Abstract: An estimated brake rotor temperature is provided including a cooling effect during active braking as well as when braking is inactive. The cooling effect is based on a difference between the rotor temperature and sensed ambient temperature and is also preferably based on wheel speed. In an active braking mode, a heating effect is provided based at least on sensed wheel speed. If no brake pressure signal is available, the heating effect is further based on vehicle deceleration. The heating effects for front and rear brake units are relatively compensated for differences in heat generation due to load shifts during braking, the compensation being preferably based on vehicle deceleration. The brake rotor temperature estimation is realized in a programmed digital computer but does not use computer resource hungry exponential functions.

Abstract: A relieved support material for a catalytic converter has a strip of support material with one or more relief cuts. This is used to insulate a segment of catalyst along with one or more inner end-cones positioned at the beginning and end of the converter. The support material is wrapped around the catalyst and the one or more inner end-cones. The wrapped support material is then covered with an outer-layer shell.

Abstract: The problem of maintaining fluid modulus during a fast mode release of fluid pressure in a force generating apparatus having a force generating actuator fluidically coupled to a force generating device is solved by limiting the rate at which the actuator can reduce fluid pressure in an apply chamber of the actuator to a rate low enough to preclude a change in modulus of the fluid during the fast mode release.

Abstract: The invention provides a vehicle damper assembly and a method for modulating fluid flow through the same. The assembly includes a housing including a fluid carried therein. A piston is slidably carried in the housing and includes a ring and a core. At least one gap to allow fluid flow is formed between the ring and core. A rod is operably attached to the piston. The ring moves axially with respect to the core to vary the gap size and modulate fluid flow during operation of the assembly. The method includes axially moving a ring with respect to a core during assembly operation. At least one gap size is varied based on the axial movement, wherein the gap is formed between the ring and core.

Abstract: A two-part solder preform for use in attaching a leaded circuit component to a circuit board. The preform is formed by two different solid components, a first of which is formed of a lower-temperature solder alloy and the second of a higher-temperature solder alloy, in which the first solid component is present in a sufficient amount to dissolve the second solid component when the preform is heated above the melting temperature of the lower-temperature solder alloy but below the melting temperature of the higher-temperature solder alloy. Upon cooling, the preform yields a solder joint having a substantially homogenous composition, which bonds the lead to the circuit board. Preferred solder alloys for the first and second solid components are lead-free.

Abstract: A motorcycle including a two-cylinder engine. The engine includes a housing, first and second cylinders having first and second combustion chambers, respectively, and first and second pistons reciprocating in the first and second chambers, respectively. The motorcycle further includes a spark generating circuit including a spark plug having a spark gap exposed to the first combustion chamber, an ion sensing circuit including the spark plug and being operable to generate an ion signal indicative of an ion current generated across the spark gap, and an analysis module coupled to the ion signal circuit. The analysis module is operable to receive the ion signal and to analyze the ion signal to determine whether a no-combustion event occurs in the first cylinder. The analysis module may be further operable to determine if the spark generating circuit has an intermittent connection.

Abstract: A power generation system providing an engine configured to produce hydrogen rich reformate to feed a solid oxide fuel cell includes an engine having an intake and an exhaust; an air supply in fluid communication with the engine intake; a fuel supply in fluid communication with the engine intake; at least one SOFC having an air intake in fluid communication with an air supply, a fuel intake in fluid communication with the of, engine exhaust, a SOFC effluent and an air effluent. Engines include a free piston gas generator with rich homogenous charge compression, a rich internal combustion engine cylinder system with an oxygen generator, and a rich inlet turbo-generator system with exhaust heat recover. Oxygen enrichment devices to enhance production of hydrogen rich engine exhaust include pressure swing absorption with oxygen selective materials, and oxygen separators such as an SOFC oxygen separator and a ceramic membrane oxygen separator.

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 method of glass frit bonding wafers to form a package, in which the width of the glass bond line between the wafers is minimized to reduce package size. The method entails the use of a glass frit material containing a particulate filler material that establishes the stand-off distance between wafers, instead of relying on discrete structural features on one of the wafers dedicated to this function. In addition, the amount of glass frit material used to form the glass bond line between wafers is reduced to such levels as to reduce the width of the glass bond line, allowing the overall size of the package to be minimized. To accommodate the variability associated with screening processes when low volume lines of paste are printed, the invention further entails the use of storage regions defined by walls adjacent the glass bond line to accommodate excess glass frit material without significantly increasing the width of the bond line.

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 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 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: 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: 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 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: 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: 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.