Abstract: An outer cover layer, for a panel that defines a rupturable deployment door of an air bag deployment system in an automotive vehicle, is formed with an invisible pre-weakened tear seam prior to being overlaid onto the panel. The outer cover layer material is pre-weakened along a defined door opening pattern by a single step impression of a variable depth scoring knife into the under surface of cover layer material. The scoring knife contains a series of cutting edges of varying depth and length along its length that coincides with the seam pattern. The scoring may be performed during the conveyance of the cover layer material by making a single impression of the scoring knife into the lower surface thereof so that the maximum cut depth does not penetrate the outer surface of the material.

Abstract: A tunable mass damper for use in a vehicle steering system in which a rack and pinion gearing subsystem would otherwise transfer resonant vibrations to the vehicle steering wheel. The mass damper element is a generally cylindrical mass supported and suspended around the shaft extending from the pinion gear by several cantilevered spring elements. The mass damper is tunable by modifying the size of the mass or the size or material or length of the springs so that the damper's resonant frequency for axial oscillation matches the resonant vibrations present at the steering shaft extending from the pinion gear.

Abstract: An integrated air bag support structure that includes a support base for attachment to the rear side of a substrate. The support base is configured to surround a door support panel and both are configured for attachment to the rear side of a substrate in an area that is pre-weakened to define an air bag deployment door in a vehicle instrument panel or a steering wheel air bag module. The upper surfaces of the support base and door support panel are attached to the rear surface of a substrate and a test tab extends from the base that is attached to the rear surface of the substrate in the same manner as the support base and the door support panel. The test tab has an unattached extension portion for the purpose of gripping and pulling to sample test that the attachment of the test tab without affecting the attachment of the support panel.

Abstract: Method and control system for adaptively controlling an automotive HVAC (heating, ventilation and air conditioning) system using a blending or combination of strategies each of which is optimized towards a particular goal in controlling the HVAC system. The blending is based on a strategy alteration signal which, in turn, is based on information provided by the occupant of the vehicle in combination with existing information available to an EATC (Electronic Automatic Temperature Control) system to adapt the optimized strategies to the occupant's preferences. The method and control system allow the response of the climate control system to change according to indications of occupant's preferences and/or detection of special conditions. The method and system provide an adaptive control strategy which utilizes pattern recognition and preference determination to blend the various strategies which include a base thermal comfort strategy.

Abstract: Method and control system for controlling an automotive HVAC (heating, ventilation and air conditioning) system using fuzzy logic to increase steady state comfort of an occupant in a vehicle and to decrease the time needed to reach steady state comfort. The control system responds to signals generated by various climate control sensors, including a humidity sensor, to produce a desired humidity, temperature and flow. Fuzzy logic calculations are performed based on fuzzy rules and membership functions to provide nonlinear compensation and to allow the control to be expressed in the same heuristic terms that an occupant could use in describing the level of comfort.

Abstract: Method and control system for economically controlling an automotive HVAC (heating, ventilation and air conditioning) system using fuzzy logic. The control system responds to signals generated by various climate control sensors including a humidity sensor to produce a desired vehicle air temperature and air flow. Fuzzy logic calculations are performed based on fuzzy rules and membership functions to provide nonlinear compensation for setting the rate of clutch cycling in a CCOT system or refrigerant metering in a TXV system.

Abstract: A fuel delivery system which includes a source of pressurized fuel (18-22), at least one fuel injector (14) in fluid communication with the source (18-22), a pressure regulator (34) for delivering the pressurized fuel to the fuel injector (14), a pressure sensor (40) for providing an indication of pressure at the fuel injector (14), a controller (42) responsive to the pressure sensor (40) for providing a pressure release signal, and a pressure release system (44) responsive to the pressure relief signal for diverting a portion of the pressurized fuel from the fuel injector (14).

Abstract: Circular reference features such as drilled holes are located in an area of a part such as a cylinder head, the surface of which is laser scanned to obtain scan data. The scan data provides height values of the part. Differences in height values are used to determine the points on scan lines which are boundary points of the circular holes. A first algorithm is used to estimate the contour and radius of each hole. A second algorithm provides a correction factor for the radius of each hole. The circular reference features are used for registering the part relative to a reference datum. Methods are provided that allow the accurate determination of the location of such reference features to within 0.01 mm. (0.0004 in.) from the scan data. The method may be utilized to create modified scan data to machine the part. The method may be utilized iteratively from different views of the part to obtain data which represents the part.

Abstract: Provided is a method and circuit for measuring the leakage path resistance in an electric vehicle having an isolated high voltage traction battery and an auxiliary battery grounded to the vehicle. The circuit operates by periodically applying a selected excitation signal and comparing the voltage induced on an energy storage element by the excitation signal to a selected reference voltage during a selected time period. An alternate embodiment of the present invention provides a circuit which operates by applying a periodic excitation signal and comparing the phase shift of the voltage induced on an energy storage element to the phase shift of a signal derived from the excitation signal.

Abstract: Method and apparatus for monitoring the operation of a plurality of electrical loads in an automotive vehicle with a single current sensor. The current sensor detects the change in the total output current associated with the electrical loads and generates an output signal based on the current change. The apparatus also includes a controller which activates each electrical load at a given time to obtain a like plurality of timing signals so that each electrical load receives a portion of the output current. The controller processes the output signal and the timing signals to obtain a diagnostic signal related to an operating condition of at least one of the electrical loads. Finally, the controller controls an operating state of the at least one of the electrical loads based on the diagnostic signal.

Abstract: An on-board oil quality sensor for use in an internal combustion engine formed of a pair of resisitve elements mounted on a common substrate, wherein one of the resistive elements is exposed to the oil for corrosion as the oil contaminants increase and the other resistive element is protectively sealed from the oil contaminants. Both resistive elements are exposed to the oil temperature and are suitable for monitoring by a bridge type circuit to determine the level of corrosive contaminants in the oil.

Abstract: A molded rotor assembly (20) including at least one molded fan (28), a method for making the same, and a vehicle alternator (160) using the molded rotor assembly (20) are disclosed. The rotor assembly (20) includes first and second pole pieces (24,26) aligned along a longitudinal axis (40) defining a region (122) between the pole pieces (24,26). Each pole piece (24,26) has an outboard axial face (69,71). At least one molded fan (28) is integrally molded to one of the axial outboard faces (69) of a pole piece (24). Preferably, a molded insert (22) is molded in the region (122) between the pole pieces (24,26) and is integral with the molded fan (28) to secure the molded fan (28) to the pole piece (24). Alternatively, anchoring recesses (241,245) are formed in an outboard face of a pole piece (224) with a molded fan (228) having anchoring portions (249,251) secured within the recesses (241,245) to retain the fan (228) to the outboard axial face.

Abstract: A slip ring assembly (36) adapted to mount on a rotor shaft (38) and to sealingly mount between respective seal surfaces (136,70) on a mold (134) and on a pole piece (24) during molding of a molded rotor assembly (20) is disclosed. The slip ring assembly (36) has a hub (94) supporting a pair of slip rings (102,104), a pair of terminals (96,98) and a mold shutoff ring (100) connected to the terminals (96,98). Seal surfaces (118,120) on the mold shutoff ring are adapted to sealingly mate with the respective seal surfaces on the pole piece (24) and on the mold (134) and to withstand large compressive loads being applied across the mold shutoff ring (100). The mold shutoff ring (100) prevents molten mold material from passing from the mold (134) to the slip rings (102,104) during molding of the molded rotor assembly (20).

Abstract: A molded rotor assembly (20) for a vehicle alternator and method for making the same are disclosed. The rotor assembly includes first and second pole pieces (24,26) aligned along a longitudinal axis (40), the pair of pole pieces (24,26) defining a region therebetween. A coil wire (46) is located in the region. The pole pieces (24,26) and a slip ring assembly (36) are mounted on a rotor shaft (38). The slip ring assembly (36) has a pair of slip rings (102,104) connected to a pair of terminals (96,98) which are attached to respective free ends of the coil wire (46) to form a pair of connections (126,128). A molded insert (22) is injection molded filling the region between the pole pieces (24,26) thereby encapsulating the connections (126,128) and the coil wire (96) and forming a smooth cylindrical periphery on the rotor assembly (20).

Abstract: A low voltage inhibiting circuit for use with a microcomputer in which a reset signal is applied during power-up or whenever the voltage of an unregulated source to a regulated supply drops below a predetermined threshold level. The reset signal is removed whenever the voltage from the unregulated source is restored to a value which is above a second predetermined threshold value defined as being above the first threshold value and after a predetermined period of time.

Abstract: Method and apparatus are provided, for use in a vehicle having an internal combustion engine (10) and a battery (38), for converting mechanical energy into electrical energy for charging the battery, the apparatus being disposed within the engine crankcase (22). The apparatus includes a stator (14), disposed within the engine crankcase (22), having a plurality of teeth (34). Each tooth on the stator has a coil (36) wound thereabout electrically connected to the battery (38). The apparatus also includes a crankshaft (12) disposed within the engine crankcase (22) for rotation relative to the stator (14). The crankshaft (12) includes a plurality of lobes (30.sub.1-4), which periodically move into close proximity with the stator teeth (34) upon rotation of the crankshaft, thereby inducing a current in the coils (36) for charging the battery (38).

Abstract: Provided is a method and apparatus for electrically detecting the location of bond failure and wire breakage occurring during tensile strength testing of a wire sample having first and second bond foots affixed to respective first and second support pads. The method and apparatus monitors the voltage levels of first and second electrically conductive probes. The first probe has a primary lead in electrical contact with the first support pad and a secondary lead in electrical contact with the first bond foot. Similarly, the second electrically conductive probe has a primary lead in electrical contact with the second support pad and a secondary lead in electrical contact with the second bond foot. Voltage detection circuitry is provided in electrical contact with the first and second probes for detecting the voltage level at each of the respective primary and secondary leads to generate the respective corresponding output signals.

Abstract: The operating speed of a motor vehicle alternator is controlled based on the frequency of power generated by the alternator. Since the frequency of the alternator power is representative of engine speed, the alternator is shifted between a high speed gear train for low engine speeds and a low speed gear train for high engine speeds. When shifting to the high speed gear train, it is only partially engaged for a brief initial time period to more gradually accelerate the alternator armature toward the corresponding high operating speed. Preferably, initial clutch pull-in is sensed to start the partial engagement period of the high speed gear train. The load on the alternator drive during shifts to high speed operation is further reduced by turning the alternator field current off prior to partially engaging the high speed gear train.

Abstract: An analog circuit provides selectable current control and power limiting for a connected load. A current control loop is combined with a voltage/power control loop to generate a current level signal via an output transistor to control current flow through a load. Current through a load is monitored with the current control loop maintaining current flow through the load at a selected value. If a selected power level is exceeded, the current is reduced by the voltage/power control loop. Voltage monitoring and feedback is used to control the operating power for a power level control operational amplifier and thereby maintain a selected power level. By providing multiple, voltage dependent gains in the voltage feedback loop, a piecewise linear approximation of a desired power curve can be obtained.

Abstract: An electrical generator (10) having particular utility as a vehicle alternating generator includes a planetary gear set (32) for providing counter rotation of a pair of fields (80,82) with respect to a coil (60) so as to provide high power output even at relatively low speeds of driving without providing excessive rotational speed at high speeds of driving. In one embodiment, the planetary gear set (32) includes a ring gear (36), a sun gear (44), and a planet carrier (50) whose planet gears (52) rotate about associated axes parallel to the rotational axis A about which the planetary gear set operates. In another embodiment, the planetary gear set has a bevel gear construction including first and second bevel gears (36',44') rotatable about the rotational axis of the planetary gear set and meshed with bevel type planet gears (52') of the planet carrier (50') so that the two field (80',82') have counter rotation with respect to each other at the same rotational speed.