Abstract: A pneumatic brake booster includes a generally cylindrical shaped piston. The piston has a first piston end and a second piston end and defines a chamber at the first piston end and a piston bore at the second piston end separated by an air flow aperture. The piston bore includes a plunger aperture located at the second piston end. A plunger includes a first plunger end and a second plunger end and is movable between first and second positions. The second plunger end is located within the plunger aperture. An air valve has a first valve end and a valve second end and is movable between first and second positions and defines a valve bore for receiving the first plunger end. A collapsing spring is located within the valve bore and is adapted to couple the plunger and the air valve.

Abstract: A spark plug for igniting an air/fuel mixture in a combustion chamber of an internal combustion engine includes a spark gap having a variable distance defined between a central electrode and a ground electrode portion of a ground terminal. The ground terminal is formed using either a bimetallic layer arrangement wherein one of the metallic materials has a different coefficient of thermal expansion than the other metallic material, or is formed using a strut or by thickening the metal where the ground terminal is connected to a metal housing of the spark plug. The ground terminal deflects away from the central electrode when subjected to an increased temperature, such as may occur when the engine warms up during operation.

Abstract: Contoured metal-containing structural members and methods for making the same. The contoured structural members comprise metal-containing materials sandwiching a support or stabilizing structure. The contoured structure can be provided by tube rolling (or roll wrapping) the metal-containing materials and the support structure together and then, if necessary, bonding them or connecting them. With a contoured and generally non-flat structure, applications for the structural members of the present invention are nearly limitless.

Abstract: A fuel permeation barrier fuel tank for a vehicle includes a tank shell having a wall formed from a plurality of layers. The layers include at least an inner layer, an outer layer and a fuel permeation barrier layer disposed between the inner layer and the outer layer.

Abstract: An air bag module including a cushion, a diffuser and an inflator is provided. The cushion is expandable radially and rearward of the air bag module. The diffuser is disposed in the cushion and is also expandable radially and rearward of the air bag module. The diffuser includes a vent in fluid communication with the cushion. The inflator generates an inflator gas exhaustible into the diffuser to deploy the cushion. The inflation gas is receivable by the diffuser for expanding the cushion and the diffuser to a first predetermined position. The vent is positioned downstream of the interior surfaces when the diffuser is at the first predetermined position. The inflation gas is diffusible by the diffuser through the vent to radially expand the cushion after the rearward expansion to the first predetermined position. The cushion is further expandable rearward to a second predetermined position after the radial expansion of the cushion.

Abstract: A brake circuit comprises a master cylinder in communication with a front wheel brake, and in communication with a rear wheel brake through a hydraulic line. A sensor senses pressure in the master cylinder, and an electronic control unit in communication with the sensor controls an apply valve to proportion pressure between the front wheel brake and the rear wheel brake.

Abstract: A power booster comprises a rear housing section and a piston. An inner bearing is disposed around the piston, and is adjustable relative to the rear housing section to translate the piston. A method of setting an axial dimension of the power booster is also provided.

Abstract: A system and method for digital steering sensor fault detection comprises monitoring steering wheel position information from a digital steering wheel position sensor at set time intervals, determining steering wheel position information for the current time interval and the previous time interval, and advancing a value change counter if the steering wheel position information for the current time interval is the same as for the previous time interval; monitoring vehicle speed, and advancing a speed cycle counter when the vehicle speed crosses a first threshold speed after crossing a second threshold speed; and setting fault bit information if the value change counter is zero after the speed cycle counter reaches a speed cycle limit. The steering wheel position information can be for a plurality of digital steering wheel position sensor outputs and provide corresponding fault bits, which can be compared to a fault table to diagnose a particular fault.

Abstract: An assembly for actuating a parking brake comprises a screw, a nut mounted for translation on the screw, and a cable connected between the brake and the nut. A compliant element is mounted on the screw, and is adapted to expand axially with a change in tension in the cable.

Abstract: A trailer braking system for use in vehicles with automated braking systems, such as anti-lock brake systems (ABS) or traction control systems (TCS), integrates the trailer brake controller physically and functionally into the on-board controller for the automated braking system of the tow vehicle.

Abstract: The problem of providing air from a vehicle engine compartment to a breather port of a vacuum booster mounted on a wall separating the engine compartment from the passenger compartment is solved by adapting the wall to provide an air passage, when the rear wall of the booster is bearing against the wall.

Abstract: A brake caliper comprises a motor having a shaft, at least one first planetary gear, and at least one second planetary gear. The at least one first planetary gear is rotatably engaged with the shaft and with a piston, and is operatively engaged with a first carrier. The at least one second planetary gear is operatively engaged with the first stage carrier and with a second carrier. A ball screw is engaged with the second stage carrier for rotation therewith, and a ball screw nut is operatively engaged with the ball screw. A parking brake for the caliper is also provided.

Abstract: A vehicle rollover detection apparatus and method are provided for detecting an overturn condition of the vehicle. The rollover detection apparatus includes an angular rate sensor sensing angular rate of the vehicle, and a vertical accelerometer for sensing vertical acceleration of the vehicle. A controller processes the sensed angular rate signal and integrates it to produce an attitude angle. The vertical acceleration signal is processed to determine an inclination angle of the vehicle. The rollover detection apparatus adjusts the attitude angle as a function of the inclination angle and compares the adjusted attitude angle and the processed angular rate signal to a threshold level to provide a vehicle overturn condition output signal. Additionally, the rollover detection apparatus detects a near-rollover event and adjusts the variable threshold in response thereto to prevent deployment of a vehicle overturn condition, thus providing immunity to such events.

Abstract: An improved vehicle radar system and control aids the vehicle driver during both parking and back-up maneuvers. The radar system is equipped with both long range and short range radar detection antennas, an RF switch for selecting the active antenna, and a range bin having a depth that is adjustable “on the fly”. The back-up aid function is provided by activating the RF switch to select the long range antenna and setting the range bin to a relatively large depth to cover the long range in a short time. The parking aid function is provided by activating the RF switch to select the short range antenna, and setting the range bin to a relatively short depth to achieve high close range accuracy.

Abstract: A constant velocity stroking joint includes an inner race mounted to a shaft and accommodated for angular pivotal movement within an intermediate race to provide angulation to the joint assembly. The intermediate race is disposed within an outer race and a plurality of recirculating ball spline tracks is formed therebetween and accommodated in a plurality of spline balls. The endless tracks support the spline balls for free rolling, recirculating movement during axial stroking of the intermediate race within the outer race through its full range of axial stroke.

Abstract: A constant velocity joint has an outer race, inner race, and balls interposed therebetween. The balls are seated in apertures of a cage. The inner wall profile of the cage has a cross section contour through the longitudinal axis that is radial about a radius that has its center origins offset from the center point of the cage along the ball center plane. The outer wall profile also has a cross sectional contour that is radial about a radius with its center also offset from the center point along the ball center plane of the cage and from the radial center of the inner wall radius.

Abstract: A magnetorheological fluid formulation comprising magnetizable particles dispersed in a multi-component liquid vehicle comprising an organoclay stabilization mixture. At least one organoclay is selected for each liquid vehicle component, each organoclay having a surface chemistry that renders it preferentially compatible with the surface functionality of one of the liquid components relative to its compatibility to the remaining components whereby it is effective to stabilize, or gel, that component. A method of making an MR fluid is also provided in which liquid vehicle components are blended together, the organoclay mixture is added to the blend, and magnetizable particles are suspended therein, resulting in a stable MR fluid of suitable viscosity and yield stress.

Abstract: A torque sensing apparatus for use with a brake caliper having opposing brake pads positioned on opposite sides of a rotor. The brake caliper causes the brake pads to apply a braking force against the rotor that generates a braking torque. A torque transfer device is supported by the brake caliper and is in contact with one of the brake pads. The torque transfer device is resiliently movable with respect to the brake caliper in response to the braking torque. A torque sensor is positioned in a sensing relationship relative to the torque transfer device. Thus, the torque sensor provides an output signal related to a change of position of the torque transfer device and the braking torque. The torque sensor includes a magnet mounted on the torque transfer device and a magnet field sensor, for example, a Hall Effect sensor, is mounted on the brake caliper.

Abstract: An electro-hydraulic brake system containing four isolation piston assemblies each of which is comprised of a cylinder, a piston, and a pair of hydraulic lines. The cylinder has only two apertures, and the piston is disposed in the cylinder. The first hydraulic line communicates between a wheel brake and a first side of the piston through one of the apertures. The second hydraulic line communicates between an accumulator and a second side of the piston through the other of the apertures. The system components are arranged in a compact, easy to manufacture package.

Abstract: A segmented core for an electric machine includes segments stamped from coated electric steel. The segments each have a first end, a second end, and winding openings. A predetermined number of segments are placed end-to-end to form layers. The layers are stacked such that each of the layers is staggered from adjacent layers by a predetermined rotation angle. The winding openings of each of the layers are in vertical alignment with the winding openings of the adjacent layers. The stack of layers is secured to form the segmented core.