Abstract: A hybrid brake apparatus for a vehicle includes a hydraulic brake circuit having a first fluid circuit and a second fluid circuit connected to a master cylinder for generating hydraulic pressure in the first and a second fluid circuits, and electrically actuated brake elements controllable as a function of the hydraulic pressure in one or the other of the first and second fluid circuits. The apparatus may include a pedal feel emulator in one of the fluid circuits. The apparatus may also include a booster for amplifying pressure in the fluid circuits, a sensor for determining that the booster has failed, and control elements providing compensation for the failed booster during operation of the electrically actuated brakes while the booster is inoperative.

Abstract: Disclosed is a method of horizontally structured CAD/CAM manufacturing for fixtures and tooling comprising: selecting a contact area geometry; creating extracts from a master process model; generating a tooling model corresponding to the contact area geometry; virtual machining the tooling model to generate the fixtures and tooling; and generating machining instructions and drawings to create the fixtures and tooling; where the tooling model exhibits an associative relationship with the contact area geometry.

Abstract: A damper includes a piston that carries a relatively compact control valve for controlling fluid flow through the piston. The control valve provides a variable amount of damping by regulating damper fluid flow between the extension chamber and the compression chamber of the damper during extension and compression strokes. Pressure regulation across the piston is controlled through a flow path as determined by the control valve. The damping force of the damper varies depending upon the loading conditions of the vehicle. The control valve is air pressure actuated to adjust the damping force and control the flow of fluid in the flow path. The piston and rod assembly include unique features such as a seal plate design, and spring retainer that aid in the efficient and reliable assembly in a commercial production setting.

Abstract: Active control of a vehicle bumper damper is provided. A damper controller receives data from a collision data acquisition device and sends a control signal to configure an active damper based on the received data. During a collision or immediately preceding a collision the vehicle bumper damper is adjusted using the damper controller mechanism that responds to real-time collision information. A vehicle including an active control system for a vehicle bumper is provided. The vehicle includes a collision data acquisition device, a damper controller coupled to the collision data acquisition device, and an active damper coupled to the damper controller. The damper controller receives data from the collision data acquisition device and sends a control signal to configure the active damper based on the received data.

Abstract: An absolute angular position sensor assembly for use with a vehicle steering column that generally includes a digitally encoded disk, an optical output device and an optical input device. The encoded disk has numerous circumferentially extending, concentric data tracks; some of these tracks include cutouts representing absolute angular position bits and some include cutouts representing error correcting bits. Preferably, the absolute angular position bits are arranged according to a grey-code type arrangement, while the error correction bits include Reed-Solomon error detecting and correcting information. The optical output device shines light against the encoded disk such that a pattern, generally determined by the cutouts, is formed on the optical input device. The optical input device, in turn, utilizes that pattern to generate an angular position signal representative of the absolute angular position of the steering wheel and having error correction information.

Abstract: A magnetorheological fluid formulation comprising magnetizable particles dispersed in a non-aqueous, glycol-based liquid vehicle thickened effectively by either a fully treated fumed silica or an organoclay. The surface treated fumed silica is fully treated with a treatment molecule having a molecular weight of at least about 200. The organoclay comprises sepiolite and/or palygorskite. The glycol-based fluid advantageously consists essentially of propylene glycol and optionally ethylene glycol.

Abstract: Disclosed herein is a method and system for initializing a rotating device such as an electronically commutated electric machine. The system comprises: an electric machine; a position sensor subsystem operatively connected to the electric machine configured to measure a position and transmit a position signal to a controller. The controller executes a method initializing position for the electric machine, the method comprising: establishing a sensor subsystem datum indicative of a measurement reference point for a sensor subsystem; obtaining a calibration value corresponding to a distance to a selected magnetic reference position for the electric machine, relative to the sensor subsystem datum; and measuring a position and calculating a position delta relative to an initial reference. The method also includes: estimating an offset from the sensor subsystem datum to an initial reference; determining an absolute position estimate of the electric machine relative to the magnetic reference position.

Abstract: Shaped, contoured crushable structural members and methods for making the same are described. The contoured structural members comprise composite or metal materials sandwiching a support or stabilizing structure. The structural members are made crushable by incorporating an initiator into the structural members. The structural member crushes at the location of the initiator by absorbing the energy of an exerting load. The shaped structure is provided by bending the generally straight shape of the structural member. With a shaped, contoured, crushable, and generally non-flat structure, applications and uses for the structural members of the present invention are nearly limitless.

Abstract: A hand wheel actuator for a steer-by-wire steering system having a steering feel that meets drivers' expectations is provided with a housing having an aperture, a steering shaft extending through the aperture and rotatably supported by the housing, an electric motor, a position sensor and torque sensor, and a mechanical steering feel enhancement device. The mechanical steering feel enhancement device is attached to the housing and provides a positive stop function, a return-to-center function, and/or a friction/weight function. The mechanical steering feel enhancement device is in mechanical communication with the steering shaft and may exist as a separate unitary subassembly prior to being installed on the housing. The electric motor has an output shaft that is in mechanical communication with the steering shaft for imparting a torque to the steering shaft.

Abstract: An electric power assist steering system is controlled by sensing torque in a steering shaft at a point along said steering shaft between a hand wheel and a mechanical connection to an electric motor, wherein the sensing includes sensing a magnetic field direction and intensity.

Abstract: A durable magnetorheological fluid for use in a vibration dampening device is described. The MR fluid includes magnetizable particles having a particle size less than about 25 microns, a carrier fluid, a thixotropic agent, and a lubricative additive. The carrier fluid includes a polyalphaolefin and a plasticizer. The lubricative additive has a particle size equal to or less than 10 microns such that the ability of the additive to lubricate the magnetizable particles is optimized. The lubricative additive includes at least one of polytetrafluoroethylene, graphite, and molybdenum disulfide.

Abstract: A steer-by-wire handwheel actuator in a vehicle is presented. The handwheel actuator comprises a driver input shaft; a gear train connected to the driver input shaft; a motor responsive to control signals from a controller and variably geared to the gear train; a electro-mechanical brake responsive to the control signals from the controller and geared to one of the driver input shaft and the gear train; and a stop mechanism attached to a housing and coupled to one of the electro-mechanical brake and the gear train.

Abstract: A ball-nut assembly includes a ball nut and a crossover member. The ball nut incudes a radial through slot and an outer surface. The outer surface has a first portion, has a ledge radially recessed from the first portion and at least partially bounding the through slot, and has an undercut wall connecting the ledge and the first portion. The crossover member has a flange and a crossover-grooved portion. A method for making a ball-nut assembly positions the crossover member from outside the ball nut to have the flange supported by the ledge and the crossover-grooved portion located in the through slot. The method also deforms the flange creating a staked portion of the flange which contacts the undercut wall of the outer surface of the ball nut.

Abstract: A ball nut and return liner assembly includes a ball nut having a tubular body having a longitudinal axis, the tubular body having an inner surface and an outer surface, a plurality of arcuate grooves defined on the inner surface. A longitudinal slot is defined on the inner surface parallel to the longitudinal axis, interrupting the plurality of arcuate grooves, and forming a pocket for receiving the return liner, the longitudinal slot having first curved walls. The return liner is provided with a first surface having a plurality of S-shaped return grooves extending from the first side to the second side to cooperate with the plurality of arcuate grooves in the ball nut. The return liner is further provided with a second surface for fitting within the longitudinal slot within the ball nut, the second surface having second curved walls.

Abstract: A composite steering column jacket including a pair of composite sections joined along a flange area. The composite sections include outer and inner walls spaced coaxially from each other, that mate at first and second flanges. A cavity is defined by the space between the inner and outer walls and is filled with a foam material that is disposed within. The composite steering column jacket has an increased stiffness and reduced weight when compared to conventional metal steering column jackets.

Abstract: An improved hydraulically assisted braking and steering system of a vehicle having a hydraulic pump communicating with a hydraulic steering assist device and including a hydraulic brake assist device coupled in series between the pump and the steering assist device includes the provision of a flow splitter which operates to reduce the interdependence of the hydraulic brake and steering assist devices on the flow of fluid from the pump. The flow splitter communicates with the outlet of the pump and the inlet of the brake assist device and is operative when the back pressure from the brake assist device exceeds a predetermined control value to divert a fraction of the flow of fluid around the brake assist device directly to the steering assist device, thereby providing sufficient flow to operate both the brake and steering assist devices within their normal design limits, rather than having the brake assist device starve the steering assist device when under heavy load.

Abstract: The subject invention provides a magnetorheological (MR) composition having improved resistance to oxidation and increased dispersability in a carrier fluid. The composition includes a plurality of metal particles and a surfactant including a hydrocarbon with at least one of a hydroxyl, a carbonyl, and an amine group bonded to the hydrocarbon for reacting with the metal particles. The surfactant is present in an amount such that from about 1% to about 20% of the amount of the surfactant is adsorbed to the metal particles. The surfactant is reacted with the metal particles such that about 75% to about 100% of a maximum amount of the surfactant adsorbs to the metal particles for improving the resistance of the metal particles to oxidation and for increasing the dispersability of the magnetorheological composition in the carrier fluid. The MR composition according to the subject invention is utilized in a magnetorheological (MR) fluid.

Abstract: A constant velocity joint includes outer and inner races with mating part-spherical surfaces in which a single functional set of ball grooves are formed bearing a single torque-transmitting ball which is urged under an applied torque load toward one axial end of the joint. A retainer is carried by one of the two races or the shaft to which they are connected and acts on the ball to maintain the ball within the grooves during all angles of the joint.

Abstract: A first vehicle wheel bearing has a monolithic shaft including two inner races and has a monolithic outer race assembly. A second bearing has a monolithic shaft including a shoulder and at least one inner race, wherein the shaft is positioned within the bore of a vehicle knuckle member with the shoulder abutting the knuckle. A third bearing has an end cap attached to an outer race assembly and covering the bearing-cavity outboard opening. A fourth bearing has an inboard seal covering the bearing-cavity inboard opening and extending outside the cavity to define a target ring for an ABS speed sensor. A fifth bearing has an ABS speed sensor positioned in the bearing cavity and attached to a shaft proximate the outboard opening and has a target ring positioned in the bearing cavity and attached to the outer race assembly.

Abstract: A method for implementing directional control of a motor vehicle is disclosed. In an exemplary embodiment, the method includes determining whether a failure of a primary steering system of the motor vehicle exists. If a failure of the primary steering system exists, then a yaw moment is created on the vehicle by causing a differential longitudinal force to be applied with respect to a first wheel on one side of the vehicle and a second wheel on an opposite side of the vehicle, thereby causing the vehicle to turn in a commanded direction.