Abstract: A wheel bearing assembly for a motor vehicle comprises a motor having a shaft and a spindle integral with the shaft. At least one row of bearing balls supports the shaft.

Abstract: A solder alloy containing indium, lead, silver and copper as its alloying constituents, and a soldering process employing the solder alloy. The solder alloy consists essentially of, by weight, about 50% to about 65% indium, about 0.5% to about 3.0% silver, up to about 3.0% copper, the balance lead and incidental impurities. The alloy preferably has a solidus temperature in a range of about 173° C. to about 178° C., and a liquidus temperature in a range of about 187° C. to about 196° C. As such, the alloy can be used in a reflow process with a peak reflow temperature of about 220° C. to about 240° C., and is therefore compatible with most circuit components and can be simultaneously reflowed with 63Sn-37Pb solder.

Abstract: A suspension damper system is provided. The damper system includes a damper with a damper rod, a portion of which extends from the proximal end of the damper. The damper rod includes a bore and an electrode disposed within the bore. A fastener for securing the damper rod to a vehicle is also provided. The fastener is disposed over the damper rod and includes a circumferential groove. An electrical connector which includes an electrically conducting terminal is connected to the electrode. The connector includes a lock which mates with the groove in the fastener and includes a ground terminal which is connected to the damper rod.

Abstract: A solid-oxide fuel cell system having an integrated air supply system, including a central air pump, distribution manifold, air control valves, mass air flow sensors, and supply ducts, for controllably supplying oxygen for the fuel cell reaction, both through and controllably bypassing cathode air heat exchangers; combustion air for a combustor of tail gas from the anodes; cooling air for electronic controls; and reforming air to a liquid fuel vaporizer integral with a hydrocarbon fuel reformer.

Abstract: An accumulator for use in a heat pump system accommodates the flow of refrigerant in first and second directions as the system heats and cools, respectively. The accumulator includes a body and a cap. The body includes an inlet for receiving refrigerant from a compressor and an outlet for sending refrigerant to the compressor. A first port communicates with a front end heat exchanger for receiving refrigerant from this heat exchanger when heating and for sending refrigerant to this heat exchanger when cooling. A second port communicates with a passenger compartment heat exchanger for sending refrigerant to this heat exchanger when heating and for receiving refrigerant from this heat exchanger when cooling. A reversing valve, disposed in the cap, moves between a first position when heating and a second position when cooling such that the accumulator can accommodate the flow of refrigerant in the either direction.

Abstract: An electrical system architecture for a vehicle brake by wire system provides three electrical power sources: an electric generator, an electric power storage device such as a battery, and a third source which may be either an electric generator or storage device. An electric circuit has a common node and (1) connects the first electric generator to the common node through a first diode, (2) connects the first electric power storage device to the common node through a second diode, (3) connects the electric power source to the common node through one of the first and second diodes, and (4) connects the common node to the electric power inputs of control unit through circuit breaker devices. A sub-circuit within the electric circuit interconnects the first and second diodes, the common node and the first and second circuit breaker devices and isolates them within a zone protected from short circuits to points outside the zone.

Abstract: A caliper for a motor vehicle braking system comprises a housing having a bore, and a piston slidable in the bore. A groove is formed in one of the housing or the piston, and a seal is disposed in the groove. The seal has a dry lubricant coating.

Abstract: A hydraulic mount provides active control through the use of a rotary track assembly connecting a primary pumping chamber of the mount to a secondary fluid chamber. With low amplitude vibrations the fluid path remains open, providing low dynamic stiffness. For high amplitude vibrations, the fluid flow path is closed, providing a high level of dynamic stiffness. The rotary track assembly control is continuously variable offering a wide range of active control of hydraulic mount stiffness.

Abstract: An acceptance tester for a fuel rail seal gland drops a weight to drive a simulated fuel injector dynamically at the opening of a seal gland to be tested, simulating accurately the mechanics of insertion of an injector into the gland on a production line. The force of insertion may be varied by varying the weight to be dropped, the height from which the weight is to be dropped, or both. A “pass” is indicated when the simulated injector and O-ring are inserted into the gland without damage to the gland or O-ring. A “fail” is indicated when the simulated injector and O-ring either fail to be inserted into the gland or damage the gland during insertion. A maximum acceptance force for a given combination of gland and fuel injector can easily be determined empirically. A continuous process for plating fuel rails may be readily controlled by testing plated glands at statistically significant intervals, permitting operators to accurately monitor plating thickness inferentially.

Abstract: An encased electrical assembly includes a housing, a printed circuit board (PCB) and a cover. The housing includes a plurality of receiving apertures and the PCB includes a plurality of securing apertures shaped to receive a conductive fastener for securing the PCB to the housing. The PCB includes a plurality of conductive traces with two of the conductive traces having first ends electrically connected to a different one of two electrical contacts that are electrically accessible from outside the housing and second ends routed to different ones of the securing apertures. Each of the remaining conductive traces are routed between a different pair of the securing apertures such that when each of the securing apertures receives a secured conductive fastener, continuity is achieved between all of the conductive traces. The cover, when attached to the housing, obscures at least one of the conductive fasteners.

Abstract: An improved pressure sensor assembly incorporates a stainless steel pressure sensing element that is welded to a stainless steel pressure port insert-molded into a molded plastic pressure vessel. Sealing between the pressure port and the pressure vessel is enhanced by a O-ring seated in a groove on the outer periphery of the pressure port, or by a sealant applied to the periphery of the pressure port prior to the insert molding operation. The pressure port is insert-molded with the pressure vessel so as to expose an axial end of the pressure port having a stepped annular surface, and the pressure sensor element is welded to the exposed end of the pressure port. The plastic material of the pressure vessel extends into a central axial bore of the pressure port to minimize leakage by maximizing a potential leakage path for the medium contained by the pressure vessel, and over a shoulder of the pressure port to secure the pressure port in the body of the pressure vessel.

Abstract: An improved over-voltage protection circuit for a motor vehicle electrical system includes an over-voltage responsive circuit for momentarily disconnecting the vehicle storage battery and alternator from vehicle electrical loads, and an auxiliary storage battery for supplying a safe operating voltage to the electrical loads during the momentary disconnection. The over-voltage responsive circuit includes a MOSFET device that couples the vehicle storage battery and alternator to the electrical loads and auxiliary storage battery, and a voltage responsive circuit that turns the MOSFET device off to decouple the electrical loads and auxiliary storage battery from the vehicle storage battery and alternator so long as an over-voltage condition is detected.

Abstract: A three region control strategy for a permanent magnet motor is presented. In a first control region, the permanent magnet motor is operated at, a 120° conduction square wave mode at reduced phase current, and below a no-load speed. The motor phase current commutation causes eddy current losses in the rotor magnets and core which are insignificant due to the low phase currents and relatively low rotor speed. Meanwhile, the inverter switching losses are kept low as two switches are in use (on/off) for each current commutation during the 120° conduction mode. In a second control region, the permanent magnet motor is operated at a 180° conduction sinusoidal wave mode with high phase currents. The 180° conduction sinusoidal wave mode minimizes the commutation loss. In a third control region, the permanent magnet motor is operated above its no-load speed or in a field weakening mode.

Abstract: The present invention relates to high oxygen ion conducting/oxygen storage (OIC/OS) materials, a catalyst employing the OIC/OS materials, and a method for converting hydrocarbons, carbon monoxide and nitrogen oxides using the catalyst. The OIC/OS materials have significantly higher oxygen storage capacity than that predicted based on Ce content due to the unexpected high and facile redox activity of the added niobium. These materials are further characterized by having a tetragonal crystalline structure under oxidizing conditions (in air) up to about 1,200° C. and a cubic crystalline structure in reducing conditions (5% hydrogen) up to about 1,000° C. for 24 hours. These materials comprise, based upon 100 mole % of the metal component in the material, up to about 95 mole % zirconium, up to about 50 mole % cerium, about 0.5 to about 15 mole % rare earth metal(s), alkaline earth metal(s) or a combination thereof, and about 0.5 to about 15 mole % niobium.

Abstract: A wobble joint for use in automatic washing appliances and the like includes inner, outer and intermediate joint members which have nesting curved sliding surfaces that enable the joint members to pivot relative to one another. The joint has motion limiting features acting between the intermediate joint member and each of the inner and outer joint members to restrict relative movement between the outer joint member and the intermediate joint member to pivotal movement within a first plane and to restrict relative movement of the intermediate member and inner joint member to pivotal movement within a second plane transverse to the first plane. The motion limiting features comprise first and second arcuate grooves extending parallel to the first and second planes and retainers captured in the grooves and relatively moveable therealong.

Abstract: A modular EGR valve includes an actuator subassembly and a metering subassembly. The metering subassembly defines a metering port and a metering chamber. The metering port and the metering chamber have a predetermined relative configuration. The metering subassembly is configured for being coupled to the actuator subassembly and for being coupled to an engine.

Abstract: A system for selectively switching the action of a valve in an internal combustion engine includes a roller finger follower having a frame and a disengageable roller. A two-part axial pin for the roller axle is spring-loaded to urge the pin axially of the roller axle to disengage the first part of the pin from the follower frame and simultaneously disengage the second part of the pin from the roller axle. Thus the roller becomes detached from the frame and the follower cannot actuate its designated valve. The roller and pins are retained within the frame by at least one torsion spring. The pins may be controllably reinserted into the sides of the roller and frame to reconnect the roller to the frame by any of various electromechanical and/or hydraulic means. When used in conjunction with a camshaft having high lift and low lift cam lobes, the deactivated follower will then actuate its designated valve according to the profile of the low lift lobes, which may be a no lift profile.

Abstract: An improved vehicle restraint system includes a seat belt tension sensor and an occupant detection control module for characterizing the occupant of a vehicle seat to determine whether to allow or suppress deployment of supplemental inflatable restraints for the occupant. The belt tension sensor includes on-board signal processing circuitry and is coupled to occupant detection control module via a two wire interface that both powers the sensor and its signal processing circuitry and supports communication of belt tension data to the occupant detection control module. The sensor produces an electrical signal responsive to seat belt tension, and the processing circuitry generates one of a specified number of messages pertaining to the range of the measured tension, and then modulates the current through the two wire interface to communicate the generated message to the occupant detection control module.

Abstract: The present invention includes a manifold catalytic converter. The catalytic converter is positioned immediately adjacent the manifold. The manifold and the converter end cone are cast from a single integral piece. The manifold/converter end cone casting includes an end cone portion having an end cone wall having a shoulder formed therein for engaging the front face of a catalytic converter substrate. A lip or ledge extends from the shoulder and surrounds and engages the outer surface of the ceramic substrate immediately adjacent the front face of the substrate. A metal shell is connected to the end cone and is spaced apart from the ceramic substrate. A support material is provided between the ceramic substrate and the metal shell. A second end cone is connected to the shell.

Abstract: A suspension damper system is provided. The damper system includes a damper with a damper rod, a portion of which extends from the proximal end of the damper. The damper rod includes a bore and an electrode disposed within the bore. A fastener for securing the damper rod to a vehicle is also provided. The fastener is disposed over the damper rod and includes a circumferential groove. An electrical connector which includes an electrically conducting terminal is connected to the electrode. The connector includes a lock which mates with the groove in the fastener and includes a ground terminal which is connected to the damper rod.