closed during a hydroforming process.

Abstract: A cup holder assembly includes a receptacle. A base defining a recess is also included. The base is pivotable with respect to the receptacle between a stored position in which the base is substantially inside the receptacle and a use position in which the base is at least partially outside the receptacle. A partial ring is supported by the receptacle and slides in the channel in one direction such that the partial ring is contained substantially within the channel when the base is in the stored position and slides in the channel in another direction to extend between the receptacle and the base when the base is in the use position to cooperatively form with the base a circumferential support for receiving and at least partially supporting a container.

Abstract: Apparatus and methods are provided for controlling a voltage output of an alternator having a regulated voltage control (RVC). The apparatus includes a processor configured to transmit one of at least two control signals and a switch coupled to the processor and configured to select one of the control signals. One of the control signals is an RVC enable signal, and another control signal is a voltage boost signal. The method includes determining whether RVC requires override, selecting an output voltage mode of the alternator, activating a boosted voltage mode of the alternator by disabling RVC when RVC requires override, and activating an RVC mode by enabling RVC when the RVC does not require override or upon an occurrence of a lapse of a pre-determined amount of time.

Abstract: A valve assembly is adapted to be disposed in an automotive engine exhaust system at an outlet of an internal combustion engine. The assembly includes a valve body having an opening therethrough including an inlet portion and an outlet portion. A first valve and a second valve are disposed in the opening intermediate the inlet and outlet portions. The first and second valves have an open position and a closed position. The first valve blocks a first predetermined amount of the opening when in the closed position. The second valve blocks a second predetermined amount of the opening when in the closed position, with the second predetermined amount being less than the first predetermined amount. An actuator is connected to the first valve and the second valve and is operable to selectively move each of the valves between respective the open positions and the closed positions.

Abstract: A punch assembly for a hydroforming die includes a servo motor, a ball screw connected to the servo motor, and a ball nut disposed about the ball screw for movement along the ball screw. The punch assembly also includes a link mechanism connected to the ball nut and a plunger operatively connected to the link mechanism and movable relative to the hydroforming die to allow fluid within a tubular member to force a wall portion of the tubular member outward against the plunger and be sheared by the hydroforming die to produce an opening in the tubular member.