Abstract: A two-piece continuous mesh synchronized reverse idler system is provided for use with a manual transmission. The system is provided for use with a vehicle transmission having an input shaft with a reverse driven gear, and an intermediate shaft with a reverse driven gear. The reverse idler system includes a reverse idler shaft which supports an upstream idler gear and a downstream idler gear. The upstream idler gear is rotatably mounted on the reverse idler shaft for engaging the reverse drive gear on the input shaft. The downstream idler gear is rotatably mounted on the reverse idler shaft for engaging the reverse driven gear on the intermediate shaft. A clutching device is provided for synchronizing and engaging the upstream reverse idler gear and the downstream reverse idler gear.

Abstract: A system for testing the electrical components of vehicles during manufacturing includes a hand held tester to which a translator unit can be detachably engaged and with which the tester is in RF communication. The translator unit can be detached from the tester and plugged into a test receptacle under a vehicle's dashboard to communicate with the vehicle by translating computer formatted data from the tester to vehicle bus-formatted data, and vice-versa. Then, the vehicle's VIN is scanned into the tester or manually input into the tester, and the tester transmits the VIN via an RF link in the assembly plant to a computer in the plant. Based on the VIN, the computer determines the electric equipment that the vehicle has, and the computer transmits this information back to the tester. The tester then determines which tests to execute, and the tester causes the translator unit to undertake these tests.

Abstract: A rack and pinion steering system for a sport utility vehicle having a solid front axle includes a pinion gear connected to the steering column of the vehicle and a rack gear meshed with the pinion gear. A coupling segment is moved by the engagement segment, and an arm is connected to the coupling segment. A drag link in turn is connected to the arm and is coupled to a first front wheel of the vehicle. Also, a tie rod couples the first front wheel to the second front wheel of the vehicle. With this structure, rotation of the pinion gear by the steering column causes the rack gear and arm to move translationally, thereby moving the drag link to turn the first front wheel. The first front wheel cooperates with the tie rod to simultaneously turn the second front wheel.

Abstract: An apparatus that stabilizes vehicle sliding doors when transitioning to and from a closed position, wherein the sliding door is guided along a track by a guide wheel contacting internal surfaces of the track. The apparatus stabilizes the sliding door by limiting movement of the guide wheel in cross-car and vertical directions. The apparatus is coupled to the track and limits movement of the guide wheel by contacting a shaft of the guide wheel as well as top and bottom surfaces of the guide wheel. Shaft and bottom surface contact is provided by a plurality of parallel members extending along a first and second side of the shaft of the guide wheel. Top surface contact of the guide wheel is provided by a longitudinal member, preferably having a longitudinal cavity for energy absorption and dissipation. The plurality of parallel members further define a curved receptacle which substantially mates with the shaft of the guide wheel.

Abstract: A hybrid vehicle utilizes a power unit to store and convert power between a turbine alternator, flywheel, and traction motor. The power unit uses a plurality of power transistors for switching power to the equipment. The transistors are set in an H-bridge configuration to provide AC power. The H bridge configuration comprises two transistor pairs, each forming a half bridge. A process for matching the transistor pairs of each half bridge includes measuring the electrical and timing characteristics associated with turn on and turn off with a first transistor module, and measuring the electrical and timing characteristics associated with turn on and turn off of each of a plurality of transistor modules. The electrical and timing characteristics associated with each of the plurality of transistors modules is compared against the electrical and timing characteristics of the first transistor module.

Abstract: A circuit monitors both digital and analog sensor readings by polling them from a single wire bus multiplex system. The circuit operates to sequentially address a plurality of smart sensor interfaces, each having an associated sensor, connected to the single wire bus. A voltage signal is supplied on the line that produces a current corresponding to the presence of a sensor at the polled interface and a current corresponding to a sensed digital or analog value where the sensor is of the digital or analog type, respectively. The currents on the bus are copied in a current mirror whose current output is applied to a resistor to produce a voltage, which in turn is converted into a digital number to be analyzed to determine the presence of a sensor at the addressed interface and its status. The current in the circuit is also measured to produce a voltage corresponding to circuit component variations and one corresponding to the contributions of the currents from the power supplies of the interfaces.

Abstract: A seal retainer for an electrical connector comprising two seal retainer halves for connecting around a wire assembly, the seal retainer halves being identical with corresponding locking tabs.

Abstract: A rear seat assembly for a vehicle can be moved between a seating configuration and a load floor configuration without requiring the operation of release pins or knobs. The seat assembly includes a mount assembly bolted to the floor of the vehicle and a seat back pivotably engaged with the mount assembly. The seat back is formed with a lower finger. A seat cushion is movably coupled to the mount assembly, and an interlock pin is immovably formed, as by welding, to the seat cushion. The seat cushion can be pushed backwardly to a seating configuration, in which the seat cushion is juxtaposed with the seat back and the interlock pin abuts the engagement surface to hold the seat back upright. Also, the seat cushion can be rotated forwardly to distance the interlock pin from the seat back and thereby permit the seat back to be pushed downwardly into a horizontal load floor configuration.

Abstract: A coupling arrangement for connecting a vehicle door lock operator to a vehicle door lock, including a rod having an outer end connected to the door lock, and a hooked inner end. A clip has an outer end pivotally connected to the door lock operator. The clip has a hole between its ends in which the hooked inner end of the rod is engaged. The clip has a sleeve at its inner end for holding the rod engaged in the hole.

Abstract: A method is provided for adaptively determining a torque-related (K-factor) value for a torque converter in a vehicle and providing adaptive torque management to an automatic transmission. The torque-related K-factor value is computed for a given torque converter as a function of engine speed and difference in torque measured with the vehicle operating in idle neutral and drive. The vehicle dynamically learns the K-factor value and manages torque applied to the transmission by limiting the engine output speed as a function of the learned torque-related K-factor and vehicle speed.

Abstract: A method is provided for determining wall wetting for an engine which includes running a multi-cylinder engine at a predetermined speed and load. The fuel delivery and spark to one of the cylinders is then interrupted. The hydrocarbon level exhausted from the cylinder is then measured for a predetermined number of engine cycles. The test results can then be curve fitted to the relationship HCPPM=(A+B* engine cycle).sup.(1/exp). In this relationship, HCPPM is the hydrocarbon count in parts per million, A and B are each constants, and the exponent exp is derived using an iterative process. The exponent which is derived is the main qualifier for wall wetting.

Abstract: A vehicle modular three-across seat, or, so-called, split bench seat assembly, including two wide outboard seat structures and a narrower middle seat structure. Each outboard seat structure is supported on the floor of the vehicle by four corner anchors for independent forward and aft movement. The middle seat is supported in a fixed manner by four corner support brackets extending outwardly and downwardly to mount on the adjacent two pairs of front and rear corner anchors. The modular three-seat assembly is adapted to be installed as a unit in the vehicle by securing the four corner anchors of each of the two outboard seat structures to the vehicle floor pan.

Abstract: A method and apparatus for limiting the fault current in a portable welding gun comprising a power circuit, the power circuit comprising a circuit breaker and an isolation contactor, the isolation contactor in series with the circuit breaker, the fault current limited by providing a safety circuit, the safety circuit comprising a safety circuit comprising two resistor/relay pairs, the resistor and the relay of each pair in series with each other and each pair in parallel with a contact of said contactor, the resistors sized to limit the fault current in the power circuit to less than 50 ma.

Abstract: A pair of parts formed in a first stamping operation is removed from a first die press and placed on a separator assembly carried by a shuttle. As the parts are carried by the shuttle to a pair of secondary die presses, they are transversely separated by a stationary cam and a pair of cam followers carried by the shuttle. Once separated, the parts are automatically transferred into the secondary die presses.

Abstract: A hybrid powertrain assembly includes a voltage bus which is operable using a predetermined voltage level within a predetermined voltage range, a generator operatively connected to the voltage bus for generating power and bilaterally transferring the power with the voltage bus independently of the voltage level, a traction motor operatively connected with the voltage bus, the traction motor bilaterally transferring power with the voltage bus independently of the voltage level, and a flywheel assembly operatively connected with the voltage bus, the flywheel assembly bilaterally transferring power with the voltage bus based on the voltage level.

Abstract: A removable detent mechanism to be utilized with a vehicle door hinge assembly for providing a temporary door check mechanism during painting of the vehicle body and door assembly. The detent mechanism is positioned between the door hinge pin and the vehicle hinge bracket. An interference lobe formed on the detent mechanism is engageable with a portion of the door hinge bracket to generate a detent force during the opening and closing of the door assembly relative to the vehicle body. The removable detent mechanism is provided with local stiffness features which enable adjustment of the detent force.

Abstract: A pre-combustion chamber for an internal combustion engine that is provided with a flow enhancing member which located in the interior of the pre-combustion chamber and permits the pre-combustion chamber to absorb additional heat energy during the combustion cycle while creating more efficient transfer of gases between the main combustion chamber of the engine and the interior of the pre-combustion chamber.

Abstract: A flexible circuit board interconnect is provided with flex strain relief capabilities. The flexible circuit board interconnect includes a polyamide or polyimide (both are nylons) substrate layer, a ground plane layer and a conductor strip layer. The ground plane layer is provided with scalloped edges along opposite sides thereof. The ground plane provides a shield for preventing radio frequency interference to and from the signals passed through the conductor strips. The ground plane layer and the conductor strips are covered at least partially by a pair of soldermask layers which are provided with scalloped edges. The scalloped edges on the soldermask layers and the ground plane prevent the generation of a crease or fold line on the surface of the flexible circuit board interconnect. Each of the conductor strips are provided with a pair of vias on opposite ends of thereof.

Abstract: A hybrid vehicle includes a power unit communicating power between a turbine alternator, flywheel and traction motor. The power unit stores DC power in capacitors and places the power on a DC bus for use in driving the induction machines. Power transistors receive the DC power from the DC bus and are pulse width modulated to output a synthesized AC waveform. The power transistors include a support plate of thermally conductive material having a first surface supporting the transistor and a second surface forming a heat sink with cooling fluid. An electrical insulation layer is fixedly connected between the power transistor and the support plate on the first surface.