Abstract: A method for quantitatively predicting and consequently minimizing the amount of critical phases such as eutectic Al2Cu formed during solidification of Al—Si—Cu alloys used in a vehicle engine component comprises developing a micromodel to simulate microstructure evolution in cast Al—Si or Al—Cu alloys. The micromodel is calibrated using experimental thermal analysis cooling curves and an optimization process. Microstructure evolution and cooling curves are simulated for a casting using the calibrated micromodel. Precipitation of critical phases such as Al2Cu in the casting is predicted as a function of solidification conditions. The model allows casting process variables to be varied with predictable results so that the casting process can be controlled via the micromodel.

Abstract: A method for eliminating hoot noise in a bearing assembly (12) of an idler or tensioner pulley (10) includes applying a three component dry lubricating compound onto steel contact surfaces of the inner and outer raceways (14, 16) on which the ball bearings (20) ride, curing the compound to bond it to the contact surfaces, and pressure rolling the lubricating compound onto the surfaces. Pressure rolling fills voids (22) in the contact surfaces with particles of the lubricating compound and smoothes the surfaces thereby reducing friction. The dry lubricating compound has a very strong affinity for oil to attract and hold oil to provide an oil film which prevents metal to metal contact thereby eliminating hoot noise.

Abstract: A method for detecting fault in vehicle motion sensors for a motor vehicle includes providing a measured lateral acceleration signal and yaw rate signal. The method further includes calculating, respectively, a first and second road bank angle estimate based on these signals. Also included is determining a first and second maximum road bank angle based on the first and second road bank angle, respectively, and calculating a first and second threshold based on these values. The method further includes comparing whether the first and second road bank angles exceeds the second and first thresholds, respectively, and if so, indicating either one or both a lateral acceleration signal fault or yaw rate signal fault.

Abstract: A method for designing an IC package having a plastic encapsulated portion and a lead frame portion that are bonded together at a bonding interface includes selecting material candidates for each of the plastic encapsulated portion and the lead frame portion to obtain possible material combinations. A peeling stress and a shear stress at the bonding interface for each possible material combination is determined. A design material combination from all of the possible material combinations is then selected based on a singularity parameter and stress intensity factors of the peeling stress and the shear stress. To enhance the IC package, a circular fillet feature having a radius is added to a singularity point at the bonding interface of the IC package to reduce the stress at the singularity point.

Abstract: A reductant injection control strategy for controlling an amount of nitrogen oxide reducing agent injected upstream of a first and second serially placed nitrogen oxide catalyst, calculates the reductant injection For the first catalyst and second catalyst. The reductant injection for the first catalyst is based on engine operating conditions. The reductant injection for the second catalyst is based on the reductant injection for the first catalyst and a conversion efficiency of the first catalyst.

Abstract: A method for transporting heat exchanger fins and forming a core subassembly for a heat exchanger uses a universal fin tray for all subassemblies instead of different tray sizes for different core subassemblies. The method includes indexing core plates forward under a stationary fin stuffing box, loading fins into the universal fin tray, indexing the loaded fins forward one at a time corresponding to the number of fins required, pushing required fins into the fin stuffing box when indexing reaches number required for the core subassembly, and pushing fins out of the fin stuffing box into the plates forming the core subassembly. A universal fin tray size, a stationary fin box, and a stationary cut off are used for all core sizes.

Abstract: A low friction cam shaft for actuating at least one valve of an internal combustion engine includes a shaft member extending longitudinally, at least one cam secured to the shaft member, the cam being made of a plurality of density metal materials and having an outer surface impregnated with a solid film lubricant that has an affinity for oil and promotes rapid formation of a stable oil film to reduce friction therebetween.

Abstract: A method for transmitting phase angle information between inverters in a parallel connected inverter system to synchronize the phase angles of the inverters includes transmitting a common phase angle signal to server inverters. The common phase angle signal is a function of the phase angle of a master inverter. The common phase angle signal is indicative of the absolute phase angle of the master inverter when the phase angle of the master inverter is equal to a phase angle value associated with a new phase cycle. The common phase angle signal is indicative of an incremental phase angle change of the phase angle of the master inverter in a given time period while the phase angle of the master inverter is different from the value associated with a new phase cycle. The server inverters control their phase angles in accordance with the common phase angle signal such that the phase angles of the master inverter and the server inverters are synchronized.

Abstract: A method and apparatus for smoothing a throttle plate position command prior to being used by a closed loop throttle control unit. The method sequentially indexes through a lookup table storing a series of values of a smoothing function at routine time intervals. The difference between the current throttle plate command and the received throttle plate command is multiplied by the value of the smoothing function indexed from the lookup table. The product is then added to a reference throttle plate position command to generate a series of smoothed throttle plate position commands applied to the throttle control unit which provides smoother operation.

Abstract: An exhaust gas oxygen sensor (10) mounted in the exhaust stream of an engine includes a zirconia plate (14) mounted to two electrodes (16,18), covered with porous layers (20,22). The two porous layers (20,22) are designed to sense the two conditions of air/fuel mixture, lean and rich, by creating a delay in the sensing of the rate of transmission of oxygen through one of these layers (20,22), without the need for a voltage source pumping oxygen through the sensor. A heating element (60) can be used with the sensor to reduce the light-off time of the sensor. Also, a latch 52 can be used to modify the signal from the sensor to provide for a more conventional EGO signal.

Abstract: A method is provided for optimizing energy dissipation in a vehicle steering column in a high energy impact. The method includes the steps of: (a) providing a variable energy dissipation system on the vehicle steering column; (b) sensing at least one occupant condition; and (c) adjusting the variable energy dissipation system based upon the sensed occupant condition to optimize energy dissipation.

Abstract: The present invention relates to an apparatus and a method for a motor vehicle security system relating to immobilizing and enabling of a fuel pump for a motor vehicle engine. The system comprises data input means for receiving driver verification data, an engine control unit (ECU) including an ECU processor for controlling engine operation, a pump control unit (PCU) including a PCU processor for controlling the fuel pump, the PCU being separate from the ECU and integrally housed with the fuel pump. Communication links permit communication between the data input means and ECU, and between the ECU and PCU. The ECU processor is activated to control the PCU when valid driver verification data is received. The PCU processor is then activated to communicate a challenge code to the ECU. The ECU and PCU processors then compute respectively a first and a second response code associated with the challenge code.

Abstract: This invention is a metal-zirconium oxide material made by sol-gel techniques from alkoxides including heterometallic alkoxides. The heterometallic alkoxides include zirconium and another metal selected from alkali metals and alkaline earth metal. Optionally, in forming this material, heterometallic alkoxides of zirconium and lanthanide metal may be included during sol-gel processing, as well as mono-metal alkoxides of these metals or zirconium.

Abstract: A method for spot-welding aluminum workpieces with copper electrodes that comprises the steps of: (a) dissolving copper and one or more alloying elements X to yield an alloy that increases the liquidus of Al when dissolved in molten Al, super heating the alloy of copper and one or more elements X that normally have little or nor solubility in copper at room temperature, such super heating being a temperature at which X is soluble in copper, X being selected from the group of Mo, Ta, V, and W, elements that form monotectic or peritectic phases with copper and aluminum devoid of an eutectic, X being present in an amount of 4-15% by weight of the copper; (b) rapidly cooling the alloy to room temperature to retain such elements in solid solution; (c) either concurrently or subsequent to step (b), forming the alloy as an electrode shape; and (d) passing current through the electrode shape to effect spot-welding of the aluminum workpieces when pressed thereagainst while extending the welding life of the electrode.

Abstract: A method and system for fuel rail compensation in a returnless electronic fuel pump arrangement provides modification of fuel pulsewidth based on measured or inferred rail temperature. The present invention applies fuel pulsewidth control modifiers to enlarge the fuel pulse to increase the quantity of fuel being delivered to at least one fuel injector to offset any drop in fuel density and injector performance caused by fuel rail temperature. The present invention generates these modifiers separate from a vehicle's normal fuel delivery system adaptive control process, thereby eliminating any unnecessary adaptive processing and limiting of adaptive control range.

Abstract: The invention is a method for treating exhaust gas containing carbon monoxide, hydrocarbons, and nitrogen oxides generated by a lean burn internal combustion engine. It includes bringing the exhaust gas into contact with a particular metal-zirconium oxide material made by sol-gel processing and which includes at least 0.1 wt. % precious metal. The alkoxides include heterometallic alkoxides containing zirconium and alkali metal or alkaline earth metal. Optionally the oxide may contain a lanthanide metal. Under lean-burn conditions nitrogen oxides are absorbed on the oxide and when the oxygen concentration is lowered the absorbed nitrogen oxide are desorbed and reduced over the precious metal.

Abstract: Method of aligning a metallic solderable object to a glass plate comprising loading a solderable object onto an end effector of a robotically supported spindle of a spindle assembly, handing a support from the spindle assembly that extends beneath the axis of the spindle and has camming surfaces precisely aligned with the spindle axis, resiliently cradling a backing member on the support by use of a cam member adapted to fit against the support camming surface when the resiliency is overcome, positioning a glass plate on the backing member to overcome the resiliency of the backing member and cause the cam to engage the camming surfaces of the support and automatically obtain normality of the spindle axis with respect to the glass plate.

Abstract: A collapsible vehicle seat assembly includes a lower seat with a seat back pivotally connected with respect to the lower seat and having a flat back. Front and rear legs are pivotally connected to the lower seat. The lower seat, seat back and legs are selectively movable between a first position for seating wherein the legs and seat back are substantially upright, a second position for storage wherein the legs and flat back are generally horizontal such that the flat back forms a load floor, and a third position for ingress/egress wherein the lower seat and seat back are substantially upright.

Abstract: A folding vehicle seat assembly includes a seat back pivotally movable between upright and folded positions, with a latch assembly operative to latch the seat back in the upright position. A drive motor is engaged with a worm gear. A follower block is driven by the worm gear and operatively engageable with the latch assembly for unlatching the seat back. A seat block is movable with the follower block and operatively connected with the seat back for pivoting the seat back to the folded position after the follower block unlatches the seat back.

Abstract: A method and apparatus is provided for modulating the flux of oxygen impinging on a calorimetric gas sensor. The method and apparatus are based on modulating the oxygen concentration of a gas mixture presented to the microcalorimeter between a predetermined high level and at a substantially zero value to create a modulated output to reduce the noise of the sensor and to eliminate its zero-offset.