Abstract: A clamp for capturing an adjusted position of a motor vehicle steering column including a stationary bracket having planar sides on opposite sides of the steering column, vertical slots in the planar sides of the stationary bracket, and a rotatably immobilized bolt spanning the planar sides of the stationary bracket through the vertical slots. A primary nut includes a frustoconical shoulder and a tubular boss. The primary nut is screwed onto the bolt on one side of the stationary bracket and cooperates with a head of the bolt on the other side of the stationary bracket in squeezing together the planar sides of the stationary bracket. A plastic operating lever of the clamp has a lateral bore around the tubular boss on the primary nut and a frustoconical cavity which faces the frustoconical shoulder on the primary nut.

Abstract: A universal locating fixture for machining various sizes of engine connecting rods. In one embodiment, the fixture includes locating pads, opposed clamps and a crank bore-engaging equalizing locator on a fixed part of the fixture for locating and clamping the crank end of a connecting rod forging for machining. A single locating pad and opposed clamp and a pin end-engaging V locator are mounted on an axially adjustable slide of the fixture for locating and clamping the pin end of a connecting rod for machining. The clamps may be made to accommodate differing widths of connecting rods and the equalizing locator has two locating points spaced to accommodate various crank bore diameters without adjustment. Adjustment of the fixture to machine connecting rods of different lengths requires only axial adjustment of the slide to position the pin end locating pad, clamp and V locator in proper position for the new length.

Abstract: An air bag cover door includes a cover substrate molded of a plastic material and a flexible fabric tether having a main body portion integrally molded directly into the plastic material of the cover substrate such that the main body portion of the tether is entirely and continuously integrally connected to the cover substrate. Preferably, the cover substrate includes an upper surface and the main body portion of the tether is integrally molded with the upper surface of the cover substrate to provide a substantially smooth and flush upper surface on the cover substrate for receiving a foam layer and skin thereon to provide a smooth and even decorative surface.

Abstract: A tubular member is manufactured in a hydroforming and hydroshearing apparatus. A substantially right circular cylindrical workpiece is placed in a die and pressurized to hydroform a substantially rectangular tubular product. The workpiece is presheared during the pressurization period and is fully sheared during the withdrawal of a plurality of plunger members while the internal pressure is maintained. The plunger members are positioned in the die by respective power cylinders which control the withdrawal thereof.

Abstract: A catalytic plasma converter combines oxidation and reduction of exhaust gas emissions such as HC, CO, NO and NOx by providing a pair of catalytic metallic porous elements, such as electrically conductive metal matrix material, spaced apart to define an intermediate reaction chamber. High voltage electric charges of opposite polarity applied to the two elements generate a gas plasma in exhaust gases passing through the converter reaction chamber. Passage of gases through the catalytic elements oxidizes CO and HC emissions present in the exhaust gases while the gas plasma in the reaction chamber causes reduction of NO and NOx and further reaction of HC and CO exhaust emissions.

Abstract: In a vehicle with a first operating mode in which all vehicle wheels have substantially no lateral movement on a road surface and a second operating mode in which at least some of the vehicle wheels have lateral movement on the road surface, and with an actuator capable of affecting vehicle yaw rate, a vehicle yaw rate control method comprising the steps of: measuring an actual vehicle yaw rate; measuring vehicle steering wheel position; in the second mode of operation, determining a desired yaw rate command linearly responsive to the measured steering wheel position; wherein the actuator is controlled to minimize a difference between the measured vehicle yaw rate and the desired vehicle yaw rate.

Abstract: A battery pack has a plurality of batteries connected in series to provide a high voltage energy source and energy storage. The battery pack has a high voltage receptacle in which a high voltage harness is connected when power is to be distributed or stored. a cover guard prevents inadvertent access to the harness connector. The cover guard has integral therewith an electrical disconnect mechanism and latch mechanism which must be manipulated prior to exposing the harness connector. The disconnect mechanism eliminates the electrical connection of the batteries to a receptacle in which the harness connector is installed. The latch mechanism prevents removal of the cover guard prior to manual disconnection and also prevents reconnection prior to the cover guard being properly positioned.

Abstract: An engine cylinder block assembly for a V-type engine wherein inner walls of the cylinder banks define a relatively oil free valley which is closed by a rigid valley cover to provide additional stiffness to the inside walls of the blocks, thereby stiffening the block against vibration and bending. The valley cover also includes sealed pockets for enclosing knock sensors mounted upon upwardly extending bosses in the bottom of the valley to both protect the knock sensors and permit their removal without requiring removal of the valley cover from the engine cylinder block. Oil entrainment due to pulsing air flows between crank chambers of the engine are reduced by providing openings in the valley floor between the front and rear crank chambers of the engine while the adjacent inner crank chambers are separated from direct connection with the valley.

Abstract: A method of spin forming, comprising the steps of: providing a tool having a first plurality of forming rollers spaced at a second plurality of distances from a spin axis; spinning around the spin axis at least one member of a set comprising (i) a work piece and (ii) the tool; and engaging the tool and a first end of the work piece. The method allows increased diameter reductions of a free end of a work piece in a single forming operation without collapse of the end of the work piece.

Abstract: A valve flapper door return spring mechanism for an automotive HVAC housing is modified so as to compensate for tolerance variations, so that the door is held in a substantially rattle free return position regardless. One of a pair of resilient spring fingers sits in a V shaped notch created by the intersection of a pair of spring finger stop surfaces that are opposed in slope. The one spring finger can therefore continually seat itself into an equilibrium position at the bottom of the V, and always make solid contact.

Abstract: The normally smooth and uninterrupted cylindrical wheel and brake drum pilot surface of a wheel bearing spindle is process in a novel manner designed to reduce the potential for water induced corrosion at the contact interface. A low lead angle, square bottomed spiral cut reduces the pilot surface area considerably and provides water drainage channels radially inset from the remainder of the surface area. There is considerably less area in the contact interface to corrode, and the remaining area has water well drained away from it.

Abstract: A cast iron exhaust manifold having an inside surface covered with a ceramic coating comprising, by weight, about 30% to about 70% unfused silica, about 5% to about 30% magnesia, about 5% to about 20% alumina and about 3% to about 10% sodium oxide. The coating will preferably be built up in multiple layers at least one of which is relatively porous and another is relatively dense resulting from vacuum degassing of the slurry used to deposit the coating.

Abstract: Crank rocker variable valve timing (VVT) mechanisms are disclosed which are relatively compact and are applicable for operating individual or multiple valves. In an exemplary embodiment, an engine valve is driven by an oscillatable rocker cam that is actuated by a linkage driven by a rotary eccentric, preferably a rotary cam. The linkage is pivoted on a control member that is in turn pivotable about the axis of the rotary cam and angularly adjustable to vary the orientation of the rocker cam and thereby vary the valve lift and timing. The rotary cam may be carried on a camshaft. The oscillatable cam is pivoted on the rotational axis of the rotary cam. For some applications the rotary cam and follower could be replaced by a crank or eccentric driving a rocker arm. Numerous other variations in the arrangements are also possible.

Abstract: A door inner panel has a wall defining an opening for receiving a door hardware module. The wall has at least one cutout with upper and lower integrally bent flanges defining the upper and lower margins of the cutout of the door inner panel. The door hardware module includes a molded plastic frame having a network of molded plastic structural elements which support hardware mounting surfaces upon which various door hardware components is mounted. The structural elements include integrally molded receptacles having upper and lower slots which are adapted to interfit respectively onto the upper and lower integrally bent flanges of the wall cutout of the door inner panel so that the molded plastic frame becomes supported on the door inner panel in readiness for the installation of fasteners between the molded plastic frame and the wall of the door inner panel.

Abstract: Internal combustion engine variable valve timing control with a camshaft phaser for varying rotational phase between a camshaft and a crankshaft in response to a control command determined through a hybrid control strategy without resort to direct temperature measurement. For a range of phase errors requiring high response compensation, a control strategy emphasizing rapid response, such as a bang-bang strategy, is deployed. For a range of phase errors requiring high accuracy compensation, a control strategy emphasizing high precision, such as a proportional-plus-integral strategy, is deployed. The phase error ranges are updated periodically to account for changes in operating conditions. The control command includes an offset which varies in response to a periodically estimated control deadband to affirmatively account for the deadband with each issued control command.

Abstract: A method and device for brake application provides braking pressure augmentation when preferred. A power booster and master cylinder generate a braking pressure in relation to an operator's input on the brake pedal. An optional brake parameter sensor is used to determine when the power booster reaches a run-out condition. At least one control valve and pump are used to apply braking pressure in response to additional increases in brake pedal application by the operator, after the power booster reaches a run-out condition. The pump and control valve are optionally used to generate braking pressure independent of brake pedal inputs.

Abstract: A pick up truck configuration is adaptable for carrying a cargo load longer than the cargo box and preferably at or above the wheel covers protruding into the cargo box. An adaptable pick up truck configuration includes a cab portion and a cargo box. A box panel portion is pivotally connected to a front wall of the cargo box and is movable to a generally horizontal position in which the box panel portion partially overlies and is supported by the wheel covers. The cargo box includes a cargo box opening when the box panel portion is in the generally horizontal position. A cab panel portion is pivotally mounted to the cab portion and is movable between a generally vertical closed condition and a generally horizontal open position. The cab portion has a cab opening when the cab panel portion is in the generally horizontal position and the cab opening is at least partially aligned with the cargo box opening.

Abstract: A push rod and pedal assembly includes a pedal pivotally mounted on a vehicle for movement in a generally longitudinal direction and a socket portion mounted on the pedal and movable with the pedal. The socket portion preferably has an opening facing in a generally forward longitudinal direction. The push rod and pedal assembly further includes a longitudinally oriented push rod having a push rod end being alignable generally forward of the socket portion and insertable within the socket portion upon forward longitudinal movement of the pedal. Thus, the push rod end becomes coupled to the socket portion of the pedal upon the application of forward longitudinal movement to the pedal, such as by a foot of an assembler. Preferably, a retainer is mounted on the push rod end and the retainer and push rod end are insertable within the socket portion of the pedal by snap-fitted connection upon forward longitudinal movement of the pedal.

Abstract: An improved film type air temperature control valve for an automotive HVAC assembly has a flexible, apertured belt that wraps closely around both faces of a heater core case internal to the HVAC housing. Winding and unwinding of the belt around the heater core case, and across a heater core bypass passage, simultaneously opens up more of the bypass passage as it closes off more of the heater core faces, and vice versa. Because of the close conformance of the belt to and across the heater core faces, both faces of the always hot heater core can be completely closed to direct or indirect air flow, preventing any undesired incidental heating of the air flow.

Abstract: An instrument panel structure for use in an vehicle having opposing side pillars, so called "A Pillars". The structure includes an extruded cross car beam having a plurality of radially spaced grooves transversely extending along the length. End caps having a receiving cavity adapted to receive the cross car beam suitably mounted to each of the pillars and the cross car beam is installed within each of the end caps. A plurality of extruded component brackets adapted to slidably engage within the cross car beam are positioned therein along the beam. The component brackets are fixed positionally along the beam by a plurality of fasteners, adhesive joining, or welding. Advantageously the instrument panel structure provides a flexible and efficient method of installing interior components within a right hand drive or left hand drive vehicle with the same structural elements.