Abstract: A process is provided for forming a thin film deposit of a Ni—Ti—Hf ternary shape memory alloy on a substrate by magnetron sputtering deposition having high transformation temperatures and good shape-memory and mechanical properties. The method of forming a thin film deposit of a ternary shape memory alloy on a substrate by sputtering deposition comprises arranging a Ni—Ti—Hf target and a substrate within a deposition chamber, maintaining a working distance from the target to the substrate of about 83 mm to 95 mm; heating the substrate to a temperature high enough to induce in-situ crystallization; introducing a krypton working gas into the deposition chamber; applying appropriate level of deposition power so that the deposition rate is from about 6 Å per second to about 120 Å per second; and, depositing a Ni—Ti—Hf shape memory alloy film having a composition ranging from about Ni48(TiHf)52 to Ni50(TiHf)50.

Abstract: A wear resistant fuel pump for a vehicle includes a pump section having a flow channel and a rotatable impeller cooperating with said flow channel to pump fuel therethrough. The fuel pump also includes a motor section disposed adjacent the pump section and having a motor to rotate the impeller. The fuel pump further includes an outlet section disposed adjacent the motor section to allow pumped fuel to exit the fuel pump. The pump section includes a plurality of plates disposed axially adjacent to and cooperating with the impeller. At least one of the plates includes a wear insert that improves abrasion wear characteristics therebetween.

Abstract: A method is provided for use in an electronic processor-controlled vehicular braking system. When integrated into such a braking system, the need for downstream caliper pressure sensors, and any algorithms associated therewith, is eliminated. The method consists of generating and using estimated caliper pressure for comparison to command pressure, instead of actual caliper pressure. The method elicits a far quicker yet accurate response to the estimated caliper pressure in line with command pressure.

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 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 magneto-rheological (“MR”) damper having a damper body tube containing an MR fluid. A piston assembly is disposed in the damper body tube and forms an annular flow gap between the piston assembly and the damper body tube. The piston assembly has a piston core containing ferrous material and an electromagnetic coil mounted on the piston core for generating a magnetic field. The damper further includes a ferromagnetic member positioned outside of the damper body tube substantially adjacent the piston assembly for providing at least a part of a magnetic flux return path for the magnetic field.

Abstract: A magneto-rheological (“MR”) damper having a gas cup that slidably moves within a damper body tube and isolates an MR fluid from a gas in one end of the damper body tube. The gas cup has a dynamic seal that comprises an MR fluid compatible O-ring located in a narrow O-ring groove disposed in an outer surface of the gas cup. The narrow O-ring groove is sized to reduce entrapment of abrasive magnetic particles in the MR fluid between the O-ring and an inner surface of the damper body tube. The O-ring groove has a free roll room of about less than 12%.

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: A disc brake rotor is retained on a bearing hub assembly during handling, shipping and installation of the wheel by a retaining clip. The clip is snapped into a machined groove on the bearing pilot hub after the disc brake rotor is assembled to the bearing and gauged for optimal runout. The retaining clip acts as a physical block thereby keeping the rotor positioned on the bearing hub and eliminates the need for specific orientation of a retention device or removal of material from the disc rotor or wheel as in prior systems.

Abstract: A circuit for disconnecting a neutral point of an electric machine includes an inductance connected to a lead of the electric machine; a three-terminal solid-state switch that has a first terminal connected to the inductance, a second terminal connected to the neutral point, and a third terminal for controlling a flow of current between the first and second terminals; a controlling circuit coupled to the three-terminal solid-state switch that includes a first loop that has a power source, a resistance, and a voltage regulator to maintain a first voltage upon the third terminal, and a second loop that has a power source, a resistance, and a trigger switch being controllably switched on to thereby close the first loop whereby a second voltage is applied to the three-terminal solid-state switch to thereby substantially electrically disconnect the first terminal from the second terminal.

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 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 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: 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 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: 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 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: 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: 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.