Abstract: A lightweight spacer for mounting a vacuum brake booster on a panel provides integral flexible sealing lips to seal the interfaces between the panel, spacer, and booster. Integral retaining tabs are provided for holding the spacer in place on the booster during shipping and installation of the booster. Tubular inserts within the spacer are retained and cushioned against rattling by a thin web of material extending over the end of the insert.

Abstract: A flexible circuit film oil sensor includes a flexible circuit film surrounded by a flexible border. A core support flap and a weld flap are attached to opposite ends of the flexible border. The flexible circuit film includes an oil level sensing electrode surface, an oil condition sensing electrode surface, a resistive temperature device, and a common electrode surface. The flexible circuit film engine oil sensor is wrapped around a core structure so that a spiral oil chamber is formed. Accordingly, the spiral oil chamber is at least partially filled with oil and electrical signals are provided across the electrode surfaces in order to monitor the level and condition of oil within the sensor. Additionally, the resistive temperature device provides a signal representative of the temperature of the oil within the sensor.

Abstract: A method is disclosed for detecting misfire or partial burn and for controlling spark retard in the cylinders of an internal combustion engine operated under the control of a microprocessor and utilizing signals indicative of the pressure in said cylinder at crank angle positions before and after initiation of combustion. A ratio of the actual pressure to the motored pressure in the cylinder at one or more predetermined crank angles is used to estimate the fraction of fuel burned which, in turn, enables a determination of combustion failure in said cylinder cycle. Confirmation of said misfire or unacceptable partial burn leads to correction of engine operation by said controller and/or to a diagnosis of possible damage to the vehicle's catalytic converter. This method also permits better engine operation under conditions of high spark retard.

Abstract: A corrosive resistant electronics assembly 10 is provided including at least one heat generating electronics component 12 mounted on a substrate 14 and positioned within potting material 18. A thermally conductive block element 24 is thermally mounted to the at least one heat generating electronics component 12 and positioned within the potting material 18, thereby providing a corrosive resistant electronics assembly 10 with improved thermal dissipation.

Abstract: The steering column tilt assembly has a tilt housing that is pivotally attached to a fixed housing. A fixed shoe is attached to the fixed housing. A pivoted shoe is pivotally attached to the tilt housing. A shoe release lever has a wedge surface that holds the pivoted shoe in engagement with a fixed shoe when in a locked position. The shoe release lever has two trunions that are received in bores in the tilt housing. A release lever slot between the bores receive the pivot end shank portion. An open quadrant of the lower bore portion permits the shank portion to be moved into the slot. A spring urges the shoe release lever toward the locked position.

Abstract: An improved vehicle crash sensing apparatus quickly and reliably characterizes frontal impacts with only minimal data processing requirements. Two or more longitudinally separated piezoelectric strips strategically located in a frontal portion of the vehicle produce impact signals that are analyzed to characterize the type of impact and the structural crush rate. In a simple implementation involving only two piezoelectric strips, a first strip extends laterally along a forward portion of the front bumper, and a second strip extends laterally along a forward portion of the hood panel, above and rearward of the first strip. In cases where an impact signal is developed by only one of the two strips, a high (under-ride) or low (over-ride) impact is indicated. If impact signals are developed by both strips, the intervening time is measured as an indication of the structural crush rate.

Abstract: An error detection circuit for an airbag deployment control system includes a delay circuit receiving an analog acceleration signal, a difference circuit producing a difference signal based on a time difference between the original and delayed acceleration signals, and a first comparator circuit comparing the difference signal to first and second threshold signals. If the difference signal falls within an error region defined between the first and second threshold values, a decision circuit inhibits an otherwise pending airbag deployment event. If, on the other hand, the difference signal falls outside of the error region, the decision circuit allows airbag deployment with minimal delay.

Abstract: According to the present invention, an in-line compounding and extrusion deposition compression molding apparatus and method for producing a fiber-reinforced molded structural component is provided. The apparatus comprises an extruder device having an internal cavity formed therein and an extruder screw rotatably disposed within the internal cavity for producing a polymer melt. A deposition die head is disposed at a first end of the device, the deposition die head having a die channel disposed therein for receiving the polymer melt from the device. The apparatus includes at least one fiber element for feeding at least one reinforcing fiber element into the die channel for compounding the at least one reinforcing fiber element with the polymer melt to produce a fiber-reinforced polymer compound. The apparatus additionally includes a mold for receiving the fiber-reinforced polymer compound to form the fiber-reinforced molded structural component.

Abstract: A force generating apparatus (10) for providing a force to a moving element based upon receipt of an electrical force signal includes a force applying element (33) coupled to the moving element for applying the force to the moving element and an actuator (21) coupled to the force applying element (33) for actuation thereof in response to receiving the electrical force signal. The force generating apparatus (10) further includes a controller (18) for determining when the force applying element (33) is in an apply mode, determining the elapsed time until reversion to a normal mode, determining when the elapsed time is greater than a predefined minimum, modifying the value of the electrical force signal sent to the actuator (21), and modifying a stored control parameter.

Abstract: A power system including a cable drive for adjusting a steering column of an automotive vehicle in response to rotation of a jack screw. A cable transmits torque from a motor-driven output shaft to the jack screw. The cable has terminal portions received in sockets in the output shaft and in the jack screw. The terminal portions and the sockets are square in cross section. An end part of each terminal portion is twisted to cause corners of the terminal portion to interfere with comers of the socket into which it extends to provide substantially a lash-free connection between the terminal portions of the cable and the sockets.

Abstract: A force generating apparatus provides a force to a moving element upon receipt of an electrical force signal. The force generating apparatus includes a force applying element coupled to the moving element for applying the force to the moving element and an actuator coupled to the force applying element for actuation thereof in response to receiving the electrical force signal. The force generating apparatus further includes a controller for receiving a desired force actuation signal, determining a parameter of the desired force actuation signal, selecting a set of gains based on the parameter, applying the set of gains to a linear control function, determining the electrical force signal as a function of the non-linear control function, and sending the electrical force signal to the actuator.

Abstract: A system for steering the wheels of a vehicle. The system includes a steering gear provided with a steering rack reciprocable in a power cylinder. A steering shaft has a pinion meshing with the steering rack. A hydraulic fluid system assists the reciprocation of the steering rack. The hydraulic fluid system includes a power piston reciprocable in the power cylinder. A control valve directs hydraulic fluid from a pump to the power cylinder at one side or the other of the piston, depending on the direction of rotation of the steering shaft. A lock valve is operable when closed to lock the rack against reciprocation to prevent steering of the wheels by preventing fluid flow in the hydraulic fluid system. The lock valve is controlled by a solenoid-operated electronic controller.

Abstract: A method and device for verifying whether a cavity (16) enclosing a micromachined sensing structure (14) between a pair of wafers (10, 12) is hermetically sealed by detecting the presence of moisture within the cavity (16). The method entails forming a bare, unpassivated PN junction diode (20) in a semiconductor substrate, preferably a device wafer (10) with the sensing structure (14). The device wafer (10) is then bonded to a capping wafer (12) to enclose the PN junction diode (20) and micromachine (14) within a cavity (16) defined by and between the wafers (10, 12). The reverse diode characteristics of the PN junction diode (20) are then determined by causing a reverse current to flow through the diode (20). For this purpose, either a known voltage is applied across the diode (20) and the reverse leakage current measured, or a known reverse current is forced across the diode (20) and the voltage measured.

Abstract: A circuit for converting an analog signal to a PWM signal samples an amplitude of the analog signal at first sampling rate and a second slower sampling rate, and produces corresponding first and second signals. A comparison signal defines a first state when the first signal is greater than the second signal, and otherwise defines a second opposite state. The PWM signal switches from a first signal level to a second signal level when the comparison signal switches from the first state to the second state only if the comparison signal thereafter remains in the second state for a specified delay period, and the PWM signal switches from the second signal level to the first signal level when the comparison signal switches from the second state to the first state only if the comparison signal thereafter remains in the first state for the delay period.

Abstract: A method of measuring elevational misalignment of an automotive radar sensor in a factory or service setting utilizes two or more targets that can be discriminated by the radar system. The targets are positioned at different elevational angles with respect to the desired elevation axis, and the degree of elevational misalignment is determined according to the ratio or difference in return signal amplitude for the two targets. Discrimination of the targets may be ensured by differences in range, azimuth angle or Doppler. Since the amplitude difference is a measure of misalignment, the measurement may be used to verify proper alignment or to indicate the amount of adjustment required to achieve proper alignment.

Abstract: A method for inhibiting or eliminating case erosion in a pencil ignition coil having an internal primary winding and an external secondary winding and shield. Three alternative means for resisting damage due to the partial discharge phenomenon arising from a high electric field in such coil configurations are provided: (i) applying an ozone resistant coating on the case; (ii) applying a coating on the case for eliminating partial discharge under the shield; and (iii) applying a polyimide tape covering to the case for resisting partial discharge under the shield.

Abstract: A fuel tank cover assembly for a fuel tank of a vehicle includes a cover adapted to close an opening in the fuel tank having a fuel reservoir disposed therein and a fuel filter disposed within and attached directly to the cover to filter fuel from the fuel tank to an engine of the vehicle.

Abstract: A seat belt tension sensing assembly fixedly secured to a vehicle. The seat belt tension sensing assembly has a housing and a slider slidably received within the housing, the slider being capable of movement between a first position and a second position within the housing, the second position corresponding to a tension in the seat belt consummate with a child safety seat being secured by the seat belt, the slider having a first opening for a portion of the seat belt to pass therethrough. A first magnet and a second magnet are secured in a second opening in the slider, the first and second magnet being in a facing spaced relationship. A Hall effect device is fixedly secured to the housing and protrudes into the second opening of the slider. The Hall effect device is closer to the first magnet when the slider is in the first position and the Hall effect device is closer to the second magnet when the slider is in the second position.

Abstract: A vehicle roll control system including a torsion bar having a longitudinal axis and first and second end portions disposed along the longitudinal axis. A first arm includes a passive end fixed to the first end of the torsion bar and extending transverse to the longitudinal axis. A second arm is provided having an active end rotatably coupled to the second end portion of the torsion bar and also extending transverse to the longitudinal axis. The opposite ends of the first and second arms are each configured to couple to the vehicle chassis. An actuator including a cam locking element is provided for selectively locking and unlocking the active end of the second arm to thereby selectively prevent and allow rotation of the active arm relative to the torsion bar.

Abstract: An ignition coil assembly includes a core formed of magnetically-permeable material extending along a main axis, a primary winding disposed about the core, a secondary winding disposed on a secondary winding spool wherein at least one of the secondary winding leads is connected to a high-voltage connector terminal portion of the ignition coil assembly configured for connection to a remotely disposed spark plug, a case formed of electrical insulating material, and a magnetically-permeable shield disposed outwardly of the case. The secondary winding is progressively wound on the secondary winding spool, thereby eliminating failure modes associated with the segment-wound secondary windings, and, eliminating the need for pole pieces in the magnetic circuit, thereby reducing components, cost, weight, and size of the ignition coil assembly.