Abstract: A fuel system for a vehicle having a generator includes a fuel reservoir which taps into the main fuel tank. A solenoid pump pumps fuel from the main fuel tank to the reservoir which in turn feeds fuel to the generator. A fuel shut-off valve is provided in the reservoir to prevent overfilling of the reservoir without the need for a fuel level sensor or pump control electronics. The valve is operable to close upon the fuel level reaching the closing height of the valve. Closing of the valve causes the pump to idle, thus stopping the flow of fuel into the reservoir. Fuel is still allowed to flow from the reservoir to the generator, thus allowing uninterrupted running of the generator. When the fuel level in the reservoir dips below the closing height of the valve, the valve opens and the pump again starts pumping fuel into the reservoir.

Abstract: A non-contact linear absolute position sensor includes a first magnetic encoder having n+1 pole pairs, a second magnetic encoder having n pole pairs and located and aligned with the first magnetic encoder so as to cover a linear distance. The magnetic encoders are affixed to a traveling body. Two pairs of Hall Effect sensors are located near each of the first and second magnetic encoders and are configured to generate linear position signals. A processor is provided to process the linear position signals to generate an output signal indicative of a linear absolute position of the traveling body.

Abstract: A robust, low cost, compact and highly accurate rotary position sensor is disclosed for measuring the relative angular position (within a range ?180°) of a housing or stator and a rotor. The housing carries a galvanomagnetic sensing element and is adapted for fixation to a relatively fixed portion of a host system. The rotor carrying a magnet is disposed for rotation about a fixed axis with respect to the stator and is interconnected to a relatively moving portion of the host system through intermediate linkage. The magnet is juxtaposed in substantially axial alignment with the galvanomagnetic sensing element for magnetic interaction therewith. The housing defines a cavity to receive potting material for encasing the galvanomagnetic sensing element and an adjacent buffer cavity interconnected by a weir, which diverts ant excess potting material into the buffer cavity.

Abstract: In a diesel engine equipped with a catalytic HC reformer for injecting reformate into the engine exhaust stream to reductively regenerate one or more emissions control devices including but not limited to a lean nitrogen trap, a combustor is disposed in the exhaust stream downstream of the LNT, and preferably downstream of all regenerable emissions control devices, to burn any residual HC, H2, or CO in the tailpipe exhaust gases. Thus only breakthrough amounts of these species are combusted. Preferably, the combustor is operated on an appropriate schedule governed by the operating schedule of the reformer. To assure combustion when the oxygen concentration of the exhaust falls below the reformate combustion limit of approximately 6%, make-up air is ported to the combustor either by diverting a portion of the reformer system air or by diverting excess turbocharger boost air from the engine air intake system.

Abstract: A tumble control valve for an intake manifold of an engine which eliminates or substantially reduces air leakage between the bottom and sides of the valve blade through a selected rotational segment of the blade as it moves from the closed position toward the open position. The sealed area is maintained by contouring the inner cavity wall to track the arc defined by the bottom edge of the rotating blade. In other embodiments, a flexible flange or wedge-shaped element is attached to the blade to engage the inner cavity wall through the selected rotational segment. In another aspect of the invention, air flow pressure is maintained and tumble is optimized compared to rotational movement of the blade by contouring the top wall surface to track the arc defined by the rotating upper edge of the blade.

Abstract: Low range limiting malfunctions of an engine coolant temperature (ECT) sensor are diagnosed by comparing a change in the sensed temperature during engine operation with a calibrated temperature change. If the change in sensed temperature fails to exceed the calibrated temperature change, and a diagnostic for detecting a stuck ECT signal is either inconclusive or passed, a low range limiting malfunction of the sensor is indicated. If the diagnostic for detecting a stuck ECT signal is failed, the low range limiting diagnostic concludes with no report even if the change in sensed temperature fails to exceed the calibrated temperature change.

Abstract: A method for detecting fuel leaking into an oil pan containing oil which is used to lubricate an internal combustion engine utilizes a plurality of sensors. The method includes the step of measuring a plurality of parameters of the oil using each of the plurality of sensors to create measured values. A fuel leakage value is calculated incorporating each of the measured values. The method then determines when the fuel leakage value exceeds a predetermined value.

Abstract: A method of making a gas treatment device, the method includes projecting a laser line onto a side of substrate from a laser line generator angled away from a viewing source; projecting a laser dot onto the substrate from a laser dot generator located above the viewing source; verifying an alignment of the substrate with at least one of: another substrate and a housing by comparing the laser line projection on the substrate to the laser dot projection on the substrate, wherein the alignment is verified when the laser line projection and the laser dot projection are co-linear; and stuffing the substrate into the housing.

Abstract: An integrated system for air-cooling a main air blower drive motor and electronic control module in a fuel cell plant support module (PSM) disposed in an enclosure. Process air is drawn by a main blower fan into the enclosure through a filter and then is drawn from the enclosure into the blower via a first shroud surrounding the electronics process control module (ECM) and a second shroud surrounding the blower motor. The air cools these components and is thereby desirably warmed before being directed to the fuel cell assembly via an air distribution system. Thus, the PSM is constantly cooled and purged through the downstream processes, and the incoming air is constantly warmed by recovered heat from the PSM.

Abstract: In one embodiment, a method of treating a gas stream comprises: controlling an amount of the NH3 entering a catalytic unit and converting NO2 and the NH3 to N2 in the catalytic unit, wherein greater than or equal to about 60 wt % of NOx initially in the gas stream is converted to N2. In one embodiment, a gas treatment system comprises: a plasma reactor disposed downstream of an engine; a cracking catalyst disposed downstream of the engine; and a catalytic unit capable of converting NO and HC to NH3, and capable of converting NH3 and NO2 to N2.

Abstract: A gas sensor seal (40) comprising a body (122), an upper portion having a flange (124), and at least one channel (130). The flange (124) has an extension (131) that extends from the upper portion, a bend (129) which extends from the extension (131) along the body (122), and a protrusion (128) which extends from the bend (129) toward the body (122). The channel (130) extends through the body (122) from the upper portion to a lower surface (126). A method for using the gas sensor seal (40) within a sensor (10) is also provided.

Abstract: A method of operating a compression ignition engine is disclosed. The method comprises, introducing an enriching component into a combustion chamber during an intake stroke, igniting the enriching component during the compression stroke, introducing a main injection of fuel to the combustion chamber after the ignition of the enriching component, igniting the main injection of fuel, and introducing a supplemental gas to the combustion chamber after igniting the main injection of fuel.

Abstract: A brake transmission shift interlock actuator includes a bobbin that has an open end and a closed end. A plunger is slidably disposed within the bobbin and a plunger rod extends from the plunger. Moreover, a primary plate is installed within the open end of the bobbin. The plunger is movable between an unlocked position, wherein the plunger rod does not extend through the primary plate and a locked position, wherein a first end of the plunger rod extends through a bore formed by the primary plate. Further, a magnetic force of attraction between the plunger and the primary plate diminishes as the plunger approaches the primary plate.

Abstract: In one embodiment, a method of reducing NOx contaminant in an exhaust stream includes: introducing diesel fuel and an oxidant to a reformer to produce a reformer effluent comprising hydrogen and nitrogen, introducing the reformer effluent to a non-thermal plasma reactor to produce ammonia, and introducing an exhaust stream and the ammonia to a SCR catalyst, whereby the NOx contaminant reacts with the ammonia.

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: An embodiment of a method for producing a gas treatment device includes disposing a mat support material about a substrate to form a subassembly; passing at least a portion of the subassembly into a main body portion of a housing that has a first portion having a decreasing internal diameter from a first end to the main body portion, the main body portion extending from the first portion.

Abstract: A minimum joint thickness can be assured by incorporating beads or particles having a diameter corresponding to the joint thickness desired and which are infusible at the brazing temperature. Preferably such particles are formed of high-melting metals, metal oxides, ceramics, or cermets and are mixed into the alloy paste prior to fusing. In a preferred embodiment, the particle-containing paste is mixed with a non-flux carrier to facilitate application to the elements to be brazed. Exemplary application methods may include painting, rolling, screening, or extrusion dispensing. Brazing alloys in accordance with the invention are useful in bonding ceramics to ceramics, ceramics to metals, and metals to metals.

Abstract: An extended rich mode engine configured and operated extremely rich of stoichiometric to produce a substantially continuous hydrogen rich engine exhaust. Oxygen enrichment devices further optimize production of hydrogen rich engine exhaust. Engines include a free piston gas generator with rich homogenous charge compression, a rich internal combustion engine cylinder system with an oxygen generator, and a rich inlet turbo-generator system with exhaust heat recovery. Oxygen enrichment devices to enhance production of hydrogen rich engine exhaust include pressure swing absorption with oxygen selective materials, and oxygen separators such as a solid oxide fuel cell oxygen separator and a ceramic membrane oxygen separator.

Abstract: An airflow metering device, including a conventional airflow sensing device signally connected to a signal processor is shown, having an input flow signal correlatable to a magnitude of mass air flowing past the airflow sensing device. The signal processor is operable to determine a flow correction factor based upon a direction and magnitude of the mass air flowing past the airflow sensing device. The output of the airflow metering device is an accurate measure of airflow, and comprises the input flow signal of the airflow sensing device adjusted by the flow correction factor determined by the signal processor.

Abstract: An internal pulse damper for use in a fuel rail for an internal combustion engine. The damper is formed from a length of tubular metal stock having a flat oval cross-section and ends flattened by crimping to form a captive-air pillow. The end crimps are improved through use of tooling to eliminate a creased sidewall area vulnerable to stress failure in prior art pulse dampers. Such tooling includes constraints to prevent the tubing sides from flaring out and forming a longitudinal crease adjacent the end crimp during squeezing-shut of the tube end.