Abstract: A drum-in-hat (DIH) disc brake assembly has a backing plate configured to be supported relative to an axle flange and to support a drum brake shoe assembly of the drum-in-hat parking and emergency brake; a caliper bracket configured to be supported relative to the axle flange and to support a disc brake caliper assembly of the disc service brake; and a parking brake anchor configured to be supported relative to the axle flange. The parking brake anchor includes an anchor body and an abutment. The anchor body has an opening formed therein which is configured to receive a lever arm of a parking and emergency brake actuator which extends through the opening in the anchor body.

Abstract: A pump cartridge for use in a hydraulic braking system includes a sleeve having an outer surface and an inner bore. A piston has a first portion that is coaxially received within the sleeve inner bore. A second portion of the piston extends from the sleeve and is configured to reciprocate the piston first portion relative to the sleeve in response to rotation of an eccentric. A retainer engages the sleeve and is configured to maintain the first portion of the piston within the sleeve inner bore. A filter assembly is formed as a separate component and has a bore configured to permit the piston second portion to extend through the filter bore.

Abstract: An attenuator assembly for use in a vehicle braking system includes a rigid tube disposed within a bore of a hydraulic control unit (HCU) for reduced HCU package size. An attenuator is disposed in the rigid tube and includes a metallic biasing member.

Abstract: An attenuator assembly is located in an attenuator chamber of a housing in a vehicle braking system and includes an orifice defining a fluid dampening flow path. The orifice has an outlet opening. A biasing member defines a closing member of the orifice. The size of the outlet opening changes continuously between a first open position and a second open position.

Abstract: A control dial (12, 14) includes an array of spaced sensor elements (18, 20) and a display (22) located within the dial for displaying a desired control value. A controller (30) is connected to said plurality of sensor elements and to the display for controlling an end-use device (34). The controller monitors the array of spaced sensor elements so as to determine a user desired command based on user touches to the array of spaced sensor elements. The controller (30) controls the display (22) and the end-use device (34) commensurate with the determined user desired command.

Abstract: A drum-in-hat (DIH) disc brake assembly has a disc service brake, a DIH parking and emergency brake, and a parking brake anchor. A backing plate, an axle flange, and a caliper bracket each have at least two mounting apertures formed therethrough. The parking brake anchor includes a bracket portion having a pair of studs extending axially outwardly therefrom. The studs are structured and configured to extend through the respective mounting apertures of the backing plate, the axle flange, and the caliper bracket for securing the caliper bracket, parking brake anchor, and the backing plate to the axle flange.

Abstract: An electromagnetic valve (32) for use in controlling fluid flow between first and second passageways (P1, P2) in a hydraulic valve block (4), includes a valve body (51). The valve body (51) defines a central axis (A), has a central opening (51A) therethrough, has a lower end (54) adapted to be inserted into a bore (19) of the valve block (4), and is provided with a lower cylindrical opening (70). An armature (56) is axially movable within the valve body (51) and is biased by a spring in one axial direction (57A). A closing element (88) is carried by a lower end (54) of the armature (56). An electromagnetic coil (64) coaxially surrounds the armature (56) and is operable to effect axial movement of the armature (56) in an axial direction opposite the one direction (57B). A valve seat member (62) is carried by the lower end (54) of the valve body (51) and has an orifice (98) providing fluid flow between the first and second valve block passageways (P1, P2).

Abstract: An input rod for connecting a vacuum brake booster to a pedal linkage member, wherein the input rod includes a connecting portion adapted to be connected to the pedal linkage member. The input rod further including a hollow body portion formed from a stamped flat blank.

Abstract: An apparatus for the inspection a vehicle component to detect the presence of a part defect and a method for performing the inspection. According to one embodiment, the apparatus for inspecting the vehicle component comprises: a camera having a lens; a borescope having a first end and a second end, the first end operatively disposed adjacent the camera and the second end having a mirror disposed therein; and a light source for supplying light to the borescope whereby the mirror is operative to reflect an image of an area of the vehicle component to be inspected to the camera.

Abstract: A method (100) is provided for controlling torque of an electric motor (12) including the step (106) of supplying drive current to drive the electric motor. The speed of the electric motor is monitored (108) and from the monitored speed, it is determined (110) when the motor has reached a steady state condition. The supply current is turned off (118) if the monitored torque of the electric motor exceeds a predetermined value (114) after the electric motor has reached the steady state condition.

Abstract: This invention refers to an electrically assisted steering system that includes a torque sensor connected to a vehicle steering wheel. The system also includes a torque control ECU that is responsive to torque signals from the torque sensor to generate a motor assist requirement signal. The system further includes a motor control ECU responsive to the motor assist requirement signal to generate a motor control signal. The system additionally includes a steering assist motor responsive to the motor control signal to provide a steering assistance torque to the vehicle steering system. Finally, the system includes a safety domain ECU connected to at least one vehicle operational parameter sensor to generate a torque signal and send the same signal to the torque control ECU. The safety domain ECU is also being in communication with the torque control ECU and the Motor control ECU.

Abstract: A vehicle braking system includes a slip control system operable in an electronic stability control (ESC) mode to automatically and selectively apply the brakes in an attempt to stabilize the vehicle when an instability condition has been sensed. The slip control system is further operable in an adaptive cruise control (ACC) mode to automatically apply the brakes to slow the vehicle in response to a control signal. The slip control system includes a variable speed motor drive piston pump for supplying pressurized fluid pressure to the brakes through a valve arrangement. In the ESC mode, the pump motor operates in an ESC speed range, and in the ACC mode, the pump motor operates in an ACC speed range lower than the ESC speed range. The slip control system further includes an attenuator connected to a pump outlet for dampening pump output pressure pulses prior to application to the brakes. The attenuator includes an elastomeric member located in an attenuator chamber of a housing.

Abstract: A method is provided for controlling the braking of a vehicle that has a first set of friction brakes for applying a first apply brake force to a first set of wheels and a second set of friction brakes for applying a second brake apply force to a second set of wheels. A powertrain assembly is coupled to the second set of wheels. The powertrain assembly includes a regenerative braking unit capable of recapturing kinetic energy from the second set of wheels. The vehicle is braked in a first phase of control using regenerative braking to brake the second set of wheels to achieve up to a first value of braking. The vehicle is braked in a second phase of control using the regenerative braking to maintain braking of the second set of wheels at the first value of braking force while selectively applying the first friction brakes to the first set of wheels up to a second value of braking.

Abstract: A method for producing an anchor bracket adapted for use in a disc brake assembly includes providing an as cast anchor bracket having two extending arms that include an inboard end and an outboard end connect by a bridge portion. Each of inboard ends defines an inboard channel and each of the outboard ends defines an outboard channel. Each of the bridge portions includes a guide pin hole. The inboard ends, outboard ends, and bridge portions define a rotor channel. One of the inboard ends and outboard ends includes a mounting opening. At least one of the inboard ends and the outboard ends are interconnected by a tie bar. Only the faces of the inboard channel and the outboard channel are machined for brake shoe assembly clearance. Only portions of the arms facing the rotor channel and not a portion of an underside the bridge facing the rotor channel are machined for rotor clearance.

Abstract: This invention relates to a brake caliper adapted for use in a vehicle disc brake assembly and method and apparatus for producing the same. The method for producing the brake caliper comprises the steps of: (a) providing a mold member having at least two mold sections; (b) providing a core member having at least a first male extension which is adapted to form an integrally cast locating recess in the brake caliper which is used as a locating surface for subsequent machining of the brake caliper; (c) disposing the core member in the mold member in a predetermined position; (d) supplying a suitable material to the mold member so as to form a brake caliper within the mold; (e) removing the brake caliper from the mold, wherein the brake caliper includes an integrally cast locating recess formed therein by the first male extension of the core member; and (f) machining the brake caliper using at least the integrally cast locating recess formed therein as a locating surface.

Abstract: A method for adapting a closing boundary for a proportional spool valve includes generating or detecting a pressure command signal. Next a pressure error is obtained by subtracting an actual wheel brake pressure from its pressure command. Then a modified pressure error is calculated a modified pressure error is calculated in such a way that steady state pressure errors resulting from mismatched feedforward term, control deadzone and other factors are subtracted from measured pressure error to leave the only error to be that due to boundary deviation. An estimator is then used to estimate an apply boundary deviation or a release boundary deviation of the spool valve, as appropriate. A boundary table is updated using the resultant boundary deviation estimate.

Abstract: A memory for an electronic brake control system is divided into portions that are classified as critical and non-critical. Each portion is periodically tested for faults. Upon detection of a fault, the memory is reconfigured with any operations of the brake system associated with a critical memory portion permanently disabled and any operations of the brake system associated with a non-critical memory portion temporarily disabled.

Abstract: A vehicle brake system includes a brake pedal unit (BPU) coupled to a vehicle brake pedal and including an input piston connected to operate a pedal simulator during a normal braking mode, and coupled to actuate a pair of output pistons during a manual push through mode. The output pistons are operable to generate brake actuating pressure at first and second outputs of the BPU. A hydraulic pressure source for supplying fluid at a controlled boost pressure is included. The system further includes a hydraulic control unit (HCU) adapted to be hydraulically connected to the BPU and the hydraulic pressure source, the HCU including a slip control valve arrangement, and a switching base brake valve arrangement for switching the brake system between the normal braking mode wherein boost pressure from the pressure source is supplied to first and second vehicle brakes, and the manual push through mode wherein brake actuating pressure from the BPU is supplied to the first and second vehicle brakes.

Abstract: A vehicle drum-in-hat disc brake assembly comprises: a shield adapted to be secured to an axle flange; a drum brake portion carried by the shield; an abutment tower operatively disposed with the drum brake portion; and a caliper bracket assembly formed separate from the abutment tower and adapted to be secured to the axle flange; wherein at least one first fastener is provided for securing the abutment tower to the caliper bracket assembly and a plurality of second fasteners are provided for securing the caliper bracket assembly and the shield to the axle flange.

Abstract: An improved guide pin structure adapted for use in a vehicle disc brake assembly comprises a first end including a head portion; a second end including an end face and a lead-in zone, the lead-in zone provided with a rounded generally bullet nose shaped radius adapted for insertion into an aperture of a component of the vehicle disc brake assembly; and a center section defining a shank having a slide surface, the center section defining a guide pin axis; wherein the bullet nose shaped radius of the lead-in zone includes an axial offset relative to the end face and a radial offset relative to the slide surface, and wherein the axial offset is larger than the radial offset by a ratio of at least 2 to 1.