Abstract: A compression limiter formed by a roll forming process includes a substantially cylindrical body portion and a plurality of feet. A plurality of notches are stamped along a lower edge of a flat sheet of stock and bent to form the plurality of feet. The flat sheet of stock is then rolled to form the compression limiter. In the preferred embodiment, the compression limiter is formed of a high carbon steel. The plurality of feet of the compression limiter transmit the bolt load of a fastener attaching a plastic intake manifold to a component. In an alternative embodiment, an angled portion attaches each foot to the body of the compression limiter which accommodates for variations in the height of the plastic intake manifold.

Abstract: A method of starting a brushless DC motor 12 at any initial speed (A) establishes a initial stator-field speed and setting a counter of synchronization, (B) measures a speed of a rotor of the motor, (C) compares the speed of the rotor with the stator-field speed to determine if the rotor is synchronized with the stator-field. If the rotor is not synchronized with the stator-field, the method includes (a) re-setting the counter of synchronization, (b) increasing an acceleration portion of motor current (Iacc) to enhance torque, (c) setting the stator-field speed higher than the rotor speed, (d) calculating a period of an open-loop timer, (e) calculating a value for a load portion of the motor current (Ild), where total motor current I=Iacc+Ild, (f) performing commutation based on the open-loop timer and returning to step (B) until the rotor is synchronized with the stator-field.

Abstract: A closed-loop control system for a DC motor includes a DC motor 12, a current sensor 14 for determining a current of the motor, a voltage sensor 32 for measuring a voltage of the motor 12, and a micro-controller 33. The micro-controller is constructed and arranged to (1) compare the determined current with a set point and output a pulse width modulated (PWM) duty cycle to control the motor, and (2) calculate a PWM duty cycle limit based on the measured voltage and compare the outputted PWM duty cycle to the PWM duty cycle limit such that when the outputted PWM duty cycle greater than the PWM duty cycle limit, the outputted PWM duty cycle is set to the PWM duty cycle limit. A method, in a DC motor, of preventing a current surge during severe voltage changes is also disclosed.

Abstract: A method provides, on a printed circuit board 16, at least a first and a second printed circuit board fuse trace A, B placed in parallel with each other in a main current carrying path 18. In a normal operating condition, it is ensured that 1) all of the traces carry a portion of a load current and 2) the traces are configured to prevent opening of the traces in the normal operating condition. When a fault condition occurs, it is ensured that the first trace A opens before a resistance thereof increases so as to divert more of a load current to the second trace B, thereby causing the second trace B to open after opening of the first trace A.

Abstract: A system 10 provides a variable output voltage to a DC brush motor. The system includes a DC brush motor 14, a DC voltage source 12, a step-up, step-down DC/DC converter 16 including a switch 18. The DC/DC converter is constructed and arranged to step-up and step-down voltage from the source to provide an output voltage to the motor between 0 and 42 volts. A control unit 22 is constructed and arranged to receive an input signal 20 and to control the switch based on the input signal to control the motor.

Abstract: A fuel vapor purge control assembly includes an intake passage, a vapor purge passage in fluid communication with the intake passage, a port between and in fluid communication with the intake passage and the vapor purge passage; a closing member movably mounted in the intake passage and an actuator assembly received in the receptacle and connected to the closing member. The closing member has a first position where the closing member closes the port and blocks fluid communication between the intake passage and the vapor purge passage and is outside of a fluid stream of the intake passage when fluid is flowing through the intake passage. The closing member has a second position where the closing member opens the port and allows fluid communication between the intake passage and the vapor purge passage and extends into the fluid stream of the intake passage when fluid is flowing through the intake passage. The actuator assembly drives the closing member between the first and second positions.

Abstract: A brush type DC motor 10 having an armature 15 and positive and negative power leads is provided. The motor includes an RFI choke 12 as a transformer in series with at least one of the positive and negative power leads to amplify current such that rotation of the armature 15 can be detected based on monitoring a voltage relating to the amplified current. Conditioning circuitry 14 is constructed and arranged to condition the voltage for detecting rotation of the armature.

Abstract: A modular exhaust gas recirculation assembly includes a flow control body, a closing member movably mounted in the manifold conduit between a first position and a second position, and an actuator assembly coupled to the closing member and driving the closing member between the first position and the second position. The flow control body includes a manifold conduit and an inlet conduit in fluid communication with the manifold conduit. The manifold conduit includes manifold conduit a recirculation opening, a first open end having a first cross-sectional shape, and a second open end having a second cross-sectional shape. The closing member includes a boundary defining an operative surface. The boundary has a configuration that is different from the first cross-sectional shape and the second cross-sectional shape. When in the first position, the closing member closes the recirculation opening and blocks fluid communication between the inlet conduit and the manifold conduit.

Abstract: A exhaust gas recirculation assembly for an engine having an intake manifold and an exhaust manifold, the exhaust gas recirculation assembly including a flow control body, a closing member, an electric motor coupled to the closing member, and an electronic controller electrically connected to the electric motor. The flow control body includes a manifold conduit and an inlet conduit in fluid communication with the manifold conduit. The manifold conduit includes a recirculation opening and a mounting member. The mounting member is adapted to connect the manifold conduit in fluid communicate with the intake manifold. The inlet conduit includes a mounting member adapted to connect the inlet conduit in fluid communication with the exhaust manifold.

Abstract: A system and method for protecting a motor from a stall condition includes a brush motor 11 having power brushes 14 and 16 that convey power to windings of the motor, and one sensing brush 20 constructed and arranged to sense a speed of rotation of an armature motor. A controller 23 is constructed and arranged to compare a sensed speed of rotation with a minimum speed value that is indicative of a stall condition. A relay 28 is constructed and arranged to disconnect power to the motor if the sensed speed is below the minimum speed value.

Abstract: A fan 10 includes a hub 12, a plurality of fan blades 14 attached to the hub at one end and extending outwardly from the hub, and a ring 18 concentric with the hub and coupled to tips 16 of the blades. A dimensionless radius (r/R) is defined from a center of the hub (r/R=0) radially outwardly, wherein each tip of the blades is r/R=1. A pitch ratio increases up to about r/R=0.85, and decreases in a range of about 0.85<r/R<1.0. In the range of about 0.6<r/R<1.0, a chord length decreases continually.

Abstract: A solenoid for use in a valve such as an exhaust gas recirculation valve for a motor vehicle. The solenoid includes a housing having a coil for generating a first magnetic field. An armature is slidably mounted in the housing. The solenoid further includes a permanent magnet having a second magnetic field, wherein the magnet is located adjacent the armature. In addition, a stator is affixed in the housing for cooperation with the armature and the magnet to form a third magnetic field.

Abstract: An electric actuated control valve, such as an EGR valve, has a solenoid that can deliver useful force over a longer stroke for operating a valve element.

Abstract: An air cleaner assembly 10 includes a filter located within a housing 12 between an air inlet 20 and outlet 22 for filtering airflow therebetween. The air inlet 20 extends from the housing 12 to communicate with an air intake port located at a vehicle location where fresh air is available. A resonator device 28 is mounted within the housing 12. The resonator device 12 includes a resonator volume 30 and a tuning neck 32. The resonator volume 30 fits into the housing 12 to reduce bulk and readily lend itself to adaptation to space requirements. The tuning neck 32 is mounted within the outlet 22 such that noise and vibration are communicated directly to the resonator device 28.

Abstract: A motor assembly 30 includes an electric motor 32 having a rotatable shaft 40, the shaft 40 having a worm 38; and a gear unit 33 operatively associated with the motor, the a gear unit has first and second opposing ends. The gear unit 33 includes a gearwheel 36 operatively coupled with the worm 38 of the shaft 40 such that rotation of the shaft rotates the gearwheel. A driver 42 is operatively coupled with gearwheel so as to rotate therewith. The driver 42 is constructed and arranged to provide a driving member 43, 44 accessible at each of the first and second ends of the gear unit.

Abstract: A jump bar shunt structure 30 includes a base 32 constructed and arranged to be mounted to a substrate and to function as a current shunt; a pair of first legs 34 and 36 integral with the base and being constructed and arranged to be connected between terminals of at least two power devices such as MOSFETs; and a pair of second legs 50 and 52 integral with the base and being constructed and arranged to be connected to a printed circuit board so as to define a current sensing connection. The jump bar shunt structure is a single component that carries high current between two or more power devices and converts current into voltage that is used by the current measurement circuitry. The advantage of the jump bar shunt structure is that no high current (motor current) flows through a control PCB.

Abstract: A vacuum generating device and method include a member that defines a passage, a first valve, a second valve, a fluid communication conduit, a transducer, and a processor. The passage extends between a first end and a second end, and includes a constriction that defines an orifice. The first valve connects the first end of the member and an ambient environment, and is electrically positionable in first and second configurations. The first configuration permits generally unrestricted fluid flow between the orifice and the ambient environment, and the second configuration substantially prevents fluid flow between the orifice and the ambient environment. The second valve has a first port and a second port. The first port is adapted for fluid communication with a pressure source at a first pressure level. The second valve is electronically adjustable. The fluid communication conduit connects the second end of the member and the second port of the second valve.

Abstract: A system and method for testing whether proper connections (30, 34) are made between wire harnesses and fuel injector assemblies (26) includes at least one gripper mechanism (44) for grasping a selected portion (32, 36) of a wire harness associated with the fuel injector assembly (26). The gripper mechanism (44) preferably moves relative to the fuel injector assembly after it has been positioned on an appropriate support (40). The gripper mechanism (44) preferably grasps a selected portion (32, 36) of the wire harness and pulls it in a direction away from the fuel injector assembly (26). If a proper connection is made, the wire harness does not become disconnected from the fuel injector assembly. If a proper connection is not made, however, that is revealed as the gripper mechanism (44) pulls the wire harness off of the fuel injector assembly.

Abstract: A jump bar shunt structure 30 includes a base 32 constructed and arranged to be mounted to a substrate and to function as a current shunt; a pair of first legs 34 and 36 integral with the base and being constructed and arranged to be connected between terminals of at least two power devices such as MOSFETs; and a pair of second legs 50 and 52 integral with the base and being constructed and arranged to be connected to a printed circuit board so as to define a current sensing connection. The jump bar shunt structure is a single component that carries high current between two or more power devices and converts current into voltage that is used by the current measurement circuitry. The advantage of the jump bar shunt structure is that no high current (motor current) flows through a control PCB.

Abstract: A fan-shroud structure 10 includes a fan 12 mounted for rotation about an axis B. The fan has a plurality of blades 20 with tips of the blades being coupled to an annular band 22. A shroud 26, including an annular labyrinth seal 28, is disposed generally adjacent to the annular band thereby defining a gap 30 between the annular band and the seal. The seal has a corrugated profile and is constructed and arranged to provide resistance to air flow as air swirls and flows back into the gap and to minimize air leakage across the gap.