Abstract: The system is directed to preserving an IC engine installation from potential overload and failure in response to electrical load increases passed along by an associated engine driven digitally controlled starter/alternator. The system controller monitors starter/alternator output and phase current and/or regulates the rate of change of output current in response to increasing electrical load. In an instance where monitored rates of output current change exceed predetermined thresholds, the response rate of the starter/alternator, i.e., rate of change of output current, is set at a predetermined threshold so as to prevent the braking effect of the increasing electrical load from stalling the I.C. engine or causing other operational failure.

Abstract: A starting apparatus for an internal combustion engine comprises a starter/alternator assembly operatively coupled to the engine and capable of being operated in a starter mode for starting the engine and in a generator mode for generating electric power when driven by the engine. The starter/alternator assembly includes a starter/alternator machine drivingly connected to the engine, an inverter provided for controlling an output of the starter/alternator machine to selectively choose either the starting mode or the generation mode, and a starter/alternator speed sensor for monitoring a rotational speed of a rotor of the starter/alternator machine that is electrically connected to the starter/alternator inverter. A method of controlling the engine starting apparatus controls transition of the starter/alternator assembly from the starter mode to the generator mode in response to the rotational speed of the starter/alternator machine directly sensed by the starter/alternator speed sensor.

Abstract: A lubricating oil filter has a housing which includes a first shell providing a housing base and a second shell providing a housing lid, wherein a filter media is suspended in a space defined by the shells by being clamped between a shoulder in the housing base and a rib projecting from the housing lid. The filter media may be either a flat filter media or a pleated pack filter media. In a preferred configuration, the housing is rectangular and has an unfiltered oil inlet in the housing lid which is at one end of the housing and a filtered oil outlet which is at the other end of the housing.

Abstract: A system of preserving a starter/alternator in an I.C. engine system installation from excessive operation in the starter mode is disclosed. The system describes a method of comparing the respective rotational speeds of the starter/alternator and I.C. engine in starter mode first to each other and then, if the same, to a predetermined threshold speed. If an overspeed condition is detected, disabling the starter/alternator in starter mode. In addition, if a predetermined number of I.C. engine start sequences have occurred without successful I.C. engine operation, the starter mode is disabled for a predetermined period of time. If several start failures have been detected, the starter/alternator can be disabled until a repair of the I.C. engine fault can be made. Where the respective rotational speeds of the starter/alternator and I.C.

Abstract: An improved steering axle provides an improved interface between the steering knuckle kingpin and the axle. The axle includes distal ends, each formed into a boss with a central bore configured to receive the kingpin of a knuckle assembly. The boss has an improved structure that includes first and second axially extending and angularly spaced ribs each defining an axial portion having increased thickness. Each rib extends angularly from a location longitudinally outboard of the bore axis to a location longitudinally inboard of the bore axis. The boss provides increased rigidity in the area surrounding the kingpin, thereby improving retention of the kingpin and preventing motion between the kingpin and the boss.

Abstract: An apparatus for manufacturing a case hardened journal cross includes an inductor having an open side to allow the journal cross to be inserted and withdrawn from the induction process with relative ease. The conductive frame of the inductor is shaped in a cross-like pattern that outlines the outer perimeter of a journal cross on each side of the journal cross. Because the induction coil passes across both sides of the journal cross, heat treating may be enhanced at specific locations of the outer surface of the journal cross by adjusting the distance of the induction coil from the journal cross. Also, a method for manufacturing such a journal cross includes determining the maximum stress distribution for the journal cross and, based thereon, determining the desired depth and location of the case hardening.

Abstract: An improved heat shield offers thermal insulation and reduced noise transmission for vehicular engine components, including exhaust manifolds. The structure has three layers: an outer structural metal layer, a center insulation layer to isolate heat and dampen noise, and an inner metal layer directly adjacent the shielded component for reflecting heat back to the shielded component. As disclosed, the shield has at least one edge portion defined by outwardly flared undulations or waves. The waved edge minimizes impact of plastic deformation of the metal edges during manufacture of the shield, which tends to produce wrinkling at the edges, and creates undesirable stiffness. Finally, the edge boundary of the outer metal heat shield layer is folded over the edges of the insulation and inner metal layers to avoid any sharp edges, thus preventing injury to installers and reinforcing the heat shield structure to enhance useful life under vibration and heat conditions.

Abstract: A method of welding at least two metal sheets protected by a zinc coating that has a low vaporizing temperature. The metal sheets are placed on top of each other in such a manner that at least one metal sheet has a curved section beginning at the weld area. The weld is performed partly on the metal sheets in contact and partly at the separation between the metal sheets in order to allow gases generated by vaporization of the protective material to escape from the weld area.

Abstract: A valve support and sealing element 23 for use with a filter cartridge is in the form of a molded unitary body (FIG. 2). The body includes (i) a first annular section 30 projecting into the filter hollow core 13 and having a sealing ring 33 for sealing with the end cap 53; (ii) a second annular section 34 sealing with the end plate 17 at interface 35; and (iii) a flange 38 radially projecting from the second section 34 to cover the inlet openings 19 to act as an anti-drainback valve. The flange 38 includes radial ribs 42 that also extend axially on the first section 30 but are spaced from the sealing ring 33. In operation, upon clogging of the media 14, oil flows between the ribs 42 and the sealing ring 33 is deflected radially inwardly to provide a bypass for the oil.

Abstract: A control algorithm provides automatic control of the turn-on angle used to excite the switched-reluctance motor (SRM). The control algorithm determines the turn-on angle that supports the most efficient operation of the motor drive system, and consists of two pieces. The first piece of the control technique monitors the position of the first peak of the phase current (&thgr;p) and seeks to align this position with the angle where the inductance begins to increase (&thgr;m). The second piece of the controller monitors the peak phase current and advances the turn-on angle if the commanded reference current cannot be produced by the controller. The first piece of the controller tends to be active below base speed of the SRM, where phase currents can be built easily by the inverter and &thgr;p is relatively independent of &thgr;m. The second piece of the controller tends to be active above base speed, where the peak of the phase currents tends to naturally occur at &thgr;m, regardless of the current amplitude.

Abstract: A wheel end assembly is provided that allows venting of pressurized air from a chamber defined by the hubcap, but prevents entry of contaminants into the chamber. The wheel end assembly includes a hubcap that is configured to be coupled to a wheel and defines a chamber for retaining lubricant for wheel bearings for the wheel. One wall of the hubcap has an aperture in fluid communication with the chamber and a plug is disposed within the aperture. The plug defines a valve for releasing pressurized air from the chamber. The assembly finally includes a cap that is supported on the body of the plug and extends in an outboard direction. The cap is disposed over an outlet of the valve and defines a first fluid chamber in fluid communication with both the outlet of the valve and ambient air. The cap and plug can be inserted into and removed from the aperture as a unit.

Abstract: The present invention relates to an improved primer coating for a multilayer gasket. The coating includes an elastomer, an epoxy resin and a particulate lubricant. The coating may also employ other components such as cure accelerators and reactive diluents. Also disclosed is a method of making the primer coating.

Abstract: A panel filter element having pleated filter paper media and precut gasket made of polyester felt is mounted in a tray inserted into the air intake housing of an internal combustion engine, wherein the air intake housing is made of NYLON® material. By having a peripheral gasket made of polyester felt, the gasket does not adhere to portions of the housing and tray. This allows the panel filter element to be easily removed from the housing. This is an improvement over polyurethane gaskets which adhere to the NYLON® of the housing when NYLON® and polyurethane are exposed to engine heat.

Abstract: The present invention relates to a method including thermal spraying a chromium nitride coating material on to an article. The chromium nitride may be in a powder form before thermal spraying. In one aspect, the thermal spraying includes melting the coating material, propelling the molten coating material toward the article to be coated, and coating the article with the molten coating material. In another aspect, the coated article is one or more piston rings.

Abstract: A method includes hydroforming a pair of side rails from a single closed structural member so as to having a plurality of mounting areas integrally formed thereon. The frame assembly includes a pair of longitudinally extending side rails having a plurality of transverse cross member extending therebetween. Each of the side rails is formed from a single integral closed structural member that extends the entire length of the frame assembly. The cross members extend generally perpendicular to the side rails and may be formed having any conventional structure. Each of the side rails is manufactured having a plurality of integrally formed mounting structures to facilitate the connection of the various components (not shown) of the vehicle directly to the frame assembly without the use of any brackets and mounts. The side rails are hydroformed to desired shapes and have respective pluralities of apertures and protrusions formed therein.

Abstract: An apparatus for, and a method of, braking a vehicle by selectively providing pressurized transmission fluid through at least one valve to brake a vehicle drivetrain proportionally to the engagement of a brake system activation means.

Abstract: A valve stem seal assembly includes an elastomeric sealing member for sealing between a reciprocally moveable valve stem and an associated valve guide in an internal combustion engine. The assembly includes a cylindrical retainer that incorporates an end wall at a first end thereof for securing the elastomeric sealing member to the retainer. The valve assembly is installed over the valve guide, and the retainer is adapted for frictional securement to the guide, whereas the retainer extends down to and engages the surface or deck of the associated engine cylinder head. The retainer includes a radially extending bottom flange at a second end opposite the end wall, wherein the flange bears directly against the cylinder head deck. The upper surface of the flange provides a bearing surface for valve return springs, while the bottom surface of the flange includes an elastomeric sealing media bonded thereto.

Abstract: A radially compliant valve stem seal assembly is adapted for installation over a valve guide of an internal combustion engine. The assembly includes a metallic cylindrical straight-walled retainer with an elastomeric sealing element chemically bonded to the interior surface of the retainer. The sealing element includes upper and lower portions; the upper portion includes a pair of sealing lips comprising an oil sealing lip and a gas sealing lip. The lips are adapted to meter oil through an interface between the seal assembly and the associated valve stem for assuring proper lubrication at the interface. The lower portion of the elastomeric sealing element provides one or more annular radially inwardly oriented gripping ribs adapted to engage the guide via an interference fit. The gripping ribs are adapted to balance forces of installation against those of securement of the valve stem seal assembly over a wide valve guide diameter tolerance range.

Abstract: A valve stem seal assembly includes a retainer with one or more built-in sprues, a cavity at one end, an annular flange on the opposite end, and a cylindrical interior passageway therebetween. The built-in sprues extend from the bottom surface of the cavity to the annular flange. When the valve stem seal assembly is fitted atop the valve guide, a gap is formed between the bottom surface of the cavity of the retainer and the top surface of the valve guide to accommodate manufacturing tolerances in the height of the valve guide. A jacket is integrally bonded to the retainer by introducing material into the cavity, through the built-in sprues, and out of the bottom of the annular flange. A method of manufacturing the valve stem seal assembly with one or more built-in sprues is disclosed.

Abstract: A filter for filtering a fluid, such as lubricating oil for an engine, has a first element for trapping small particles and a second filter element for trapping sludge, the second filter element being stacked on the first filter element. A flow-deflecting element is disposed between the first filter element and second filter element to provide a spinning motion to oil flowing from the second filter element as that oil joins oil which is passed through the first filter element. The spinning motion of the oil from the bypass filter element encourages mixing of the oil from the second filter element with the oil filtered by the first element. A centrifugal separator is disposed in an annular space between the filter elements and filter housing for imparting a rotary motion to the fluid prior to the fluid passing through the filter elements. This removes large particles from the fluid by centrifugal force so that large particles do not add to the contaminant load in the filter elements.