Abstract: A magnetorheological fluid formulation exhibiting consistently high yield stress during use. The MR fluid comprises martensitic or ferritic stainless steel particles prepared by a controlled water or inert gas atomization process. The stainless steel particles are resistant to corrosion and oxidation, are generally smooth and spherical, and maintain their shape and size distribution throughout their use under an applied 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 of the present invention is provided for use in an electronic processor controlled vehicular braking system. When integrated into such a braking system, the need for down-stream caliper pressure sensors, and any algorithms associated therewith, is eliminated, the method generating and using estimated caliper pressure, for comparison to command pressure instead of actual caliper pressure, and eliciting far quicker yet accurate response to be estimated caliper pressure in line with command pressure.

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: 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: 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: 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 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: 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: 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: A rotary damper for use in motor vehicle suspensions comprising a rotor disposed within damping fluid in a fluid chamber of a casing to form inner fluid volume and outer fluid volume, with first valve and second valve for controlling flow between the inner fluid volume and the outer fluid volume, and an accumulator using closed cell foam as a compressible material for fluid fill variation and thermal expansion. First valve controls flow from the outer fluid volume to the inner fluid volume for one direction of rotation of the rotor, while second valve controls flow from the inner fluid volume to the outer fluid volume for the opposite rotation of the rotor. Thus, the valves are configured to provide independent control of damping for each direction of rotation. A valve holder supporting the valves and providing flow passages is designed for powdered metallurgy fabrication.

Abstract: A rotary damper for use in motor vehicle suspensions comprising a rotor disposed within damping fluid in a fluid chamber of a case to form fluid volumes, with valves for flow control and an accumulator for fluid fill variation and thermal expansion mounted internal to the rotor. A first check valve and first control valve mounted in a first flow passage within the rotor allow flow from second fluid volume to first fluid volume, but restrict flow from the first fluid volume to the second fluid volume. Similarly, a second check valve and a second control valve mounted in a second flow passage within the rotor allow flow from the first fluid volume to the second fluid volume, but restrict flow from the second fluid volume to the first fluid volume. Thus, the valves are configured to provide independent control of damping for each direction of rotation.

Abstract: A haptic braking method and system is disclosed. A controller operates a pump to apply brake fluid to a brake when it is necessary to decelerate a wheel during an active cruise control mode of a vehicle. The controller further operates one or more valves to cyclically vary a pressure level of the brake fluid to cause one or more haptic movements of the brake.

Abstract: A method of positioning a cap on an output rod of a power booster comprises holding the cap in a fixed position, inserting a shaft of the cap into a bore in the output rod, and fixing the cap relative to the output rod.

Abstract: The invention provides a one-piece mounting bracket for mounting a vehicle damper assembly to a knuckle, a vehicle damper assembly, and a method for mounting a vehicle damper assembly to a knuckle. The one-piece mounting bracket includes a body having first and second opposing portions; the body portions include at least one opening formed therein. The bracket further includes a plurality of straps operably attached adjacent end portions of the first and second body portions. The bracket is adapted for operable attachment to a portion of the vehicle damper assembly with a plurality of proximate welds. The vehicle damper assembly includes a damper including a reservoir tube, and a one-piece mounting bracket operably attached to the reservoir tube with a plurality of proximate welds. The mounting method includes providing a one-piece mounting bracket, attaching the bracket to a portion of the vehicle damper assembly by a proximate welding process, and attaching the bracket to the knuckle.

Abstract: A micro-electro-mechanical structure including a semiconductor layer mounted to an annular support structure via an isolation layer wherein the semiconductor layer is micromachined to form a suspended body having a plurality of suspension projections extending from the body to the rim and groups of integral projections extending toward but spaced from the rim between said suspension projections. Each projection in said groups has a base attached to the body and a tip proximate the rim. The structure includes a plurality of inward projections extending from and supported on the rim and toward the body. Each such projection has a base attached to the rim and a tip proximate the body; wherein the grouped projections and the inward projections are arranged in an interdigitated fashion to define a plurality of proximate projection pairs independent of the suspension elements such that a primary capacitive gap is defined between the projections of each projection pair.

Abstract: The problem of flow induced instability in a control valve for a vehicle damper is solved by a generally tubular shaped valve spool having an open, bridged, flow-through end, rather than side flow openings. The flow-through end of the spool has a narrow flat edge oriented perpendicularly to the axis of the spool, with an inside surface of the spool forming a 55 to 90 degree angle with the flat edge, and meeting the flat edge in a sharp corner.