Abstract: A composite heat exchanger has an inner, serpentine circuit fluidly isolated from a surrounding outer, parallel flow circuit, allowing two different heat exchange media to be in thermal contact without physical mixing. A series of longer, inner tubes are bent into a U shape, with the parallel legs of each arm of the U jacketed by surrounding, outer tubes. Header plates are inserted over the outer tubes, moved to a spaced apart relation, and then all but the first and last inner tube ends are joined by separate U shaped junctions to created the primary, serpentine circuit. Finally, manifold tanks are attached to the header plates, covering, but fluidly isolated from, the U shaped junctions of the serpentine circuit. Corrugated fins are installed between the parallel surfaces of adjacent outer tubes.

Abstract: A fuel system and method for priming a diesel engine fuel system after assembly or when run out of fuel in which the system has a filter that can trap air allowing drainback of fuel to the tank. The system is provided with a fuel priming connection to the injection pump inlet, the connection having a closure for shutting the connection when not in use. A mechanically openable check valve, such as a Schraeder valve, is a preferred form of closure. The system is primed by reverse flow of fuel from the priming connection through the filter to the fuel tank to virtually eliminate trapped air from the system. The engine may then be started with a minimum of cranking. The engine may be restarted after running out of fuel by partially filling the tank and operating the normal feed pump while bleeding air from the system through the priming connection, which is closed prior to engine starting. The engine may then be reprimed after shutdown if required.

Abstract: A method for assembling a permanent magnet ring on a rotor body for an electric motor or generator where the body has a higher coefficient of expansion than the permanent magnet ring includes the steps of sizing the internal diameter of the ring for the greatest thermal expansion of the rotor and introducing longitudinal grooves in the rotor surface uniformly spaced about its circumference to accommodate the expansion of the adhesive used to bond the ring to the rotor.

Abstract: A connection between a collapsible mast jacket of an energy-absorbing steering column and a body of a motor vehicle including an outboard mounting bracket on the mast jacket having a pair of lateral flanges, a pair of open slots in the lateral flanges each having a pair of side edges interrupted by a plurality of evenly-spaced notches, a pair of capsules in the open slots rigidly clamped to the vehicle body, and a plurality of equally-spaced plastic shear pins on the capsules seated in the notches to couple the capsules to the outboard mounting bracket. Each capsule includes a capsule base having the plastic pins thereon and a separate capsule cover. The linear pitch between the plastic shear pins is the same as the linear pitch between the notches.

Abstract: A method of making a steering hand wheel for a motor vehicle having a metal spider, a molded plastic rim, and a plurality of molded plastic spokes integral with the rim and mechanically interlocked with the spider. The method according to this invention includes the steps of extruding a billet having a cross sectional shape matching the profile of the spider, forming the spider by cutting off a flat section of the extruded billet from an end thereof, and insert molding a plastic rim and a plurality of integral plastic spokes around the spider. Each of the plastic spokes has an inboard end molded around a corresponding one of a plurality of spoke bases on the spider with a plurality of integral plastic pins captured in respective ones of a plurality of perforations in the spoke bases to mechanically interlock the spider and the molded plastic spokes.

Abstract: A vehicle power liftgate cable drive has a cable drive housing. An electric motor with a motor housing and an output shaft is secured to the cable drive housing. A clutch pack with a first clutch driven by the output shaft and a second clutch driven by the first clutch, is mounted in the cable drive housing. One of the clutches in the clutch pack is a one way clutch and the other clutch is an electromechanical clutch. A pinion gear is driven by the second clutch. A driven gear is rotatably journaled on a fixed shaft and driven by the pinion gear. The cable drum is attached to the driven gear. A coil spring has one end fixed to the fixed shaft and its other end attached to the cable drum. The fixed shaft is rotated to preload the coil spring in a direction that tends to wind a cable on the cable drum and then the fixed shaft is fastened to the cable drive housing. A cable is attached to the cable drum and to the liftgate.

Abstract: A split rotor cooling fan clutch includes an input member that is constantly driven at engine speed, or at some selected proportion thereof. An output member is journaled on the input member so as to be supported thereon in a substantially nonrotating state when decoupled and alternately, to be concentrically rotatable in concert therewith at a variety of speeds. A space presented between the input and output members contains a quantity of magnetorheological fluid. An engagement mechanism includes the split rotor and coil, with a ferromagnetic element positioned to define an operative gap between the rotor and the ferromagnetic element. The coil is selectively energized with a given current to result in a torque transfer between the input and output elements that provides a rotational speed of the fan tailored to the cooling requirements of the associated engine. Internal heat generation is managed electronically to prevent overheating.

Abstract: A diagnostic for diagnosing fault conditions including leak and restriction conditions in a positive crankcase ventilation (PCV) system of an internal combustion engine in which temperature of intake air passed to the PCV system and temperature of exhaust gas exhausted from the PCV system are monitored under test conditions and a temperature change across the PCV system generated therefrom for comparison to an expected temperature change reference as a function of current engine operating conditions. A significant persistent deviation of the temperature change away from the expected temperature change is indicated as a fault condition of the PCV system.

Abstract: A door latch for latching the vehicle door in the closed position includes a fork bolt pivotally mounted on the latch housing for movement between the latching position engaging a striker in an unlatching position to unlatch from the striker and permit opening of the door. A detent lever is pivotally mounted on the latch housing for movement between an engaging position engaging the fork bolt in its latching position and a disengaging position disengaged from the fork bolt to permit pivoting of the fork bolt to its unlatching position. A spring acts between the detent lever and the latch housing to urge the detent lever to the engaged position. A catch member is provided to retain the detent lever in the disengaged position and block pivoting movement of the detent member to the engaging position in response to absence of the spring.

Abstract: Internal combustion engine ignition timing control for timing combustion events of an air-fuel mixture in engine cylinders in response to cylinder mean effective pressure feedback information. Cylinder mean effective pressure information is provided through monitoring of variation in ion content in cylinder combustion plasma through ionization current variation measurement and integration. Ion content variation monitoring is carried out at varying ignition timing angles and ignition timing is driven toward timing associated with a minimum ion content variation corresponding to a preferred ignition timing associated with maximum combustion efficiency.

Abstract: A soft magnetic structure substantially comprised of a plurality of magnetic field carrying particles molded and retained in a predetermined shape, bonded in that shape by an insulating binding agent, wherein said particles have grain alignment substantially parallel to a preferred direction, and wherein said preferred direction is parallel to a direct axis providing the structure with a high direct axis to quadrature axis reactance ratio.

Abstract: A magnetorheological fluid fan clutch effects modulated rotational motion transmission between a rotatable input shaft carrying an input clutch plate and a housing having a front cover and a rear cover forming a cavity about the input clutch plate wherein the front and rear covers operate as output clutch plates. A nonmagnetic spacer is positioned between the front and rear covers and radially outside the input clutch plate. A bearing supports the housing on the input shaft through the rear cover so that the input clutch plate is rotatable on the input shaft relative to the housing. Magnetorheological fluid is carried in the cavity, through which torque is variably transferred between the input clutch plate and the housing.

Abstract: A chassis system control method comprising the steps of measuring rotational speed of a plurality of vehicle wheels; estimating, responsive to each wheel rotational velocity, a relative velocity between the wheel and a corresponding corner of a vehicle body; determining a chassis system control command responsive to the estimations; and applying the chassis system control command to control the chassis system responsive to the estimations, wherein need for body to wheel relative position and/or relative velocity sensors is eliminated.

Abstract: A method of manufacturing a suspension damper with a welded rod fitting includes attaching a piston rod to a piston assembly. The piston assembly with the attached piston rod is inserted into a tube so that the piston rod extends from the tube. Hydraulic fluid is added to the tube either before or after the piston assembly is inserted. A rod guide assembly is slidingly received over the piston rod and is secured to the tube. An end fitting is secured in a weld fixture. The tube, containing hydraulic fluid, the piston assembly, the secured rod guide and the extending piston rod is positioned so that the piston rod abuts the end fitting. An electrical current is passed through the end fitting and the piston rod. The piston rod is moved away from the end fitting forming a gap as the electrical current is passing through the end fitting and the piston rod so that an arc is established across the gap to weld the end fitting to the piston rod.

Abstract: A rod guide including an elongated strip base for connection with a vehicle door panel and to encircle an elongated control rod mounted adjacent the door panel, the strip base being spaced away from the rod; at least one mesh wing with a base end connected with the strip base, the mesh wing angularly extending from the strip base and the wing having a contact end for encircling contact with the control rod and dampening any transverse movement of the control rod while freely allowing generally linear movement of the control rod.

Abstract: A vehicle chassis system control method, comprising the steps of: measuring vehicle yaw rate, vehicle speed, and vehicle lateral acceleration; determining, responsive to the yaw rate, vehicle speed and lateral acceleration, an index ratio; comparing the index ratio to a predetermined threshold indicating a limit above which active chassis control is not desired; and responsive to the comparison, setting a signal indicating termination of active chassis control if the index ratio is above the predetermined threshold.

Abstract: A control method for a manual back-up electro-hydraulic braking system in which the rear service brakes of the vehicle are intentionally operated in a manual back-up mode under specified non-failure operating conditions to conserve electrical energy. The manual back-up mode for the rear service brakes is initiated if braking is commenced while the vehicle speed is below a near-zero threshold speed. If braking is commenced above the threshold speed, the manual back-up mode for the rear service brakes is initiated when the vehicle speed falls below the threshold and the pressure command for the rear brakes has been substantially constant for at least a predetermined time. In this case, the rear manual back-up mode is initiated by reducing the rear brake pressure command to the rear boost units at a controlled rate until the rear brake pressure reaches the manually developed pressure, and then entering the manual back-up mode.

Abstract: A proportional pressure control solenoid valve includes a valve spool with dual feedback pins slidable relative to the spool within a common bore of the spool as the spool moves. The feedback pins have unequal cross sectional areas defining an operative feedback area and enabling minimization of the valve's size in a cost efficient manner. To control output pressure as a function of control current, an electro-magnetically generated force initiates modulation of the valve with assistance from a hydraulic feedback force and in opposition to the force of modulating spring.

Abstract: A continuously variable transmission (CVT) of the variable belt (CVU) type provides a variable drive range. A simple planetary gearset disposed between a power source and the CVU provides a forward direct ratio and a reverse underdrive ratio. The CVT is controlled at a lower overall ratio determined by the diameter of the input sheave being controlled during the forward drive condition at a dimension M. During the reverse drive condition, the diameter of the input sheave is maintained at a larger diameter (M*R) where R is the reverse underdrive ratio of the planetary.

Abstract: The present invention relates to a supplementary lubrication system for an internal combustion engine operable to lubricate the engine and an accessory prior to engine start-up and to lubricate the accessory after engine shut-down. The supplementary lubrication system includes an oil source in fluid communication with a supplemental oil supply conduit, which branches to define two parallel conduits, a prelube branch and a postlube branch. Disposed within the prelube branch is a prelube one-way check valve and disposed within the postlube branch is a postlube one-way check valve. The prelube branch is in fluid communication with a first end of a two-directional pump and the postlube branch is in fluid communication with a second end of the two-directional pump.