Abstract: A plate making process for a lead acid battery which eliminates the need for steaming and curing steps to produce the active material. Mixing, reacting and crystallizing occur in a closed reactor under controlled temperature and mixing conditions to produce a paste having the desired crystal morphology. A polymer is then added to the paste to bind the crystals together and to produce desired rheological properties in the paste. The paste having the polymer addition is then pasted onto a grid where the paste is dried to form a battery plate of the lead acid battery. The process is applicable for both the positive and negative plates of a lead acid battery.

Abstract: A method for calibrating hydraulic actuators includes installing an actuator in a test stand and performing an electrical signal sweep to obtain a series of pressure values. Based on desired pressure values, signals yielding unwanted pressure values are removed and the remaining signal values and pressure values are stored in a central database as a look-up table for the actuator. Multiple actuators are then assembled to form a module assembly. The customized look-up tables for the actuators forming the module assembly are retrieved from the database. Based on those tables, signals are applied to the actuators to determine if the pressure values fall within specified tolerance windows. If the pressure values fall within the specified tolerance windows, the customized look-up tables are stored in the memory of a vehicle electronics package. If not, the signals are adjusted so that the pressure values fall within the specified windows, and the adjusted customized look-up tables are then stored in the memory.

Abstract: A method for determining a level of water contamination in a fuel containing ethanol, including determining the ethanol concentration of the fuel; sensing the resistance of the fuel; determining a resistance limit of the fuel; and comparing the resistance to the resistance limit to provide the level of water contamination. Ethanol concentration is preferably obtained by comparing a measured capacitance to known values in a look-up table. The resistance limit can be determined by multiplying a resistance corresponding to the ethanol concentration by an alarm fraction. The resistance is obtained by a look-up table of resistance values at known water contamination levels. Reporting occurs when the measured resistance is at or below the resistance limit. Alternatively, the measured resistance is normalized with respect to the resistance with no water contamination and reporting occurs when −1.6667*normalized resistance+1.6667 approaches 1.0.

Abstract: The switched reluctance machine providing soft chopping in the output current controls the voltage across the phase winding. When the current through the phase winding in the generating mode reaches a first predetermined value, the voltage across the phase winding is reversed and as a result, the current through the phase winding decreases. When the phase winding current reaches a second value, the phase winding is shorted so that the current increases due to the positive back-EMF through the phase winding until the first predetermined value is again reached, at which time the voltage across the phase winding is again reversed.

Abstract: A mounting fixture for an engine knock sensor is provided. The fixture includes a base and a support member. The support member is joined to the base with a press fit joint. The base includes an aperture and the support member is inserted in the aperture. The support member can be a bolt or a sleeve. The invention can also include a lip, associated with the support member for retaining a spring washer. The spring washer can be deflected between the support member and a knock sensor component for pressing the knock sensor component against the base.

Abstract: A high-density stator core for use in electrodynamic devices is fabricated by the electromagnetic pressing of an iron-based powder coated with a dielectric material and methods for performing the electromagnetic pressing are disclosed. The stator core includes a yoke portion that may further include a plurality of integral poles extending either radially outward from an outer circumferential surface of the yoke portion or radially inward from an interior circumferential surface of the yoke portion. The stator core is formed as a near-net-shape compact by an electromagnetic pressing process and has an as-formed density of at least about 98% of the theoretical density.

Abstract: A battery protection system for a battery having a switching mechanism positioned intermediate to the positive terminal and an electrical load of the battery. A controller manipulates the switching mechanism between an open position and a closed position, the closed position connects the electrical load to the battery and the open position disconnects the electrical load from the battery. The battery protection system utilizes a battery state-of-charge detection system, which instructs the controller to open the switching mechanism when the detection system detects a battery state-of-charge that is lower than a threshold value. The battery protection system is also equipped with a vehicle status detection system, which instructs the controller to close the switching mechanism when a vehicle startup condition is detected by the vehicle status detection system.

Abstract: A coil assembly includes a spool that is rotatably attached to a connector. In order to wind a coil on the spool, the spool is rotated with respect to the connector until the connector does not interfere with the winding bay on the spool. Thereafter, a wire is wound around the spool within the winding bay to form the coil. Once the coil is complete, the spool can be rotated with respect to the connector until a locking mechanism on the spool engages a corresponding locking mechanism on the connector. Thus, a complete coil assembly can be manufactured in one operation with minimal manufacturing steps.

Abstract: Tilt and vibration sensor and method for forming the sensor with a piezoresistive membrane having a weight affixed proximate its center for detecting the tilt and vibration of a body. The membrane may include four piezoresistors placed proximate the edges of the membrane at the points of maximum stress when the membrane is subject to a uniform applied pressure. The piezoresistors may form a Wheatstone bridge circuit to generate a first and second output voltage in response to changes in resistance of the piezoresistors under the uniform applied pressure. The first output voltage may be indicative of the angle of inclination of a body and the second output voltage may be indicative of the vibration of the body. The membrane may be fabricated from a silicon wafer using known photolithography and etching processes. The membrane may be connected with a voltage source and secured within an appropriate housing to be placed in an operational environment.

Abstract: A target wheel sensor assembly includes a target wheel, a magnet, and a sensing element placed therebetween. The magnet and the sensing element are configured so that as the target wheel rotates the sensing element outputs an asymmetric signal. This asymmetric signal is used to determine the position of the target wheel as it rotates and the direction of motion of the target wheel.

Abstract: Method and system for controlling a permanent magnet machine are provided. The method provides a sensor assembly for sensing rotor sector position relative to a plurality of angular sectors. The method further provides a sensor for sensing angular increments in rotor position. The method allows starting the machine in a brushless direct current mode of operation using a calculated initial rotor position based on an initial angular sector position information from the sensor assembly. Upon determining a transition from the initial angular sector to the next angular sector, the method allows switching to a sinusoidal mode of operation using rotor position based on rotor position information from the incremental sensor.

Abstract: A multiple contact fluid pressure switch includes a plate from which a rib extends to establish a cavity on the plate. Two lower contacts are on the plate within the cavity. A diaphragm is disposed on the rib to enclose the cavity. Further, an upper contact is disposed on the diaphragm directly above the lower contacts. The multiple contact fluid pressure switch is movable between an open position wherein the upper contact does not engage the lower contacts, a first closed position wherein the upper contact engages one lower contact, and a second closed position wherein the upper contact engages both lower contacts.

Abstract: Tilt sensor and method for forming the sensor with a piezoresistive membrane having a weight affixed proximate its center for detecting the tilt of a body. The membrane may include four piezoresistors placed proximate the edges of the membrane at the points of maximum stress when the membrane is subject to a uniform applied pressure. The piezoresistors may form a Wheatstone bridge circuit to generate an output voltage in response to changes in resistance of the piezoresistors under the uniform applied pressure. The output voltage may be indicative of the angle of inclination of a body. The membrane may be fabricated from a silicon wafer using known photolithography and etching processes. The membrane may be connected with a voltage source and secured within an appropriate housing to be placed in an operational environment.

Abstract: In a magnetoresistive sensor employing a single stage comparator circuit for signal threshold detection, an hysteresis deadband is established substantially proportional to signal amplitude. The sensor includes a transducer comprising at least one magnetoresistive element and an hysteresis circuit also including the at least one magnetoresistive element.

Abstract: Composite galvanomagnetic devices having a desired combination of properties in specific temperature ranges and magnetic field ranges and so combined that desired properties are provided over an extended temperature and magnetic field range. In practice this can be accomplished with a single die with layers of different properties. Particularly, the present invention addresses this method as related to magnetoresitors and Hall plates.

Abstract: A method of assembling an ignition coil cassette assembly for use with an internal combustion engine having a plurality of cylinder assemblies each including a spark plug, and an ignition coil cassette assembly provided in accordance with the invention methodology. The cassette assembly includes a plurality of ignition coils for respective electrical coupling to the respective spark plugs, whereby to deliver high voltage charges to the spark plugs in accordance with a predetermined firing order, a cassette body structure interconnecting and mounting the ignition coils in spaced downstanding relation with respect to the body, a printed circuit board for delivering power to the coils, and electronic components mounted on the board.

Abstract: A grid plate for high power lead acid battery having a plate (14) covered with a conductive polymeric matrix (10) of preferably polyaniline and its derivatives, which is then coated with nanoscale particles of active material (14) such as lead sulfate and basic lead sulfate complexes.

Abstract: An ignition apparatus including a primary and a secondary winding for producing a spark voltage, an ion current detection circuit for producing an ion current signal, a slope detector and a knock detector. The slope detector determines when the ion current signal exhibits a slope indicative of a time period when knock is likely to occur, and de-asserts a knock reset signal. The knock reset signal holds the knock detector in reset, thus disallowing or masking the processing of signals by the knock detector that may be mistaken for knock.

Abstract: A solenoid assembly includes a solenoid having a magnetic circuit comprising stationary primary and secondary pole pieces and a moveable armature. The primary pole piece includes an inner cylindrical wall operable to define, with the armature, a fixed radial gap for the passage of magnetic flux, and a tapered outer wall operable to increase the mass of the pole piece through which flux may pass, as the armature moves axially within cylindrical inner wall, the primary pole piece further includes an inwardly tapered, conical portion that extends toward the armature which operates, with an associated conical portion on a periphery of the moveable armature, to substantially maintain the axial opening force on the armature by establishing a secondary gap for the passage of magnetic flux as the armature approaches the conical tapered portion of the cylindrical wall to compensate for the saturation of magnetic flux through the fixed air gap.

Abstract: An ignition coil having ion sense capability with combustion and knock outputs features improved determination of when to open and close a combustion window during which a combustion signal indicative of the level of combustion is calculated. The system also includes a knock window during which a knock signal indicative of the level of knock is determined. A PWM combustion signal is multiplexed on the same physical line as a current flag signal, and, a PWM knock intensity signal is multiplexed on the same physical line as a knock window signal, which reduces system connections. Closed loop multicharge ignition is provided with combustion detection during multicharging to ensure the availability of knock detection, thereby providing a longer effective spark burn time while still allowing for knock detection.