Abstract: A wiper arm (30) for a vehicle windshield wiper assembly (14) has at least a section along its longitudinal extent formed of a longitudinally extending base portion (80) and two spaced side walls (82,84) extending outwardly along opposite sides of the base portion (80) to form an open channel (85). A spray nozzle (70i is disposed in the outboard portion of the wiper arm (30) and a fluid delivery tube (60) extends longitudinally along the wiper arm (30) to deliver wash fluid from a supply to the spray nozzle (70). The outboard edges (86,88) of the outwardly sidewalls (82,84) are folded inwardly towards each other to partially close the open face (87) of the channel (85), thereby retaining the fluid delivery tube (60), which is freely disposed, within the channel.

Abstract: A vehicle transfer case for changing between two- and four-wheel modes of operation has a transmission with an inventive stop. The stop extends radially outwardly beyond the nominal height of gear teeth on a worm gear in the transmission. The stop engages a worm which is part of the transmission at a location outside of a primary contact area between the worm and worm gear. When the stop contacts the worm it stops further rotation of the worm gear. The motor for the worm gear is reversible such that both the worm and worm gear can rotate in either direction. A single stop defines two circumferentially spaced ends of travel. Since the stop contacts a moving surface on the worm, there is a reduced likelihood of seizure when compared to the prior art.

Abstract: The present invention teaches an improved brush holder assembly. The holder has a first terminal wire and comprises a support plate and a tower attached thereto for securing the first terminal wire. The tower comprises a body and an end. The body comprises an interior passageway with a number of ribs for securably positioning the first terminal wire within the body and a groove for securing the first terminal wire within the tower. The tower's end functionally crimps the first terminal wire and has a plurality of support members for securably positioning the crimped first terminal wire within a mouth of the end. A coil spring forming an inductor is also incorporated for mechanically biasing a brush and for filtering out electromagnetic interference (EMI).

Abstract: An engine starter drive clutch assembly which comprises a starter motor with an armature shaft, pinion gear for engaging and disengaging an engine drive gear, a spline for transmitting axial rotational movement to the pinion gear, and a clutch assembly for transmitting torque between the armature shaft and the pinion gear.

Abstract: A multi-speed, direct current motor (120) incorporates a high speed (24) brush disposed between the low speed (22) and the common ground (26) brushes and having a non-arcuate end face (25) which, unlike the conventional arcuate brush end face (23,27), is not subject to speed-drift erosion. The non-arcuate end face (25) is configured of two offset surfaces (55,65 & 57,67) which intersect to provide a line of contact (43) between the end face (25) of the high speed brush (24) and the commutator (40) which is displaced from the center line of the high speed brush (24) in a direction counter to the direction of rotation of the motor, that is toward the leading edge (21) of the brush (24). The intersecting surfaces (55,65 & 57,67) may comprise either flat planar surfaces or contoured surfaces.

Abstract: A method and system is provided for controlling the operation of a brushless electric motor of the type having at least two phase windings, each of the phase windings being connected in series with a respective switch to form a respective circuit branch between the terminals of a constant voltage source thereby forming a plurality of said circuit branches in parallel to each other. A plurality of signals, each signal indicative of the electromotive force developed in a respective one of the phase windings during operation of the motor, is generated and compared with a predetermined reference value so as to generate synchronization logic signal. A control signal indicative of the angular rotor position of the motor is generated using the synchronization signal and compared with a first and a second reference signal for generating respective processing signals for controlling the current flow in each said respective circuit branch.

Abstract: An armature assembly 50 for an electric motor 10 is inherently balanced despite the presence of a secondary shaft 74 extending from a primary armature shaft 72 longitudinally along an eccentric axis 75 offset radially from the longitudinal axis 15 of the primary armature shaft 72. A lamination stack 60 mounted on the armature shaft 70 is formed of a plurality of lamination plates 62 arrayed in abutting face-to-face relationship. The lamination plates 62B and 62C provided at the respective ends of the stack 60 are modified in that some of the radially directed spokes 66 are removed along a selected portion or spaced portions 63,67 of the circumferential extent of the hub portion 64 so as to provide counterweight lamination plates having a spoke pattern which is not symmetric about the longitudinal axis 15 of the primary shaft 72.

Abstract: A continuous current brushless electric motor is disclosed in which the phases (W1, W2, W3) are energized sequentially, so that a time interval exists in which one phase being deactivated and another phase being activated are both energized with current. During this time interval, the current supplied to the phase being deactivated is decreasing while the current supplied to the phase being activated is increasing. The rate of decrease in the current in the phase being deactivated is controlled to be equal approximately to the difference between a predetermined reference current (Iref) and the increasing current in the phase being activated.

Abstract: Two windshield wiper blades are powered by separate electric motors. The blades overlap and when one blade is at its reversal point the other blade leaves part as the other blade begins to return to park. The position of the blades is encoded. The blades, if synchronized should be at identical locations and position codes at the same time. Motor power to the blade that arrives first is be removed, allowing the blade to coast. If the other blade still does not arrive at the position after an elapsed time, the first to arrive blade is dynamically braked. Intermittent wiper operation is provided in a way that initiates an immediate wipe if wiper delay is changed while the blades are parked.

Abstract: A method is disclosed for improving the metallurgical bond between the end of an armature wire of an electric motor and the connector riser or tine on the motor armature. The armature wire has a titanium oxide-containing insulation coating. The titanium oxide content improves the resistance of the wire to erosive forces which occur during the winding operation but it also tends to interfere with the metallurgical bond between the wire and the riser or tine. The disclosed method involves the roughening of the surface of the riser or tine at least to a depth equal to the thickness of the insulation. Grit or vapor blasting with silica glass beads as well as other roughening techniques are disclosed.

Abstract: The connecting link is manufactured from an elongated hollow extrusion of aluminum, which can be cut to any desired length and bent, as required. Molded plastic coupling members have tongues which are inserted into the open ends of the hollow extrusion and crimped in place to hold them securely. The coupling members have integrally formed socket structures to receive complementary ball structures which form the pivot connections of the wiper system.

Abstract: A multi-speed, direct current motor (120) incorporates a high speed (24) brush disposed between the low speed (22) and the common ground (26) brushes and having a non-arcuate end face (25) which, unlike the conventional arcuate brush end face (23,27), is not subject to speed-drift erosion. The non-arcuate end face (25) is configured of two offset surfaces (55,65 & 57,67) which intersect to provide a line of contact (43) between the end face (25) of the high speed brush (24) and the commutator (40) which is displaced from the center line of the high speed brush (24) in a direction counter to the direction of rotation of the motor, that is toward the leading edge (21) of the brush (24). The intersecting surfaces (55,65 & 57,67) may comprise either flat planar surfaces or contoured surfaces.

Abstract: An electric starter having an electric motor with a rotatable shaft, a pinion gear for driving a flywheel, and a friction clutch for transmitting torque which includes a drive plate connected to the shaft and a friction coupling for frictionally transmitting torque between the drive plate and pinion gear wherein the coupling is compressible and a stop limits compression to a predetermined maximum compression so as to set a predetermined slip torque or limit torque transfer to a predetermined maximum torque.

Abstract: A dynamoelectric machine of the type having rolling element bearing assemblies larger than the commutator and armature and brushcard subassemblies for automated assembly with the brushcard having a displaceable brush retainer for retaining the brushes to form an unobstructed passageway for the bearing assembly and the armature having a self-positioning actuator disk for automatically displacing the brush retainer during assembly so the brushes engage the commutator.

Abstract: The space between a pinion and starter case in an electric starter is sealed by a flexible disk. This disk rotates on the pinion. The pinion contains a circular slot for the disk, which has a central cut-out portion in the profile of the pinion teeth, which hold the disk in place in the slot once the disk is installed. The disk is installed by lightly forcing it over the teeth on the pinion. This seal blocks path for particulate and contaminants into the interior of the starter through the space between the pinion and the starter case.

Abstract: An engine starter pinion drive and method for assembly which comprises a starter motor with an armature shaft, a clutch subassembly, a pinion gear for engaging and disengaging an engine drive gear, an anti-drift spring and a retainer sleeve locking the clutch subassembly in position on the armature shaft. The retainer sleeve is configured for axial push-on mounting to the armature shaft with a plurality of tabs for snap lock engagement with a groove in the armature shaft.

Abstract: An automobile window lift mechanism having a lift arm assembly for raising and lowering a window along a travel path between an open and closed position, a pinion gear for supplying rotative force from a motor or manual handle for actuating the lift arm assembly, and a gear train interconnecting the pinion gear and the lift arm assembly to provide a substantially instantaneous increase in mechanical advantage and window closing force as the window engages an upper seal in the closed position. The gear train includes a gear reduction configuration and/or an increased lever effort arm to increase the mechanical advantage only during the closing movement of the window as it engages the upper seal.

Abstract: A dynamoelectric machine in the form of a windshield wiper motor having an armature shaft with a worm driving a worm gear mounted in a gear end housing. The armature shaft bearing is positioned against a shoulder on the shaft by a washer and push-on retainer. The bearing is slip-fit mounted in the gear end housing and a U-shaped retainer is mounted in a slot in the gear end housing adjacent the bearing such that the retainer engages the bearing to retain it against axial loading on the shaft. A bowed washer is mounted to engage the bearing to urge it against the retainer.

Abstract: A dynamoelectric machine of the type having rolling element bearing assemblies larger than the commutator and armature and brushcard subassemblies for automated assembly with the brushcard having a displaceable brush retainer for retaining the brushes to form an unobstructed passageway for the bearing assembly and the armature having a self-positioning actuator disk for automatically displacing the brush retainer during assembly so the brushes engage the commutator.