Abstract: A magneto-rheological (“MR”) damper having a damper body tube containing an MR fluid. A piston assembly is disposed in the damper body tube and forms an annular flow gap between the piston assembly and the damper body tube. The piston assembly has a piston core containing ferrous material and an electromagnetic coil mounted on the piston core for generating a magnetic field. The damper further includes a ferromagnetic member positioned outside of the damper body tube substantially adjacent the piston assembly for providing at least a part of a magnetic flux return path for the magnetic field.

Abstract: A piston assembly for use with an MR fluid damper. The piston assembly has a piston core and a flux ring positioned in a desired alignment with the piston core so that the flux ring forms an annular flow gap the piston core. The flux ring is secured to the piston core in the desired alignment by a plurality of projections extending across the flow gap between an inner surface of the flux ring and an outer surface of the piston core. The projections are molded through flux ring holes intersecting the inner and outer surfaces of the flux ring. A method for making the piston assembly is also described and claimed.

Abstract: A damper body for a magnetorheological (MR) damper and associated methods of forming the damper body. The damper body is formed of a base material, such as a steel, and is coated with an abrasion-resistant layer comprising chromium. The layer of chromium provides a sliding wear surface for sliding contact with a reciprocating piston. To avoid high-stress abrasive wear over the expected service life of the magnetorheological damper, the layer of chromium has a minimum thickness greater than or equal to a minimum thickness of about 8 &mgr;m. In other embodiments, be fore applying the abrasion-resistant layer of chromium, the damper body is coated with a layer of a hard coating material having a hardness greater than the hardness of the base material. The effective hardness of the damper body is a composite of the respective hardnesses of the base material comprising the damper body and the layer of hard coating material.

Abstract: A method for providing C4-type bumps which are higher than conventional C4 bumps. A dielectric substrate is copper cladded on both sides. At each prospective bump location, a via is laser ablated through the cladded substrate. A copper core is deposited within the vias to thereby connect the two claddings. A photoresist is applied to both claddings, a photomask having a predetermined exposure pattern is placed over the claddings, the photoresist is exposed to ultraviolet (UV) light to thereby polymerize in the exposed areas thereof, and the resulting photoresist image is developed by use of a developer solution to wash away of the unpolymerized areas of the photoresist. Now, the photoresist image provides a retainer wall spaced from, and circumferentially around, the vias. Next, a lead-tin solder alloy is electroplated, such as by a lead-tin fluoroborate bath, at the vias into the volumes defined by the retainer wall at each end of the vias.

Abstract: An energy absorber for a steering column includes a pair of plastic guides each of which is molded flat and closes at an integral living hinge around a corresponding one of a pair of serpentine flat metal straps so that the straps are captured in the guides between pairs of convex anvils on the guides. Each guide snaps into a guide slot in a mounting bracket on the steering column mast jacket. An inboard end of each flat metal strap is clamped to a vehicle body so that during a collapse stroke of the mast jacket, relative linear translation between the mounting bracket and the serpentine flat metal straps causes each of the straps to be thrust against and pulled across corresponding ones of the convex anvils. Plastic deformation of the flat metal straps at the convex anvils resist linear translation of the mast jacket. The dimensional accuracy of the molded plastic guides contributes to consistently predictable performance of the energy absorber.

Abstract: An integrated active steering and braking control system for providing one or more corrective yaw moments to a vehicle in response to a plurality of signals indicative of operational and environmental conditions related to the vehicle is disclosed. The system comprises a reference model, an estimator, a vehicle level brake/steer controller, and an actuator controller. The reference model provides a feedforward front steering angle correction signal a feedforward rear steering angle correction signal, a desired yaw rate signal, a desired lateral velocity signal, and a desired side slip angle signal. The estimator provides an estimated surface coefficient of adhesion signal, an estimated lateral velocity signal, and an estimated side slip angle signal. In response to the signals from the reference model and the estimator, the vehicle level brake/steer controller provides either a desired speed differential signal, a desired front steering angle signal and/or a desired rear steering angle signal.

Abstract: Disclosed is a current sensing system for measuring the current flowing through a current sensing resistance. The system has a calibration resistance coupled to the current sensing resistance and a pair of input resistances each having a first end coupled to one of the ends of the current sensing resistance and a second end coupled to one of the ends of the calibration resistance. A voltage is created across the calibration resistance and the calibration resistance is set at a predetermined level to compensate for the current sensing resistance deviating from a reference value. The voltage is filtered and amplified to produce an output representative of the measured current.

Abstract: A vehicle satellite crash sensor includes a microcomputer with a stored datum indicating intended use in a frontal application such as the front crush space or a side application such as a vehicle side door. The microcomputer also stores a program that processes a sensed acceleration signal, derives an oscillation value and derives an occupant restraint deployment signal at least in response to the oscillation value. The program includes stored code for two alternative oscillation derivation algorithms: one of which is used in frontal applications and derives an integral of the absolute value of the sensed acceleration signal; the other of which is used in side applications and derives an integral of the sensed acceleration. The stored datum determines which of the stored oscillation algorithms is used.

Abstract: A magnetorheological fluid formulation exhibiting high yield stress at high surfactant concentrations. The formulation has a strong network formation due to incorporation of a high surface area untreated fumed silica as a thixotropic agent. This untreated fumed silica has a surface area of at least about 250 m2/g, which enables a surfactant concentration in the formulation in an amount up to about 35% by weight relative to the weight of the fumed silica.

Abstract: A damper includes a piston that carries a relatively compact control valve for controlling fluid flow through the piston. The control valve provides a variable amount of damping by regulating damper fluid flow between the extension chamber and the compression chamber of the damper during extension and compression strokes. Pressure regulation across the piston is controlled through a flow path as determined by the control valve. The damping force of the damper varies depending upon the loading conditions of the vehicle. The control valve is air pressure actuated to adjust the damping force and control the flow of fluid in the flow path.

Abstract: An adjustable pedal system has a first pedal pivotally attached to the translatable nut of a first jack screw actuator for adjusting the fore and aft position of the first pedal and a second pedal pivotally attached to the translatable nut of a second jack screw actuator for adjusting the fore and aft position of the second pedal and a third pedal pivotally attached to the translatable nut of a third jack screw actuator for adjusting the fore and aft position of the third pedal. An electric motor drives the translatable nuts fore and aft, and a motor control switch assembly controlled by the fore and aft movements of two of the nuts maintain alignment of the three pedals. A memory circuit may be incorporated into the system for moving the pedals to a preselected adjusted position or indicating the preselected adjusted position. The memory circuit may be separate or incorporated in a seat memory module.

Abstract: An automotive ignition system includes a control circuit (52) operable to drive a coil current switching device (24) connected to an ignition coil (30) referenced at battery voltage. The control circuit (52) includes a drive circuit (20) and ring damping circuit (58) producing an inhibit signal (INH) to which the drive circuit (20) is responsive to control the state of the coil drive signal (GD). In a single pulse ignition system; i.e., an ignition system employing a single coil charging event per combustion cycle, the ring damping circuit (58) is responsive to a spark control signal (ESTBF) to control charging and discharging of a single capacitor (C1) to define the inhibit signal (INH). In a multiple pulse ignition system; i.e.

Abstract: There is provided a process that includes providing an extruded fitting having a bore formed therein. The bore is machined from one or both sides of the extruded fitting to provide a ledge on one side for interacting with a corresponding fitting and a stop on the other. A pipe and braze sleeve are placed in combination into the bore and engage the stop. The pipe and bore include anti-rotation and location irregularities formed thereon to maintain a desired orientation of the parts. A mandrel is used to deform the pipe and sleeve to the shape of the bore. The parts are then brazed in a furnace.

Abstract: A resistive surface pad 10 is provided, including a first upper contact surface 32, a second upper contact surface 34, a first lower contact surface 38 and a second lower contact surface 40. The first upper contact surface 32 and the second upper contact surface 34 are shaped to form a generally arc-shaped upper contact gap 36. The first lower contact surface 38 and the second lower contact surface 40 are shaped to form a generally arc-shaped lower contact gap 42. The second upper contact surface 34 and the second lower contact surface 40 are shaped to form a continuous, generally horizontal, center contact gap 44.

Abstract: A pressure sensor connector (10) for use with a pressure sensor element (12) that includes a plurality of pressure sensor terminals (13). The pressure sensor connector (10) includes a cap (18), a plurality of connector terminals (20) and a frame element (22). A plurality of contacts (24), included in the frame element (22), connect each of the plurality of connector terminals (20) to a corresponding pressure sensor terminal (13).

Abstract: A head up display (HUD) has multiple light sources of varying intensities for projecting a high quality image under various lighting conditions. The light sources provide illumination through an electronic display (e.g. an AMLCD) in the HUD. A high brightness light source illuminates the electronic display during bright or day light conditions. A low brightness light source illuminates the electronic display during night or low light conditions. Both light sources illuminate the electronic display during intermediate lighting conditions. A light panel conducts and diffuses light from the light sources to illuminate the rear of the electronic display. An optional light mixer reduces uneven lighting of the high brightness light source. In operation, the intensities of the light sources are controlled as a function of ambient lighting conditions to optimise the projected image quality.

Abstract: A method for making a sensor is disclosed, comprising mixing a metal oxide with a polymer to create a composition. The composition is applied to at least a portion of the sensing element comprising two electrodes with an electrolyte disposed therebetween, and calcined to form a protective coating. A gas sensor created in accordance with the above-referenced method is also disclosed.

Abstract: A brushless DC motor modifies motor commutation events to reduce noise by providing overlapping activation of the switch being deactivated with the switch being newly activated so that three switches are temporarily activated. The newly activated switch is pulse width modulated with a motor torque controlling duty cycle, and the switch being deactivated is pulse width modulated synchronously with the newly activated switch but with a duty cycle decreasing from the torque controlling duty cycle. The decreasing modulation of the switch being deactivated allows a slower current decrease in the phase turning off to reduce or eliminate the disturbances, and thus the noise. The decreasing modulation is preferably exponential in manner, with a time constant varying inversely with motor speed so that the duty cycle reaches a predetermined minimum in a predetermined maximum number of motor electrical degrees.

Abstract: In a preferred embodiment a vehicle instrument, comprising: a housing; a light pipe disposed in said housing; an applique disposed on a face of said light pipe; and a retainer disposed over said face of said light pipe, said retainer having structure pressing against an outer periphery of said applique to hold said applique against said face of said light pipe, said applique having no other means of attachment to said face of said light pipe.

Abstract: A fuel pump includes a pumping plunger reciprocable within a bore formed in a pump housing under the influence of a cam drive arrangement. The cam drive arrangement includes a reciprocable tappet member, a surface associated with the tappet member defining, in part, an auxiliary pumping chamber. A flow path interconnects the auxiliary pumping chamber and the bore such that fuel displaced from the auxiliary pumping chamber, in use, can be supplied through the flow path to the bore.