Abstract: A high temperature electrical connector suitable for use in a high temperature gas sensor. The electrical connector incorporates a ceramic connector body having a pair of opposing ceramic body portions which each house a plurality of conductive terminals. The body portions are in pivoting engagement and fixed in a connector body retainer which also enables their pivoting, hinged movement. The pivoting engagement permits the ceramic body portions and terminals to hinge open to receive a gas sensor with a low insertion force and a hinge closed to provide the desired contact force. The ceramic body portions may also include a taper section in a pivot portion with a taper angle that may be varied to control the pivoting, hinged movement of the electrical connector.

Abstract: A sealed fuel level sensor for a fuel tank is provided. The sealed fuel level sensor includes a frame having a cavity therein. The sealed fuel level sensor further includes a variable resistor disposed in the cavity and operatively supported by the frame. The sealed fuel level sensor further includes a wiper disposed in the cavity for rotation relative to the variable resistor and for contacting the variable resistor. The sealed fuel level sensor further includes a cover connected to the frame to enclose the cavity. The cover includes an aperture extending therethrough. The sealed fuel level sensor further includes a bushing disposed within the aperture. The bushing having a body portion and a lip seal portion disposed on the body portion. The lip seal portion and the body portion having a bore therein. The sealed fuel level sensor further includes a float arm having an end extending through the aperture of the cover and the bore of the bushing and connected to the wiper.

Abstract: In a method for forming an injection molded manifold, the portion of the mold that forms a septum is modified to provide a substantially thicker septum, preferably about 8.5 mm or greater. In the molding operation, one or more removable slides are inserted through this region of the mold, each slide being preferably about 2.5 mm thick and about 30 mm wide. The septum is cast around the slides which are then withdrawn from the septum after the polymer composite is set, resulting in a septum that is substantially thicker than a prior art septum, comprising first and second plates, each about 3 mm thick, and a plurality of open core voids about 2.5 mm high and about 30 mm wide between the plates. The improved septum is stiffer than a single 4 mm thick prior art septum, has a higher natural frequency, and improves suppression of engine noise.

Abstract: Systems and methods for determining a temperature of a ferroelectric sensor are provided. The ferroelectric sensor has operational characteristics defined by a polarization versus voltage hysteresis loop. In one exemplary embodiment, the method includes applying a symmetrical periodic voltage waveform to the ferroelectric sensor so as to induce the ferroelectric sensor to traverse the polarization versus voltage hysteresis loop. The method further includes monitoring voltages across the ferroelectric sensor and polarization states of the ferroelectric sensor over a first time interval to determine a first zero field polarization state and a first coercive field voltage. The method further includes determining a first temperature value indicative of the temperature of the ferroelectric sensor based on the first coercive field voltage.

Abstract: In a solid-oxide fuel cell system, the fuel cell stacks, the fuel reformer, tail gas combuster, heat exchangers, and fuel/air manifold, are contained in a “hot zone” within a thermal enclosure. A separate and larger structural enclosure surrounds the thermal enclosure, defining a “cool zone” outside the thermal enclosure for incorporation of “cool” components such as the air supply system and the electronic control system. To prevent unwanted temperature rise in the cool zone during shutdown, from residual heat escaping from the hot zone through the thermal enclosure, the structural enclosure is provided with vents through the lower and upper walls thereof to permit thermal convective circulation of air through the enclosure. The vents are baffled to prevent entry of splash and other contaminants, and the lower vent is provided with a float valve to prevent flooding of the enclosure in event of immersion of the SOFC system.

Abstract: A system and method for controlling an engine involves providing a pumping torque estimation model. The model distinguishes between pumping losses due to throttling and pumping losses due to valve flow losses. The model is implemented by a pair of look-up tables. The data in each look-up table reflect Pumping Mean Effective Pressure (PMEP), which is indicative of the pumping work. The throttling loss table provides a first contribution based on an engine delta pressure. The valve flow loss table provides a second contribution based on an engine speed and a relative airload. The first and second contributions are summed and then multiplied by a predetermined factor to convert the pumping work (PMEP) into pumping torque. The model will work with naturally-aspirated, turbo-charged and super-charged air induction configurations and provides improved altitude compensation. The model will also work with both spark-ignition and compression-ignition configurations.

Abstract: A computer implemented system for engine misfire detection employs a crankshaft-originated speed signal that includes normal variability due to target wheel tooth error and the like. A Discrete Fourier Transform (DFT) is performed on the speed signal to convert it into a frequency-domain raw misfire detection metric. The system is configured to normalize the raw misfire detection metric using a non-misfire metric that is obtained by and corresponds to non-misfire operation of an internal combustion engine. A resulting normalized misfire detection metric has such normal variations removed leaving variations attributable to misfire. The system detects a misfire when the normalized misfire detection metric exceeds a predetermined threshold and is bounded by a predetermined phase angle region. The system detects both continuous misfire as well as intermittent misfire. The system also detects single cylinder misfire and multiple cylinder misfire.

Abstract: A method and apparatus for overmolding a plastic shroud onto a bobbin including the step of providing a protrusion ring on the surface of the bobbin surrounding each standoff between the bobbin and a mold wall and extending outwards from the surface of the bobbin. A plurality of standoffs and protrusion rings is presently preferred. The protrusion rings are small relative to the standoffs, have low thermal mass, and thus are readily melted by the injected molten plastic, causing interstitching between the bobbin material and the overmolding material. The interstitching creates a highly effective hermetic seal against moisture leakage along the surface of the bobbin away from the standoff site. Perfect melting of the standoffs is no longer required, and standoffs can be designed to assure proper positioning of the bobbin during the complete overmolding process.

Abstract: A system and method for controlling a compressor recirculation valve involves establishing a compressor surge flow threshold expressed in terms of a compressor corrected volume air flow rate. A torque-based engine management system computes a desired mass air flow rate in accordance with a torque request and other operating/predetermined data. The desired mass air flow rate is converted into a desired, corrected volume air flow rate, which is then compared to the compressor surge flow threshold. The controller is configured to open the valve when the desired corrected volume air flow rate is less than the compressor surge flow threshold. A hysteresis function is implemented by providing a surge flow hysteresis threshold that is offset from and greater than the initial compressor surge flow threshold. The controller is configured to close the recirculation valve when the desired corrected volume air flow rate becomes greater than the surge flow hysteresis threshold.

Abstract: An electronic throttle control system and method for detecting a throttle plate obstruction when the ignition key is on and the engine is either not running or running, and for clearing the throttle plate obstruction before a fault setting is set by the ECU.

Abstract: An anti-coking bushing assembly for sealing a pintle shaft of an EGR control valve, comprising a bushing carrier disposed in the valve body and supportive of close-fitting pintle shaft bushing liners formed of a polyimide such as Vespel. The bushing carrier and bushing liners are installed into a carbon shield extending into the exhaust flow space within the valve. Within the carbon shield, between the gas flow space and the bushing carrier, is a ring seal on the pintle shaft and a gas expansion chamber to cool exhaust gas escaping along the pintle shaft, allowing contaminants in the exhaust gas to precipitate in the gas expansion chamber. The carbon shield, ring seal, bushing carrier, and bushing liners are conveniently pre-assembled as an anti-coking bushing assembly for subsequent installation into a valve body during final valve assembly.

Abstract: Disclosed is a curable composition having a low CTE. In one embodiment, a curable composition is disclosed that comprises (i) a binder comprising at least one epoxy compound of the structure: X—((CH2)m—(N)—((CH2)n-(Z))2)p wherein X is an aromatic ring or a six membered cycloaliphatic ring, m is from about 0 to about 2, n is from about 1 to about 3, Z is an epoxy group of empirical formula: C2H3O, p is a number from about 2 to about 3, and (ii) a cross-linking agent comprising at least one polyamine. This curable composition is characterized by a CTE of no more than 60 ppm/° C. when cured for a time of from about 20 to about 60 minutes at temperature of from about 100 to 240° C. Also disclosed are methods of making integrated circuits and integrated circuits made there from, especially flip chips.

Abstract: A system for discrimination of spurious crankshaft encoder signals. A position encoder connected to an engine crankshaft sends a pulsed signal indicative of crankshaft rotational performance to an engine controller. The controller is programmed to trigger an interrupt service routine (ISR) on every falling or rising edge of each pulse. The ISR calculates and stores the period of each pulse and the period of the previous pulse and calculates the rotational speed and instantaneous acceleration or deceleration of the engine at all times. The controller is further programmed with realistic engine acceleration and deceleration limits and recognizes a next signal only within a time window corresponding to those limits and the engine speed. Signals arriving outside the calculated time window are considered spurious and are rejected. The system improves engine performance by preventing loss of synchronization between spark and fuel injection and piston and valve timing.

Abstract: Disclosed herein are fuel reformers utilizing dew point plateau process control and methods of using the same. In one embodiment the fuel reformer can comprise a mixing zone capable of receiving a fuel mixture, a reforming zone disposed downstream from the mixing zone, an exhaust zone disposed downstream from the in operable communication with the reforming zone, a temperature sensor, and a system controller connected in operable communication with the temperature sensor. The temperature sensor can be disposed in fluid communication with the exhaust zone and capable of measuring a gas temperature of the gas stream, or in fluid communication with the mixing zone and capable of measuring a mixture temperature of the fuel mixture. The system controller can be capable of adjusting an operating variable of the fuel reformer and determining a dew point plateau temperature.

Abstract: A motor vehicle exhaust aftertreatment system includes an exhaust conduit that includes a NOx adsorber, a particulate filter, a reformer for generating reformate containing hydrogen and carbon monoxide from a fuel source, a reformate conduit, and an oxygen sensor. In response to a pressure drop through the particulate filter attaining a threshold value, reformate is introduced under selected controlled flow conditions into the exhaust conduit and caused to undergo combustion. The resulting exotherm maintains the temperature within the particulate filter within a selected range that is effective to cause oxidation and removal of soot from the particulate filter. Introduction of reformate into the exhaust conduit is discontinued when the pressure drop through the particulate filter is decreased to a selected value.

Abstract: A motor control circuit for supplying power to a DC motor which drives a mechanism having a driven shaft, the control circuit having a parallel combination of a capacitor and switch in series with the DC motor. When the movement of the driven shaft is obstructed, the motor driver and the switch are synchronized in a manner to first charge the capacitor and then to reverse the voltage generated by the motor driver to momentarily double the voltage applied to the DC motor so that the increased torque of the DC motor is able to overcome the obstruction. The mechanism having a shaft driven by the DC motor may be, for example, an ETC valve or a window regulator.

Abstract: A method for compensating fuel injection timing when a torque signal or throttle command indicates that a transient operation is about to transpire. The control adjusts the fuel injection timing in advance of the transient operation to prevent loss of torque due to change in combustion phase position. During engine operation in pre-mix mode of combustion, rapid changes in fueling quantity can affect the combustion angle as well as the temperature in the combustion chamber, causing late or early combustion phasing. The present invention anticipates a change in combustion phasing by sensing a change in demanded fueling rate. The Engine Control Module (ECM) then applies a nest of algorithms to advance fuel injection timing during acceleration or to shorten ignition delay for deceleration by retarding fuel injection timing. As the engine returns to steady state operation, the compensation in injection timing is progressively reduced to zero.

Abstract: An evaporative emissions control canister for adsorbing fuel vapors from a fuel tank on a marine vessel. The canister comprises a polymeric extruded housing that may be formed to any desired length or cut from extruded stock. Identical end caps having tubing connectors are bonded to opposite ends of the housing, defining an inlet and an outlet. Marine-grade pelletized activated carbon is disposed within the housing between porous slidable plates that are spring loaded against the end caps to pack the carbon tightly against the housing walls. Mounting brackets at each end are rotatably attached to the end caps so that opposite ends of the assembly may be attached to different surfaces of the vessel's hull, thus relieving stress which might be introduced into the assembly. Preferably, the assembly is wrapped in a fire retardant material.

Abstract: A sensing system, including: a sensing assembly, the sensing assembly having: a trim resistor; and a controller removably secured to the sensing assembly, the controller being configured to determine a resistance value of the trim resistor; a database in operable communication with the controller, the database having a plurality of resistance values, each identifying a pair of compensation values; a microprocessor receiving the resistance value of the trim resistor, a first signal and a second signal, the resistance value of the trim resistor being used to define a selected pair of compensation values from the database, one of the selected pair of compensation values is used to adjust the first signal and the other one of the selected pair of compensation values is used to adjust the second signal.

Abstract: An exhaust emission control system that provides on-board ammonia generation includes a valve disposed upstream of the LNT and SCR catalyst that operates to selectively control the flow of engine exhaust gas to an LNT and/or an SCR catalyst; while reformate fuel is being conveyed from a reformer to the LNT, the valve operates to cause the exhaust gas to bypass the LNT and flow directly to the SCR catalyst. The exhaust emission control system further includes a controller provided with an algorithm that monitors engine operating conditions and exhaust gas conditions, estimates the cumulative amount of exhaust gas created by the engine and the amount of NOx stored in the LNT, and calculates the amount of NOx required to be converted to NH3.