Abstract: An electric trailer brake controller includes a deceleration sensor for generating a brake control signal. The controller also includes a device to decrease the sensitivity of the deceleration sensor to spurious inputs. Additionally, the controller includes a brake current limiting circuit that progressively reduces the current supplied to the controlled trailer brake when the brake current exceeds a predetermined level.

Abstract: This invention relates to an improved fabricated vehicle wheel. According to one embodiment of the invention, the vehicle wheel includes a wheel rim having a plurality of holes formed therein; a wheel disc having a central mounting surface and a plurality of outwardly extending spokes, each of the spokes having at least two holes formed therein; at least one rim to disc interface area provided along each of the spokes wherein some portion of a surface of the rim and some portion of a surface of the spoke contact one another; and a fastener extending through each of the at least two holes of each of the spokes and through an associated at least two holes of the plurality of holes of the rim to secure the rim and disc together.

Abstract: An integrally cast aluminum subframe for a vehicle suspension system has control arm connections that avoid high stress in the connections. Mounting studs may be an integral part of the subframe casting or may be subsequently joined to the subframe. Bushings of the articulations of the control arms are joined to the mounting studs from one side only, so that the flexing of the connection that was present in the prior art clevis connection is avoided. Consequently, the articulation is retained between a head of the mounting bolt and the mounting stud.

Abstract: A flexible manufacturing line and manufacturing process employs an overhead gantry system to transfer fixtured workpieces between machining stations served by the gantry system. The manufacturing system includes a fixturing system including a transfer unit specially configured for quick connection and quick disconnection from a machining table. An accurate placement of the transfer unit is achieved using a combination of locating features.

Abstract: A high offset dual vehicle wheel assembly includes a pair of full face wheels (20, 20) each defining an axis and including a wheel rim and a full face wheel disc. The rim includes an inboard tire bead seat retaining flange, an inboard tire bead seat, a generally axially extending well, and an outboard tire bead seat surface. The disc (42) includes a centrally located wheel mounting flange and an outer annular portion which defines an outboard tire bead seat retaining flange of the vehicle wheel and is located wholly outside a plane defined by the inboard tire bead seat retaining flange. The inboard tire bead seat (38) is provided with a radially in-turned flange having a generally radially inwardly sloping surface, a generally radially extending surface, and an axially extending surface.

Abstract: A spindle to aluminum wheel carrier mounting is provided having increased contact area for reducing stress in the aluminum. The wheel assembly comprises a spindle, a wheel carrier, and a fastener. The spindle is comprised of ferrous material and includes a shank portion, a boss portion, and a fastening portion. The boss portion has a monotonically changing diameter along its longitudinal axis. The wheel carrier is adapted to be supported by a suspension system of the vehicle and has a wheel-facing side. The wheel carrier is comprised of aluminum and has a spindle-receiving aperture therethrough. The aperture has a variable diameter along its length to form a boss-receiving socket. The boss-receiving socket has a monotonically changing diameter substantially matching the boss portion. A fastener is joined to the fastening portion and draws the boss portion against the boss-receiving socket. Consequently, stresses in the aluminum wheel carrier are distributed over the boss-receiving socket.

Abstract: A permanent mold casting system has a modularized architecture and remote placement of certain portions of the casting system. The casting system has a frame and a casting module supported on the frame is adapted to receive a plurality of molds for casting articles from a fill material according to a casting process. The casting module includes first motive actuators for moving at least portions of the molds during the casting process. An accessories module is supported on the frame and comprises at least one accessory device and second motive actuators for selectably positioning the accessory device in relation to the casting module. A utility module is located remotely from the frame and comprises motive power supplies coupled to the first and second actuators. The utility module also comprises a programmable controller coupled to the motive power supplies for controlling the casting process.

Abstract: Apparatus for making a cast article includes a rotary table with a drive for indexing the rotary table to a plurality of rotational positions. A molten metal supply apparatus is placed at a first fixed location adjacent to said rotary table. A plurality of casting machines are supported at predetermined spacings on the rotary table, each respective casting machine having a respective holding furnace feeding a respective stalk tube and having a molten metal inlet port for receiving molten metal from the molten metal supply apparatus when the respective casting machine is indexed to a fill position adjacent the first fixed location. Each respective casting machine is adapted to receive one or more molds and has an open mold configuration and a closed mold configuration.

Abstract: This invention relates to an improved fabricated vehicle wheel.

Abstract: This invention relates to an improved fabricated vehicle wheel. According to one embodiment of the invention, the fabricated vehicle wheel includes a wheel rim having a plurality of holes formed therein; a wheel disc having a central mounting surface and a plurality of outwardly extending spokes, each of the spokes having at least one hole formed therein; at least one rim to disc interface area provided along each of the spokes wherein some portion of a surface of the rim and some portion of a surface of the spoke contact one another; an adhesive deposited in at least some portion of the rim to disc interface area; and at least one fastener extending through the holes of the rim and the spokes to secure the rim and disc together.

Abstract: This invention relates to a casting machine furnace apparatus including a casting machine furnace, a supply furnace in fluid communication with the machine furnace and operative to supply a molten metal to the machine furnace, and a stopper module device disposed in a fluid path between the casting machine furnace and the supply furnace. The stopper module device includes a block housing and a stopper assembly. The block housing includes an inlet opening and an outlet opening, and is disposed in the fluid path. The stopper assembly is supported for movement relative to the inlet opening of the block housing between a working position, wherein the molten metal flows from the supply furnace to the casting machine furnace, and a non-working position, wherein the flow of molten metal is prevented.

Abstract: An improved vehicle wheel cover retention system and method for producing the same includes a disc, a first wheel cover and a second wheel cover. The disc defines an outboard facing wheel surface and includes an outboard tire bead seat retaining flange. The outboard tire bead seat retaining flange includes an inner surface having a circumferential, radially outwardly facing groove formed therein. The first wheel cover is secured to the disc and covers at least a portion of the outboard facing wheel surface. The second wheel cover is secured to the disc and covers at least the entire portion of the outboard tire bead seat retaining flange. The second wheel cover includes an inner portion which extends into the groove when the second wheel cover is secured to the disc. When the first wheel cover and the second wheel cover are secured to the disc, the first wheel cover and the second wheel cover do not interfere with the attachment of a balance weight to the outboard tire bead seat retaining flange of the disc.

Abstract: A device for clamping onto an end of a wheel casting rim and transporting the wheel casting includes a pair of movable arms mounted upon an end of a robot arm. A pair of brackets are mounted upon the ends of each arm. A roller is mounted upon each end of each bracket. The rollers engage a flange formed upon the end or the wheel rim casting. The arms are contracted toward one another to clamp the wheel casting between the rollers.

Abstract: An improved wheel rim expanding tooling apparatus includes an inboard and an outboard wheel rim expanding tooling assembly. The inboard wheel rim expanding tooling assembly includes a plurality of segmented inboard press members each including a pair of side surfaces. The side surfaces include a first outer section and a second inner section. The first outer section extends radially inwardly a first radial distance and the second inner section extends radially inwardly a second radial distance which is greater than the first radial distance. The first outer section of the inboard press members is provided with a generally curved surface profile which extends across at least a portion of an axial width thereof. The outboard wheel rim expanding tooling assembly includes a plurality of segmented outboard press members each including a pair of side surfaces. The side surfaces include a first outer section and a second inner section.

Abstract: A method for producing a cast article comprising the steps of: (a)providing a casting apparatus having a mold, a casting chamber containing a molten metal under pressure and a fluid under pressure, the casting apparatus having a first supply port for supplying the molten metal to the casting chamber and a second supply port for supplying the fluid to the casting chamber; (b) supplying the molten metal to the first supply port; (c) supplying the fluid to the second supply port; (d) determining the amount of the molten metal in the casting chamber as a variable V1; (e) determining the amount of the fluid in the casting chamber as a variable V2; (f) determining the amount of humidity in the casting chamber as a variable V3; (g) determining the amount of the fluid entering the casting chamber as a variable V4; (h) determining the pressure of the fluid in the casting chamber as a variable V5; (i) determining the amount of the molten metal needed to produce a cast article in the mold as a variable V6; (j) determini

Abstract: A wheel assembly for a vehicle comprises a spindle and a wheel carrier. The spindle includes a shank portion and a shoulder portion. The shank portion includes a press-fit portion adjacent the shoulder portion and has a first predetermined diameter. The wheel carrier is adapted to be supported by a suspension system of the vehicle, is comprised of aluminum, and has a spindle-receiving bore therethrough. The bore has an initially-formed diameter smaller than the first predetermined diameter. The press-fit portion is press-fit into the bore. The difference between the initially-formed diameter and the first predetermined diameter is sufficiently large that the press-fit portion is surrounded by a deformation zone having a radial thickness of at least 10 microns. In one preferred embodiment, this deformation zone is comprised of plastically deformed aluminum having a radial thickness of at least 3 microns.

Abstract: A remote manual control is provided for an electronic wheel brake controller. The remote manual control is connected to the wheel brake controller with a cable having quick disconnect connectors at each end. Accordingly, cables having different lengths may be easily substituted for connecting the remote manual control to the wheel brake controller.

Abstract: A vehicle wheel cover retention system wherein the outboard tire bead seat retaining flange of the associated wheel includes a unique construction for securing a wheel cover to the wheel. In particular, the vehicle wheel includes a disc which defines an outboard facing wheel surface and includes an outboard tire bead seat retaining flange. The outboard tire bead seat retaining flange includes an outer surface having a circumferential, radially inwardly facing groove formed therein. A relatively thin wheel cover (which may or may not conform to the exact contour of the disc) covers at least a portion of the outboard facing wheel disc surface. In particular, the wheel cover includes an outer annular lip which extends into the groove.

Abstract: The present invention relates to a full face wheel comprising a full face wheel disc and a partial wheel rim. The wheel disc has an annular inboard portion. The wheel rim has an annular outboard end. A chemical bond is formed between the outboard end of the wheel rim and the inboard portion of the wheel disc to secure the wheel rim to the wheel disc.

Abstract: A method for assembling a wheel rim and a wheel disc together to produce a vehicle wheel includes the steps of: (a) providing a rim defining an axis and including an inboard tire bead seat retaining flange, an inboard tire bead seat, a well portion, an outboard tire bead seat, and an outboard tire bead seat retaining flange, the inboard tire bead seat retaining flange including a radially extending first inner surface, the well portion including a radially extending second inner surface, the outboard tire bead seat retaining flange including a radially extending third inner surface; (b) providing a disc having a centrally located inner wheel mounting portion and an outer annular portion which terminates in an axially extending outer annular flange, the inner wheel mounting portion including an inboard mounting surface and an outboard mounting surface, the outer annular portion including an inner surface; (c) supporting the rim at the first inner and at least one of the second inner surface and the third inner