Abstract: A generator for providing electric power. The generator includes an engine associated with an alternator. Rotation of the engine causes the alternator to generate an AC source voltage that is fed to at least one analog output receptacle. The generator further includes an inverter connected to receive the AC source voltage and generate a digital AC output voltage having a constant voltage value and a constant frequency. The inverter allows the engine to operate at less than full speed when an electric load is drawing a relatively low amount of power from the generator. The analog receptacle allows larger electric loads to be connected to the generator where the electric loads cannot be supported by the digital AC output voltage.

Abstract: A speed controller for a DC motor minimizes speed droop and load droop through pulse width or frequency modulation. The controller provides an extra power increase upon engine starting or whenever a heavier load is temporarily encountered. The control circuit also has a current limiter, overload indicators, and a battery recharger. The controller is very inexpensive, primarily because all of the timing components are contained on a single integrated circuit timer chip such as a 556 timer. The controller contains other features, including a circuit for limiting the pulse width of the control signal from the pulse width modulator.

Abstract: A mechanical key and lock set with a rotating cylinder includes an electronic interlock which is responsive to the insertion of a mated key in the cylinder and proper rotation of the cylinder. A sensor is placed in communication with the cylinder and senses proper rotation of the cylinder to generate an activation signal. Systems controlled by the lock cannot be enabled without the generation of the activation signal. Fail safe blocking circuitry is placed in communication with the activation signal generator and in the event the actuation signal is attempted to be read in an unauthorized manner without properly rotating the cylinder, the blocking circuitry is functional to preclude reading.

Abstract: The engine housing for a small internal combustion engine lessens exhaust emissions by reducing cylinder bore distortion during manufacture and during use. Cylinder bore distortion is reduced by providing reinforcing material in two opposed wall sections for a relatively small length of the total cylinder length. This uppermost cylinder wall portion also includes bolt bosses for receiving the cylinder head bolts. The cylinder is divided into successive cylinder wall portions along its length, with the thicknesses of the cylinder walls decreasing in each wall portion away from the cylinder head. Cylinder bore distortion is also lessened by using concentric air vanes instead of the asymmetrically-shaped vanes typical of prior art engine housings.

Abstract: A reliable mechanical and electrical connection is formed between a slotted rivet and an insulated ground wire using a minimum number of manual steps. The slotted rivet head has two spaced, opposed, semi-frustoconical sections that define a slot between them. The slotted rivet is placed and properly aligned in a coil frame, and the ground wires are placed into the slot. The rivet head is then deformed by an orbital riveter to capture a portion of the insulated wire within the rivet head. A resistive welder engages the rivet head to vaporize the insulation from the captured wire portion without touching the wire. The resulting terminal assembly has a unique design in which the deformed rivet head is substantially flat.

Abstract: A reversible double-bitted key is reconfigured to permit a cylinder lock and key set to fit in the standard architecture of certain American automobiles. Preferably, the maximum required diameter of the cylinder is maintained under 13 millimeters, permitting the cylinder to be placed in standard instrument panel architecture for many American made vehicles. The minimum width of the key is maintained at approximately 4 millimeters, assuring that the key can withstand the torque requirements of the lock systems. This permits a single key to be used in both the primary and secondary locks. The tumbler is configured such that the minimum distance between the outer edge of the key window in the tumbler and the outer perimeter of the tumbler is greater than the thickness of the tumbler, further assuring that the lock can withstand repeated use without fatigue failure.

Abstract: A connecting rod for a reciprocating piston of an internal combustion engine. The connecting rod includes a two-piece crankpin bearing which is formed by an integral crankpin bearing portion and an arcuate-shaped cap member disposed in mating relationship therewith to attach the connecting rod to a crankpin of a crankshaft. The crankpin bearing includes a wedge-shaped key which cooperates with a tapered key-receiving groove which is dimensioned to permit an initial press fit assembly between the cap member and the crankpin bearing portion. The key and groove facilitate assembly of the cap member to the crankpin bearing portion by providing proper alignment of these components, and further facilitates disassembly of the cap member from the crankpin bearing portion should the connecting rod need repair or replacement.

Abstract: An internal combustion engine has an integral cylinder head, a one-piece connecting rod, and a crankshaft disposed at the interface between the first engine housing and the second engine housing. In an overhead cam shaft embodiment, the cam shaft drive means includes first and second gearsets of cross-helical gears. Also directly mounted to the cam drive shaft are the oil slinger, the centrifugally-responsive speed governor components, and the auxiliary power take-off shaft. This arrangement eliminates the need for additional shafts and subassemblies. In another embodiment, both the crankshaft and the cam shaft are disposed at the interface between the two engine housings to decrease manufacturing and assembly costs. The crankshaft and/or cam shaft bearings are formed integral with the engine housings to eliminate the need for separate bearing components.

Abstract: A key with a resistor pellet is assembled by mechanically inserting the pellet into a suitable aperture in the key and displacing a portion of the key material into the body of the pellet by compressing the key around the perimeter of the pellet in a swaging process. The pellet is automatically selected from a plurality of pellets having a plurality of distinctive resistance properties. The pellet is tested to determine conformance with a pre-selected resistance property prior to insertion in the key. After insertion and swaging of the pellet in the key, the resistance properties of the pellet are reconfirmed.

Abstract: A fuel/mixing device for mixing producer gas with air is provided to generate a suitable air/fuel mixture for firing an internal combustion engine. Stepped venturi inlets are utilized, whereby the gas is expanded as the air is reduced, to both accelerate and mix the gas with the air as it is introduced into the throat of a carburetor. Means are provided for adjusting the air flow without disturbing the standard throttle on the carburetor. The mixing device is adapted to be mounted on existing carburetors, permitting retrofitting of existing equipment. The device permits start-up with gasoline and a smooth transition from gasoline fuel start-up to full operation on producer gas.

Abstract: A floatless carburetor with a fuel reservoir in communication with the carburetor throttle bore includes an integral primer system which is operable to introduce fuel directly into both the carburetor throttle bore and the fuel reservoir. A plurality of check valves control flow of fuel from the fuel tank into the primer system and into the throttle bore and fuel reservoir. The carburetor and primer system are adapted to be operated in conjunction with an impulse-type fuel pump, wherein the primer system is operable to manually pump fuel into the reservoir when the fuel pump is not functioning.

Abstract: A starter motor construction including a drive shaft and a spline having an external helical thread is disposed concentrically of the shaft and rotates therewith. An internally threaded pinion is engaged with the spline and moves axially outward on rotation of the drive shaft against the force of a biasing spring to effect engagement of the pinion with a ring gear on the flywheel of the engine. A cushioning mechanism is incorporated between the drive shaft and the spline and includes a pair of metal plates, one of which is secured to the drive shaft and the other to the spline. A resilient disc composed of a rubber-like material is bonded to the opposed faces of the plates and is provided with a continuous peripheral groove. The cushioning mechanism acts to absorb radial torque and axial force as the pinion is moved into engagement with the ring gear.

Abstract: An electrically responsive oil level sensor is mounted within a vehicle oil sump. An enclosure encloses the ends of two spaced electrodes. The high voltage electrode has a pointed end and the other low voltage electrode has a blunt end opposed to the pointed end. The low voltage electrode is connected to ground in series with an indicator. The enclosure has three vertically spaced openings. An entrance opening is aligned with the electrode gap for in flow of oil. A second is located below the entrance opening and establishes a restricted oil outflow. The third opening is above the entrance opening for air and fume escapement. A baffle is interposed between the entrance opening and the electrode gap. The baffle prevents the motion of the oil in the sump from moving directly through the entrance opening and into the electrode gap. The enclosure has an integral tower for the high voltage electrode and the tower has annular radial projections to increase the surface creepage path.

Abstract: A wheel assembly includes a cam and a cam gear mounted on a camshaft of an internal combustion engine. The cam gear is constructed of a laminated stack of flat plate members which are disposed in abutting relationship to one another to form a plurality of axially spaced and radially extending interfaces. The cam gear is press fit onto the camshaft and the frictional forces between the gear and the camshaft provide the substantially sole force for maintaining the interfaces between the plate members in abutting relationship at their radially outer ends to form integral tooth members. The cam is also constructed of a laminated stack of flat plate members and press fit onto the camshaft in substantially the same manner as the gear to form an integral cam surface. The plates which form the cam are stamped from the plates that form the gear.

Abstract: A low level lubricating oil detector for an internal combustion engine. The detector includes a tube that is located in crankcase of the engine and the tube has an opening in its lower end located at the predetermined minimum oil level. The upper end of the tube communicates with a chamber and one side of the chamber is enclosed by a piezo electric element. When the oil level in the crankcase recedes beneath the minimum level, pressure pulsations in the crankcase are transmitted through the tube to the piezo electric element which generates a signal that operates through an electric circuit to stop operation of the engine.

Abstract: A shallow penetration, key operated lock. The lock includes an outer casing and a cylinder is mounted for rotation in the casing and is adapted to be connected through a lever assembly to a working member. The cylinder is provided with a central keyway and a locking member, such as a side bar, acts to removably lock the cylinder to the casing to prevent rotation of the cylinder. At least one pair of tumbler plates are mounted in flatwise sliding relation within the cylinder and each tumbler plate is provided with an opening which is aligned with the keyway. In addition, the tumbler plates of each pair are provided with aligned elongated openings and a spring is positioned longitudinally within the openings and bears against the respective ends of the openings. A double bitted, non-reversible key is received within the keyway and the key bits slide the tumbler plates relative to each other to move the tumbler plates into an operative position.

Abstract: A wheel assembly includes a cam and a cam gear mounted on a camshaft of an internal combustion engine. The cam gear is constructed of a laminated stack of flat plate members which are disposed in abutting relationship to one another to form a plurality of axially spaced and radially extending interfaces. The cam gear is press fit onto the camshaft and the frictional forces between the gear and the camshaft provide the substantially sole force for maintaining the interfaces between the plate members in abutting relationship at their radially outer ends to form integral tooth members. The cam is also constructed of a laminated stack of flat plate members and press fit onto the camshaft in substantially the same manner as the gear to form an integral cam surface. The plates which form the cam are stamped from the plates that form the gear. A method of forming the wheel assembly is also disclosed.

Abstract: An ignition magneto having an improved primary wiring assembly that consists of a plastic bobbin having a generally rectangular configuration and composed of a pair of end flanges connected together by a pair of side walls and a pair of end walls. The side edges of each wall are spaced from the side edges of adjacent walls, to provide a gap or slot at each corner of the bobbin. A wire is wound in a plurality of turns around the walls and extends across the slots. One end flange is provided with grooves within which the free ends of the wire are gripped. The primary winding assembly is positioned in a cup-shaped casing around a central upstanding chimney which extends upwardly from the bottom of the casing. After installing a transistor and trigger coil, as well as a secondary winding around the primary winding assembly, the components are potted in the casing with a thermosetting resin.