Abstract: A method and apparatus for spin forming a portion of a workpiece includes at least two rollers rotatable about a spin axis. Each one of the rollers is axially and radially offset from the others. An axial drive mechanism reciprocates the rollers or workpiece to causes the first roller and then the second roller to sequentially engage the workpiece. A higher reduction ratio is achieved which enables improved efficiency. The present invention reduces floor space requirements as the forming operation may be completed on a single machine.

Abstract: Disclosed herein are methods for operating a reformer and for operating a vehicle. In one embodiment, the method for operating the reformer comprises: introducing an oxidant and fuel to a reformer at greater than or equal to about 25,000/hr space velocity; combusting the oxidant and the fuel the reformer to produce a combustion gas, wherein the reformer comprises a reformer substrate comprising a reformer catalyst and having a thermal conductivity of greater than or equal to about 35 W/m° K; extinguishing the combustion; and introducing additional fuel and oxidant to the reformer at an air to fuel weight ratio appropriate for reforming. A method of using the reformate produced to reduce cold start emissions and/or regenerate an exhaust control device is also disclosed.

Abstract: A vane-type throttle valve assembly including a body having a passage therethrough and a pivotable shaft transverse of the passage and supporting a vane for variably restricting the flow of material through the passage. The shaft is disposed in opposing bores in the valve body. Each bore includes an access slot. The valve is assembled by inserting an integrated shaft and vane into the passage, engaging the ends of the shaft into the access slots, and translating the shaft ends in the access slots until the ends of the shaft are positioned in the bores. The shaft is retained in the bores by bushings inserted from outside the valve body. In a currently preferred embodiment, the access slots are formed over an angle from an axis of the bores, and the shaft ends are entered into the bores by rotating the shaft and vane about the passage axis.

Abstract: An integrated multi-functional catalyst system includes a diesel particulate filter having an inlet side for receiving flow and an opposite outlet side, a substrate in the diesel particulate filter having an interior wall surface and an exterior wall surface, a first washcoat layer applied to the interior wall surface and adjacent the inlet side, and a second washcoat layer applied to the exterior wall surface and adjacent the outlet side, wherein flow distribution through the substrate is dispersed for minimizing back pressure. The diesel particulate filter may be one of a plurality of honeycomb cells.

Abstract: A default value of transmission input speed in a motor vehicle powertrain having an automatic-shift multi-gear ratio power transmission is continuously updated based on a measured value of the input speed and other reliable speed data including transmission output speed and engine speed. The default value is substituted for the measured input speed when a malfunction of the input speed sensor is detected, and transitions back to the measured input speed when the input speed sensor malfunction is no longer present.

Abstract: A diesel fuel delivery system that maintains optimum fuel delivery to the engine despite the presence of an ice blockage at the fuel strainer. Ice formation in diesel fuel can cause fuel blockage at the fuel strainer and generate high vacuum conditions as the engine tries to draw fuel from the tank. A normally closed bypass valve automatically opens in response to an engine vacuum condition higher than normal engine vacuum levels. Upon the bypass valve opening, fuel is drawn through an auxiliary inlet port and line located above the ice formation in the tank.

Abstract: A hydrocarbon emissions scrubber for use in an evaporative emissions control system of a motor vehicle includes a scrubber element having an elongate body. The body defines a plurality of passageways for the flow of fluid therethrough. The plurality of passageways are one of coated with or constructed of a sorbent material. The sorbent material is adsorptive of hydrocarbons.

Abstract: An electrical connector for use in forming a wire-wrapped welded terminal connection. The connector is formed by stamping and folding from a sheet of metal stock to include an integral sleeve element attached by a strap. During assembly of the connection prior to welding, the terminal is wrapped with wire as in the prior art and then the strap is folded to position the integral sleeve element correctly about the wrappings to form a weldable assembly functionally identical with the prior art sleeved assembly. Because the sleeve element is formed integrally with the connector and attached by a foldable strap, the element is automatically positioned correctly and is held in place by the strap during welding.

Abstract: A battery assembly is designed to include a plurality of cells positioned parallel to each other. A frame including end supports position the cells appropriately. Each of the cells includes a first terminal and a second terminal. Two buses are positioned over all of the first terminals and all of the second terminals. Each of the buses includes slots allowing the terminals to extend therethrough. Once through, the terminals are bent over the bus bar. A slide is then positioned over the terminals protecting the terminals and maintaining the terminals in electrical contact with each other. This battery assembly allows more than three cells to be connected to each other and is versatile enough to allow the removal of certain cells to enhance the airflow through the battery assembly.

Abstract: An internal combustion engine is supplied with reformate from a hydrocarbon reformer at engine start-up and during engine warm-up. The reformate fuel mixture is fuel-lean at start-up to ensure that all the fuel is burned while the exhaust converter is thermally non-functional. Shortly after start-up, the mixture is changed to be fuel-rich, providing unburned reformate fuel in the exhaust stream. During start-up and warm-up, the output of an air pump is controllably divided between the reformer (primary air) and the engine exhaust system (secondary air). Unburned reformate from the engine and secondary air from the air pump ignite and thereby rapidly heat the converter. Gasoline or diesel fueling of the engine by fuel injection is preferably delayed until the engine and the converter both reach operating temperatures, whereupon the engine is fueled by fuel injection and further reforming is terminated.

Abstract: A control system and method to monitor an intake air temperature sensing circuit for an internal combustion engine is shown. The electronic controller is connected to the intake air temperature sensing circuit, coolant temperature sensor, and a plurality of other engine sensors. The controller determines whether the measured intake air temperature changes in response to a change in actual intake air temperature, based upon the engine operating conditions and the measured intake air temperature. The controller determines whether the measured intake air temperature is representative of actual intake air temperature, based upon the measured intake air temperature, the coolant temperature, and at least one engine operating condition. The invention is an element of an on-board diagnostic system, typically related to vehicle emissions.

Abstract: A hydraulic valve lifter including venting means to assure venting of air through the lifter and filling thereof with oil during pre-start filling of the engine oil galleries after engine assembly. Patterning of a hemispherical pushrod seat surface, and/or patterning of either or both of the mating surfaces of a pushrod seat and a piston, permits air purged from the engine through a pushrod to be vented through the lifter. Such means may be temporary or permanent and may include coatings of the surfaces with materials that are destroyed by engine action after starting. Permanent means may include surface grooves in the mating surfaces and/or small-diameter passages between the hemispherical seat surface and the cylindrical outer surface of the pushrod seat. Venting means in accordance with the invention is useful for both valve-deactivating and non-valve-deactivating valve lifters.

Abstract: A process for controlling an exhaust system can comprise flowing exhaust gas from the engine past a first oxygen sensor, through a NOx adsorber, past a second oxygen sensor, through a catalyst and past a third oxygen sensor, wherein the first oxygen sensor, the second oxygen sensor, and the third oxygen sensor, are in operable communication with an electronic control module, and using a switching delay between the first oxygen sensor and the second oxygen sensor to determine a NOx value, wherein the NOx value is selected from the group consisting of a NOx regeneration time, a stored NOx amount, a NOx storage efficiency, and combinations comprising at least one of the foregoing NOx values. A desulfurization process can be initiated when the NOx value is less than or equal to a first selected value. During the desulfurization process, when the third oxygen sensor signals a condition rich of stoichiometry, oxygen can be provided to the catalyst.

Abstract: Galvanomagnetic sensor array system and method for providing data interface to a basic sensor array are provided. The sensor system includes an array of galvanomagnetic elements, and a processor coupled to receive each output signal from the array of galvanomagnetic elements. The processor and array of galvanomagnetic elements are integrated in a single semiconductor die.

Abstract: A catalyst for preferentially reducing carbon monoxide in a hydrogen stream. The catalyst is formed from a chemical composition including a hexaaluminate, a metal hydroxide and a precious metal. The composition may be disposed on a support or may be extruded or cast into or onto a support. Incorporation of hexaaluminates allows inclusion of metal hydroxides that flux the active precious metal surface at higher temperatures than can aluminum oxide-based catalytic compositions, thereby enhancing resistance of the catalyst and monolithic support and increasing the durability and thermal range of the PROX catalyst. An additional advantage is that lesser amounts of precious metal oxides need be deposited onto the hexaaluminate, while retaining activity similar to aluminum oxide compositions.

Abstract: A system for determining the angular position of a rotating element such as an engine crankshaft. An encoder wheel is divided into a plurality of equal-angle segments, each comprising a peripheral tooth extending radially over a central angle representing an angular percentage of each segment. The total angle in each segment is a tooth dwell angle and a gap dwell angle. The ratio of the tooth dwell angle to the total segment angle is the duty cycle. A prime segment is given a first tooth dwell angle. Each segment has a unique tooth dwell angle. As the wheel rotates, a sensor begins timing at a first tooth rise and determines the time to the first tooth fall and the time to the second tooth rise. Since each duty cycle is unique, for a wheel having 45 degree segments the system can determine the segment being interrogated within 90 rotational degrees.

Abstract: A deactivation valve lifter includes a lifter body. The lifter body has a first end configured for engaging a cam of an engine and at least one annular pin chamber. A pin housing includes a pin housing bottom. The pin housing bottom defines at least one pin stop aperture and a radially directed pin bore. A deactivation pin assembly is disposed within the pin bore and includes pin members. The pin housing is concentrically disposed within the lifter body. A portion of each pin member may be disposed within the annular pin chamber to thereby selectively couple and decouple the lifter body to the pin housing. A drain aperture defined by the pin housing bottom extends from the pin bore to an outside surface of the pin housing. A stop pin is disposed in the at least one pin stop aperture for limiting the inward motion of the pin members.

Abstract: A default value of transmission output speed in a motor vehicle powertrain having an automatic-shift multi-gear ratio power transmission is continuously updated based on a measured value of the output speed and other reliable speed data including transmission input speed and vehicle speed. The default value is substituted for the measured output speed when a malfunction of the output speed sensor is detected, and transitions back to the measured output speed when the output speed sensor malfunction is no longer present.

Abstract: A thermoplastic carrier sheet is die-cut to have a size and shape matching that of a PEM bipolar plate. A plurality of holes are punched in the carrier sheet in the pattern of gasket beading to be formed subsequently. In a mold, liquid gasket resin fills the mold on both sides of the carrier sheet to form the gasket, flowing through the holes in the sheet and thereby causing the gasket to become mechanically attached to the sheet. A carrier element having a flange portion substantially identical with the outer profile of the bipolar plates is laminated to the sheet edge. During assembly of a fuel cell, the carrier element automatically positions the gasket correctly on the plate and prevents the gasket from twisting or shifting. In a currently preferred embodiment, a membrane electrode assembly is attached within an appropriate opening in the carrier sheet.

Abstract: An exhaust system can comprise a NOx adsorber, a reformer disposed upstream of a NOx adsorber and in fluid communication with a fuel source, a first valve for controlling the introduction of the fluid to an exhaust conduit; and a particulate filter disposed upstream and in fluid communication with the NOx adsorber and downstream an in fluid communication with the reformer such that the first valve controls introduction of fluid to the exhaust conduit upstream of the particulate filter. The reformer can be designed to generate a fluid comprising sufficient thermal energy, hydrogen, and carbon monoxide. Optionally, the particulate filter can be designed to be regenerated by the thermal energy and to adsorb a sufficient amount of the thermal energy to reduce the temperature of a gas stream comprising the fluid from a first temperature of about 600° C. to about 1,000° C. to a second temperature of less than or equal to about 500° C.