Abstract: A multi-strike throttle minimum learning system compares a signal received from at least one throttle position sensor to a predetermined minimum throttle position range based on throttle system component tolerances. A possible throttle obstruction is indicated when all of the sensor signal minimum values are outside the predetermined minimum range. In this case, the system deactivates electrical power for a predetermined delay period and then initiates another learn attempt in an effort to overcome the obstruction. This cycle is repeated until a valid throttle minimum position is detected, the number of learn attempts reaches a preset maximum, or a sensor fault is detected. If a valid throttle position minimum is detected within the allowed number of learning attempts, normal engine startup proceeds; otherwise, appropriate fault codes are communicated to the balance of the engine management system and, ultimately, to the operator.

Abstract: A fuel permeation resistant fuel tank for a vehicle includes a tank shell having a wall formed from a plurality of layers. The layers include at least an inner layer, an outer layer and a fuel permeation barrier layer disposed between the inner layer and the outer layer and being made of a liquid crystalline polymer (LCP) material.

Abstract: An improved quick-disconnect connector assembly for connecting hoses, having a female element for connection to a first hose and a male element for connection to a second hose. The female element has an axial bore having a sealing mechanism for sealably receiving a tubular portion of the male element. The male element further comprises resettable valve including a coil spring that extends into the bore in the female element and is retained therein by a U-shaped clip. The spring is sized to hold the male element axially within the sealing mechanism up to a desired inline pressure. When the pressure limit is exceeded, the male element spring is extended until the seal is broken, relieving the overpressure condition. When the un-sealing force has been relieved, the extended spring biases the male element back into sealing relationship with the female element, thereby automatically resetting the relief valve.

Abstract: A spark plug for igniting an air/fuel mixture in a combustion chamber of an internal combustion engine includes a spark gap having a variable distance defined between a central electrode and a ground electrode portion of a ground terminal. The ground terminal is formed using either a bimetallic layer arrangement wherein one of the metallic materials has a different coefficient of thermal expansion than the other metallic material, or is formed using a strut or by thickening the metal where the ground terminal is connected to a metal housing of the spark plug. The ground terminal deflects away from the central electrode when subjected to an increased temperature, such as may occur when the engine warms up during operation.

Abstract: A fuel permeation barrier fuel tank for a vehicle includes a tank shell having a wall formed from a plurality of layers. The layers include at least an inner layer, an outer layer and a fuel permeation barrier layer disposed between the inner layer and the outer layer.

Abstract: An improved method of operation for an electromechanical purge valve of a vehicle evaporative emission control system reduces the activation level of the purge valve below a nominal minimum level by a variable offset amount under specified operating conditions to lower purge flow. Specifically, the low flow control is permitted when the fuel in the purge vapor being drawn into the engine exceeds a calibrated percentage of the engine fuel requirement and the activation level of the purge valve has been reduced to the nominal minimum, provided that the system voltage level is at or above a specified value. When low flow control is permitted, the offset amount is incrementally increased so long as the engine fuel control is able to maintain the air/fuel ratio error at or below a calibrated amount, and incrementally decreased when the low flow control is no longer permitted or the air/fuel ratio becomes lean enough to potentially degrade combustion stability.

Abstract: A gas sensor, comprising an oxygen pump cell with a first pump electrode and a second pump electrode disposed on opposite sides of a first solid electrolyte layer and a second pump electrode. The sensor also comprises an emf cell with an emf electrode and a reference gas electrode disposed on opposite sides of a second solid electrolyte layer. The emf electrode is disposed in fluid communication to the second pump electrode. A via hole is disposed through the first solid electrolyte layer, such that the first pump electrode is in fluid communication with the second pump electrode. A protective insulating layer, having a passage for gas to be sensed, is disposed in contact with the first pump electrode. A first insulating layer, having a conduit, is disposed in contact with the emf electrode. A second insulating layer, having an air channel, is disposed in contact with the reference gas electrode. A heater is disposed in thermal communication with the emf cell.

Abstract: A gas sensor is disclosed comprising an oxygen pump cell having at least one exterior pump electrode and at least one interior pump electrode disposed on opposite sides of a first solid electrolyte layer. An emf cell having a first and second emf electrodes and first and second reference gas electrodes are disposed on opposite sides of a second solid electrolyte layer. At least one insulating layer is in contact with the first and second emf electrodes. At least one via hole is disposed through the first solid electrolyte layer. At least one air channel is disposed through at least one insulating layer. An air vent is disposed in at least one insulating layer in contact with the first and second reference gas electrodes. A heater is disposed in thermal communication with the sensor. And at least five electrical leads are in electrical communication with said sensor. A method of using a gas sensor is also disclosed.

Abstract: A catalyst for adsorbing oxides of nitrogen from the exhaust gases of an internal combustion engine, comprising an alkaline earth active catalyst site, and a transition metal oxide having a surface area of at least about 75 m2 /g.

Abstract: The method of making a wide range oxygen sensor of the present invention enables ease of handling and processing, particularly in a mass production environment. This process comprises forming planar composite elements of the sensor where the elements are individually laminated. These laminated composites are easily handled and readily stacked. Furthermore, electrodes and electrode leads can be readily deposited on the laminated composites, across the intersection of the various materials forming the composite. After deposition of the electrodes, leads, and a heater, the elements are stacked accordingly and laminated to produce the oxygen sensor.

Abstract: An improved position control for a solenoid actuated valve, wherein the solenoid is activated based on the combination of a feed-forward component based on a model of the steady state operation of the valve and a closed-loop feedback component that responds to changes in the commanded position and compensates for any inaccuracy in the steady state model. The method involves a valve characterization procedure in which the actual force generated by the solenoid is measured for various combinations of valve position and solenoid current, resulting in a table of coil current in terms of developed force and valve position. In operation, the model is used to estimate the solenoid force required to achieve the commanded valve position under steady state operating conditions, and a controller addresses the table to obtain a feed-forward coil current command as a function of the commanded valve position and the estimated solenoid force.

Abstract: An improved method of determining and preserving soak-related time intervals of an internal combustion engine resets a continuous timer at the end of each engine run period, and reads the value of the continuous timer at specified events during an ignition key cycle. The method measures and preserves the engine soak time preceding the current and previous ignition key cycle, and determines an extended soak time that includes intervals of engine operation that are too short to significantly affect the engine thermal and fuel vapor purge conditions. The determined soak-related times are then utilized by various engine control and/or diagnostic algorithms, such as a hot re-start fuel control algorithm.

Abstract: An exhaust gas sensor element has an electrolyte body, an inner electrode disposed on an inner surface of the electrolyte body, an outer electrode disposed on an outer surface of the electrolyte body, and a ground isolating coating disposed over the outer electrode. The ground isolating coating is typically alumina and extends from an active end of the electrolyte body toward an opposing end of the electrolyte body. The invention also includes a method for constructing a gas sensor element, the steps of which comprise forming an electrolyte body having an inner surface and an outer surface, applying an electrode ink to the inner surface to form an inner electrode and to the outer surface to form an outer electrode, and depositing a combination poison resistant/ground isolating coating, which is typically alumina, over the outer surface such that the combination coating extends from an active end of the electrolyte body toward an opposing end of the electrolyte body.

Abstract: A digital signal fuel sensor includes a digital sensor and a wiper assembly for rotation relative to the digital sensor. The digital sensor has a plurality of sensing portions having at least one conductive segment thereon forming a fuel level portion. The wiper assembly also includes a plurality of contact arms extending toward the digital sensor for contacting the sensing portions of the digital sensor as the wiper assembly rotates to produce a binary output.

Abstract: A method of starting a solid oxide fuel cell system is disclosed. The method comprises pressurizing a main plenum to a first pressure. The main plenum comprises a first supply of fuel, blowers, and air control valves. The first supply of fuel and a first supply of air are directed to a preheated micro-reformer. A heated pre-reformate is created in the micro-reformer and discharged from the micro-reformer to a main reformer. The main reformer is preheated with the heated pre-reformate. A second supply of fuel and a second supply of air are introduced to the main reformer. A heated main reformate is created in the main reformer and directed to a waste energy recovery assembly. A cathode supply is heated in the waste energy recovery system and then directed to a solid oxide fuel cell stack in order to heat the solid oxide fuel cell stack. Methods of transitioning, operating, shutting down, and maintaining in standby mode are also disclosed.

Abstract: A method and apparatus for conducting dynamometric testing of an internal combustion engine at a test site under a simulated atmospheric pressure that differs substantially from an actual ambient atmospheric pressure existing at the test site. The internal combustion engine has an air inlet for supplying an intake airflow for combustion within the internal combustion engine and an exhaust outlet for exhausting an exhaust flow exiting from the internal combustion engine. The method includes the steps of subjecting the air inlet to the simulated atmospheric pressure, subjecting the exhaust outlet to the simulated atmospheric pressure and operating the internal combustion engine while both of the air inlet and the exhaust outlet are subjected to the simulated atmospheric pressure.

Abstract: A photocatalytic device for photocatalytically treating evaporative emissions comprises a substrate with a photocatalyst. A shell is disposed about the substrate, and can optionally comprises one or more sections of transparent material capable of being penetrated by an ultra violet light. Additionally, sealing agent can optionally be disposed between the shell and sections of transparent material to provide a gas tight seal.

Abstract: The electrolyte comprises up to about 80 wt % zirconia, up to about 30 wt % stabilizer, and up to about 40 wt % dopant-zirconia. Alternatively, the electrolyte can comprise zirconia having a phase chemistry, wherein the phase chemistry, at about 25° C., is about 15 wt % to about 35 wt % monoclinic, less than about 10 wt % tetragonal, balance cubic, based upon the weight of the zirconia in the electrolyte.

Abstract: An improved method of estimating the oil pressure of an internal combustion engine utilizes a physical model that takes into account both engine speed and engine oil temperature. The oil pressure is estimated as the sum of static and dynamic components, where the dynamic component includes a first portion that primarily models flow-related effects, and a second portion that primarily models temperature-related effects. The constants and temperature-related variables of the physical model are combined to form one constant calibration value, and two temperature-dependent calibration values. The parameters of the physical model provide a starting point for the calibration values, and the calibration values are then tuned during a calibration procedure so that the estimated oil pressure tracks an accurate measure of the oil pressure during both steady-state and transient engine operating conditions.

Abstract: A fuel cell system and a method of using a pressure regulator in a fuel cell system are disclosed herein. The method comprises controlling a purge gas pressure of a purge gas disposed in an enclosure disposed around a fuel cell stack and a waste energy recovery assembly, by seating a pressure plunger in a seating portion of a pressure regulator, wherein the purge gas unseats the pressure plunger when the purge gas pressure exceeds a desired pressure. The method further comprises passing a sufficient amount of the purge gas past the seating portion to reduce the purge gas pressure to at least the desired pressure.