Abstract: Electroplated chromium coatings on automobile suspension damper piston rods are replaced with thermal or kinetic spray coatings of: (a) suitable corrosion-resistant metal alloys such as iron and chromium containing nickel-based alloys or chromium containing steels, or (b) suitable ceramic coatings such as electrically insulative alumina ceramics. The spray coatings are porous, and the metal alloy coatings usually should be sealed for corrosion protection.

Abstract: A brake pedal for a motor vehicle brake-by-wire brake system including a pedal lever resiliently flexible in beam bending, a foot pad on the pedal lever, and a mounting for the pedal lever on a body of the motor vehicle which constitutes the pedal lever a variable stiffness cantilever spring. The mounting for the pedal lever includes a socket for an inboard end of the pedal lever, a stationary reaction surface on the body of the motor vehicle, and a pedal lever reaction surface on the pedal lever which faces and diverges from the stationary reaction surface in a release position of the pedal lever. The stationary reaction surface and the pedal lever reaction surface become progressively engaged concurrent with resilient flexure of the pedal lever in cantilever spring bending to vary the stiffness of the cantilever spring.

Abstract: A jounce bumper plate for a damping module of a type commonly employed automotive suspension system having a hydraulic cylinder with an upper end cover, a piston rod slidably extending from the upper end of the cylinder and ajounce bumper mounted upon the piston rod. The jounce bumper plate mounted on an upper end of the cylinder and includes a central bore therethrough to allow slidable passage of the piston rod, and includes a series of arches extending about the outer periphery of the plate. The arches increase in curvature from the central bore to the outer periphery, thereby forming gaps between the jounce bumper plate and the associated hydraulic cylinder to facilitate the expulsion of moisture and contaminants from the upper end of the hydraulic cylinder during compression and extension cycles of the associated cylinder.

Abstract: A vehicle suspension system is responsive to an active brake signal from a brake system indicating the application of a greater braking force to one front corner brake than to the other front corner brake to affect vehicle yaw rate. The vehicle suspension system determines the relative velocities of the front corner suspension adjacent the front corner brake receiving the greater braking force and the diagonally opposed rear corner suspension and further determines a compression damping command for the front corner suspension and a rebound damping command for the rear corner suspension. While the active brake signal is present, the suspension control applies the compression damping command for the front corner suspension when its relative velocity indicates that it is in compression. While the active brake signal is present, the suspension control also applies the rebound damping command for the rear corner suspension when its relative indicates that it is in rebound.

Abstract: A brake booster (10) comprising a housing (12); a diaphragm (16,18) mounted within the housing to define front and rear chambers (30-36) within the housing; and a cylindrical component (38) mounted within the housing and having an end (42) which passes through a sealing aperture (40) during installation within the housing to make a seal with the cylindrical component; wherein the cylindrical component has a plurality of fingers (46) extending away the said end, the fingers being circumferentially spaced apart around the end, and the outer surface (48) of each finger being chamfered such that the free ends (50) of each finger lie on a circle having an outer diameter (D1) which is less than the inner diameter (D2) of the sealing aperture prior to installation. Easier installation of the cylindrical component during booster assembly, especially where blind installation is required.

Abstract: A vacuum booster for a vehicle brake system provides a working pressure valve seat on a valve member axially movable with respect to an input member. A rotary electric motor within the booster has an output shaft coupled through rotary to linear motion conversion apparatus to move the valve member with its working pressure valve seat relative to the input member. The combination of elements is designed as a drop-in replacement for a standard air valve member. The motion conversion apparatus provides much greater mechanical force than a linear solenoid; and this allows a more straightforward design of the valve arrangement, particularly the use of a high friction seal such as a simple "O"-ring in a groove. In further contrast to a linear solenoid, it further provides positive control of the working pressure valve seat position and an extended range of travel with constant force throughout the range.

Abstract: A monotube suspension damper including a cylinder tube having a fluid chamber and a gas chamber, a piston dividing the fluid chamber into a compression chamber and a rebound chamber, a primary fluid flow path across the piston including flow control valves which throttle fluid flow, a secondary fluid flow path across the piston parallel to the primary flow path including flow control valves which throttle fluid flow, and a tubular connecting rod on the cylinder tube connected to the piston. A valve spool is supported on the piston for linear translation between closed and open positions blocking and unblocking the secondary flow path. A control rod inside of the connecting rod is disposed between the valve spool and a flexible diaphragm exposed to pneumatic pressure in an expansible load leveling chamber between sprung and unsprung masses of the motor vehicle.

Abstract: A friction material pad comprises a lamination of stacked sheets, each of which has a top edge forming the friction face that is generally parallel to the direction of relative rotation between the friction pad and an opposing rotary member. Each sheet is formed by a wet paper making process and has a plurality of unwoven fibers, platelets, flakes, or the like, more than half of which are oriented within 45.degree. of perpendicularity to the top edge, the sheets being bound together by a resin binder to form a lamination in which the sheet edges progress from inner to outer sheets to form the friction face of the pad, each sheet having the same blend of friction and lubricating particles, fibers and fillers in a resin matrix. Three groups of sheets are heat aged to different densities and have different friction, hardness and stiffness characteristics.

Abstract: A control circuit for controlling the current through an inductive load powered by a unipolar power source. The current through the inductive load is controlled by three electronic switches and a subcircuit. The switches provide three different voltage levels across the inductive load. The closing of the first switch supplies positive voltage across the load, thereby increasing the load current. Opening of the first switch and closing of the third switch disconnects the power source from the load and short circuits the inductive load resulting in zero voltage across the load. Opening of the third and first switches directs the inductive current through the subcircuit, developing a negative voltage across the load and thereby rapidly decreasing the inductive current. By controlling the load voltage between a positive and zero voltage and between a negative and zero voltage, the load current is changed quickly and efficiently.

Abstract: An improved cold temperature compensation control method for an EH braking system in which cold temperature operation is detected without requiring a temperature sensor. An electronic controller monitors the pressure developed by one or more electrically operated boost units for a characteristic pressure profile that occurs in cold temperature operation of the braking system, and adjusts the control strategy when the characteristic pressure profile is detected. The characteristic pressure profile is deemed by its frequency and amplitude parameters; specifically, a frequency above a threshold frequency, and an amplitude above a threshold amplitude. In a first mechanization, the controller responds to a detected cold temperature operation by reducing the gain of a closed-loop pressure control, while in a second mechanization, the controller responds by switching from the closed-loop pressure control to a closed-loop position control.

Abstract: An electric caliper for a brake system includes a cylindrical housing having a bore, a bridge extending from the housing, and a pair of friction elements operatively disposed under the bridge. The electric caliper also includes a motor disposed within the bore and a planetary gear system disposed within the bore and operatively connected to the motor. The electric caliper further includes a ball screw disposed within the bore and positioned around the motor and operatively connected to the planetary gear system. The electric caliper includes a piston operatively connected to the ball screw. Displacement of the piston causes the friction elements to operatively engage a disc disposed between the friction elements.

Abstract: A method for monitoring motor position in a multiple phase switched reluctance motor having phase windings which are energized by a controller involves producing a signal indicative of a current delivered to an active phase winding and producing a signal indicative of a voltage across the active phase winding. A flux linkage associated with the active phase winding is then established based at least in part upon the current indicative signal and the voltage indicative signal. A position of the motor is then estimated based at least in part upon the current indicative signal and the established flux linkage.

Abstract: An engine ignition coil and wiring arrangement uses a connection position assurance device to assist in the connection of ignition wires to an ignition coil and the maintenance of the connections in engine use. The ignition coil is provided with a pair of parallel terminal posts and a mounting surface adjacent a bolt opening. Each of a pair of ignition wires has a cable portion and a connector portion. The connection position assurance device is a T-shaped element having tower portion with a bolt opening extending lengthwise therethrough and pair of connector holding portions extending in opposite directions adjacent one end of the tower portion. Each of the connector holding portions defines a central cavity for the retention of a connector portion of one of the ignition wires. Specific insertion and access openings from the cavity are also provided for insertion and access of the ignition wire connector portion.

Abstract: A shock absorber for a motor vehicle includes a compression stoke valve having one or more deflectable discs mounted on the piston on the rebound chamber side and a rebound stroke valve having one or more deflectable discs mounted on the piston on the compression chamber side. A compression flow passage extends through the piston, opening at one end into the compression chamber and having an opening at the other end into the rebound chamber which is closable by the deflectable disc or discs of the compression stroke valve. A rebound flow passage extends through the piston, opening at one end into the rebound chamber and having an opening at the other end into the compression chamber which is closable by the deflectable disc or discs of the rebound stroke valve. One or both valves further includes a flexible disc positioned between the deflectable disc or discs and the piston and extending partly across the associated passage to leave an opening in the passage.

Abstract: A parking brake assembly for a motor vehicle includes a lever acting against a brake shoe to urge the brake shoe into contact with a brake drum. The parking brake assembly includes a clasp pivotally mounted to the lever. The clasp includes a plate portion having a slot therein. The clasp pivots to accommodate blind assembly of the cable strand to the lever. Retention to the cable is accomplished by pivoting the clasp upward and out of the way while a bullet staked at one end of the cable strand passes through the slot. The clasp drops about the cable strand and a tensile force applied to the cable strand causes the bullet to engage the plate portion of the clasp to couple the cable strand to the lever.

Abstract: A brake apply system includes a pressure charging module having a bore carrying a pumping piston that has a base piston surface and an augmentation piston surface. The pressure charging piston separates the bore into an input chamber adjacent the base piston surface and an output chamber adjacent the augmentation piston surface. A suspension damper is hydraulically connected to the input chamber of the pressure charging module, preferably through a continuously open fluid communication circuit. A wheel brake is hydraulically connected to the accumulator output chamber through a selectively open fluid communication circuit.

Abstract: In a vehicle with four corner suspensions, wherein during a transient turning maneuver, a body of the vehicle tends to compress two of the corner suspensions on a first side of the vehicle and expand two of the corner suspensions on a second side of the vehicle, wherein road inputs cause random compression and rebound of the four corner suspensions, a suspension control method comprising the steps of: sensing vehicle speed; monitoring steering wheel velocity; responsive to the vehicle speed and the steering wheel velocity, determining a signal indicative of a transient turning maneuver of the vehicle; responsive to the signal, determining compression damping commands for the two corner suspensions on the first side of the vehicle; responsive to the signal, determining rebound damping commands for the two corner suspensions on the second side of the vehicle; monitoring relative velocity of each corner suspension; applying the compression damping commands for the two corner suspensions on the first side of the

Abstract: A damper provides tunable variable rates in both extension and compression operation. A piston is carried in a cylinder tube separating out extension and compression chambers. The piston carries a first valving assembly that is tuned to provide a first damping level when fluid flows through the piston from the extension chamber to the compression chamber and a second valving assembly that is tuned to provide a second damping level when fluid flows through the piston from the compression chamber to the extension chamber. A control valve assembly is mounted to move with the piston. When the control valve assembly is closed, fluid flow between the compression and extension chamber flows substantially only through the first and second valving assemblies and when the control valve is open at least some fluid flows between the compression and extension chambers through a secondary valve assembly without passing through the first and second valving assemblies.

Abstract: A brake apply system includes a modulator that has a first bore carrying a power driven dual-effect piston. The piston has a base piston surface and an augmentation piston surface. A wheel brake is hydraulically connected to the modulator through an open fluid communication route that is provided between the wheel brake and the base piston surface. A selectively open fluid communication route is provided between the wheel brake and the augmentation piston surface with a check valve mechanism positioned in the selectively open fluid communication route. An augmentation chamber is defined adjacent the augmentation surface of the dual-effect piston. The modulator includes a second bore carrying a valve mechanism that provides an open flow path between the augmentation chamber and a reservoir when pressure at the wheel brake is relatively high and that significantly restricts the flow path when the wheel brake pressure is relatively low.

Abstract: A hydraulic mount includes a mounting plate and a wall, with a working chamber defined between the mounting plate and the wall. The mounting plate and the wall are separated by a relatively thick elastomeric element so that the size of the working chamber varies as the elastomeric element is compressed and expanded by operation of the mounting plate and the wall moving closer together and farther apart. A reservoir is defined substantially by the elastomeric element in combination with a relatively flexible diaphragm that extends between the mounting plate and the wall so that the reservoir is generally annular in shape and is positioned around the working chamber. The elastomeric element serves as a separation wall between the working chamber and the reservoir.