Abstract: A rotary valve 10 which includes a first sleeve member 24 and a second shaft member 32. The members 24 and 32 cooperatively provide pressure to a cylinder assembly 36, effective to cause the cylinder assembly 36 to move the wheels 20, 22 in a desired direction. The valve 10 provides increased pressure to the low-pressure side of the piston as the amount of torque which is communicated to it is increased or as the velocity of the rack assembly 18 is increased from wheels 20, 22.

Abstract: A method and apparatus for operating a lean-burn internal combustion engine in cooperation with an exhaust gas purification system having a three-way catalyst and a NOx trap located downstream of the three-way catalyst includes a controller which calculates current levels of tailpipe NOx during lean engine operating conditions based upon the difference between a determined instantaneous feedgas NOx concentration and a determined instantaneous trap efficiency. The controller discontinues lean engine operation when the tailpipe NOx, expressed in terms of either grams-per-mile or grams-per-hour, exceeds a predetermined threshold level, either instantaneously or as averaged over the course of a trap purge-fill cycle.

Abstract: An apparatus 10 and a method for producing homogeneous charge compression ignition within a cylinder 14 by the controlled introduction of material into the cylinder 14 when the piston 16 reaches a top dead center position. The material may have a relatively high temperature and pressure and may comprise superheated water.

Abstract: A method of operating an internal combustion engine having a variable cam timing mechanism in cooperation with a plurality of deactivatable cylinders and corresponding intake valves includes the steps of scheduling a transition mode of the engine, determining a desired engine torque during the transition mode, determining a VCT phase angle based on the desired engine torque and operating the variable cam timing mechanism in accordance with the VCT phase angle to provide the desired engine torque during the transition mode.

Abstract: A control system 14 and method for preventing exhaust gases from entering an intake manifold 26 of an engine 21 after engine shutdown is provided. The engine 12 includes a valve controlling air flow into the intake manifold 26. The method includes determining when the engine 12 has been shutdown. The method further includes opening the valve for a predetermined amount of time after the engine shutdown to allow air at ambient atmospheric pressure to communicate with the intake manifold 26. Thus, a relatively high air pressure in an intake manifold 26 prevents exhaust gases from migrating into the intake manifold 26 which reduces a subsequent engine crank period.

Abstract: Method for optimizing the operational efficiency of a hybrid electric vehicle is disclosed. The method comprises operating an engine of a hybrid electric vehicle preferentially on an optimized power curve of the engine for maximizing the efficiency of the engine and sensing a state-of-charge (SOC) condition of a battery of the hybrid electric vehicle being at a preferential value indicative of no additional charging being desired. The running torque of the engine is reduced below the optimized torque curve to a point that the power produced by the engine is substantially equal to the power demanded for driving the hybrid electric vehicle.

Abstract: A variable length connecting rod (12) has a first locking mechanism (36) for releasably locking connecting rod parts in a first effective length setting (FIG. 3) for the rod, and a second locking mechanism (38) for releasably locking the connecting rod parts in a second effective length setting (FIG. 2) to change the compression ratio for an engine cylinder. When a length change is to be made, hydraulic fluid unlocks a locked one of the locking mechanisms, allowing inertial force to effect the length change during an engine cycle. At completion of a length change, the other locking mechanism automatically unlocks.

Abstract: A secondary seat belt warning system for a motor vehicle includes at least one control module for activating at least one secondary warning signal. The secondary seat belt warning system also includes a driver seat belt sensor for producing an input signal indicative of a state of a driver seat belt between a buckled and unbuckled condition. The secondary seat belt warning system includes at least one passenger seat belt sensor for producing an input signal indicative of a state of at least one passenger seat belt between a buckled and unbuckled condition. The at least one control module communicates with the driver seat belt sensor and the at least one passenger seat belt sensor for activating the at least one secondary warning signal to alert a corresponding occupant of the motor vehicle if the state of at least one of the driver seat belt and the at least one passenger seat belt is the unbuckled condition.

Abstract: A vehicle security system 10 including a controller 12 which allows a vehicle to be operated only with an authorized key 36. The system 10 includes a diagnostic tool 32 which cooperates with the controller 12 to allow a user to selectively and securely program an unlimited number of keys 36 which allow the vehicle to be operated.

Abstract: A headlamp system stores a plurality of beam patterns on a microprocessor 32 that selects a predetermined beam pattern based on driving conditions and sends the predetermined beam pattern to a digital micromirror device (DMD) 18 that is capable of generating the desired beam pattern by adjusting the position of individual pixels on the DMD 18. Several vehicle parameters are inputs 36, 37, 38, 29, 70 to the microcontroller 32 and are used to determine the appropriate beam pattern to be produced by the DMD 18 and projected by the headlamp system of the present invention.

Abstract: A transfer case control system or apparatus 10 is provided for use on a four-wheel drive vehicle of the type having a transfer case 32, a front driveshaft 22 and a rear driveshaft 26. Transfer case control system 10 includes a conventional microcontroller or controller 40 having a memory unit 42 and operating under stored program control. Controller 40 is communicatively coupled to sensors 44, 46, 48, and to transfer case 32. Controller 40 selectively transmits a torque control or minimum duty cycle signal to transfer case 32, which is at least partially based upon the angular position of the vehicle's steering wheel and the speed of driveshafts 22, 26.

Abstract: A variable length connecting rod (12) has a first locking mechanism (36) for releasably locking connecting rod parts in a first effective length setting (FIG. 7) for the rod, and a second locking mechanism (38) for releasably locking the connecting rod parts in a second effective length setting to change the compression ratio for an engine cylinder. When a length change is to be made, hydraulic fluid unlocks a locked one of the locking mechanisms, allowing inertial force to effect the length change during an engine cycle. At completion of a length change, the other locking mechanism automatically unlocks.

Abstract: The present invention relates to an interior automotive trim member comprising a backing substrate, a layer of elastomeric material bonded to and overlying the backing substrate, and a soft skin formed of polyolefinic material. The soft skin is bonded to and overlies the layer of elastomeric material. The soft skin is cured by electron beam curing. The present invention also relates to a method of making a soft skin for use with an interior automotive trim member comprising a backing substrate, a layer of elastomeric material bonded to and overlying the backing substrate, and the soft skin bonded to and overlying the layer of elastomeric material. The method comprises providing a polyolefinic material, and exposing the polyolefinic material to electron beam radiation to cure the polyolefinic material.

Abstract: A control system and method is provided for selecting one of first and second cylinder groups of an internal combustion engine when a frequency of air/fuel ratio oscillations in the selected cylinder group is to be adjusted. The method includes determining which of first and second frequencies of air/fuel ratio oscillations in the first and second cylinder groups, respectively, has a greater frequency. Further, the method includes selecting one of the first and second cylinder groups having the greater frequency of air/fuel ratio oscillations. The selection is made to reduce engine torque fluctuations when changing a frequency of air/fuel ratio oscillations in the selected cylinder group.

Abstract: Systems for the manufacture of reinforcing preforms for structural composite products. The robotic application system allows use of a single robot in a multiple cell system, and provides offline programming of the robotic routine. The robot moves between the cells on a track system.

Abstract: A filter used to remove particulates from a diesel engine exhaust is regenerated by increasing the exhaust temperature to achieve burn off of the accumulated particulates. Regeneration of the filter is inhibited when the sensed level of fuel in a diesel fuel tank for the engine falls below a first threshold level. Optionally, filter regeneration may be initiated when the sensed fuel level is between the first threshold and a higher threshold, and the load level of particulates accumulated in said filter is above a preselected, relatively high load level. Increase of the exhaust temperature to achieve burn off may be achieved by a variety of techniques, including throttling the intake of said engine, reducing the oxygen content in the exhaust gases delivered to said engine, closing an EGR valve of said engine, or performing post injection of fuel in the engine's combustion cylinders.

Abstract: A control system (10) for an automotive vehicle (50) has a remote object sensor (18) that generates an object signal in the presence of an object. A vehicle trajectory sensor (34) generates a signal indicative of the vehicle traveling on a curved road. A vehicle speed sensor (32) generates a speed signal corresponding to the longitudinal speed of the vehicle. A controller (12) is coupled to the object sensor (18), the vehicle trajectory sensor, and the vehicle speed sensor. When the remote object sensor (18) indicates the presence of an object with a minimum cross section in a pre-defined decision zone meeting pre-defined relative velocity criteria, and when the vehicle speed is above a first threshold and below a second threshold, and when said vehicle trajectory signal indicates the vehicle traveling on a curved road with a radius of curvature above a threshold value, a vehicle safety countermeasure system (40) is deployed.

Abstract: The invention relates to a new method and system for optimizing the efficiency of an automotive catalytic converter. The claimed invention comprises adjusting an air/fuel ratio in the cylinders of an internal combustion engine to maintain a desired level of oxidants in the catalytic converter. At various times, the actual amount of oxidants stored in the catalytic converter is determined. The actual oxidant amount is compared to a target amount of oxidants to be stored in the catalytic converter. The air/fuel ratio in the cylinders is adjusted based on the magnitude of the difference between the actual oxidant amount and the target oxidant amount to prevent NOx and hydrocarbon breakthrough.

Abstract: A transfer case control system or apparatus 10 is provided for use on a four-wheel drive vehicle of the type having a transfer case 32, a front driveshaft 22 and a rear driveshaft 26. Transfer case control system 10 includes a conventional microcontroller or controller 40 having a memory unit 42 and operating under stored program control. Controller 40 is communicatively coupled to sensors 44, 46, 48, and to a transfer case 32. Controller 40 selectively generates a control signal having a proportional term or component and an integral term or component. The control signal is generated to transfer case 32 and controls the amount of torque provided to driveshafts 22, 26.

Abstract: The invention relates to a device (10) for depositing a flowable medium, in particular lubricating oil, onto a workpiece (16). The device (10) has a base body (13) having a duct (14a) for supplying the lubricating oil, the duct (14a) ending in a cavity (14d). The cavity (14d) is covered by a mask (15) having an opening. The opening of the mask (15) is closed by a hard metal sphere (11) which is prestressed into this closure position by a spring (12). When contact is made with a workpiece the sphere is pressed into the cavity (14d) and thereby opens up the opening in the mask (15) for the discharge of lubricating oil.

Abstract: A spindle characterization system for characterizing performance of a spindle used in an industrial machine includes a machine base for providing a mounting and support surface and having a recessed portion. The spindle characterization facility includes a table base assembly for supporting the spindle disposed within the recess portion and the table base assembly has a table top and height adjustment mechanism for adjusting the height of the table top. The spindle characterization system also includes a spindle mounting mechanism having a top portion mounted to the spindle and a bottom portion mounted to the table top, and a spindle forcing assembly operatively connected to the spindle, and the spindle forcing assembly generates an axial load, radial load and a torque that is applied to the spindle to simulate a machine tool load.

Abstract: A method of determining an operating state of an internal combustion engine in a hybrid electric vehicle drive system comprising an internal combustion engine having an output shaft which is coupled to a generator. The engine includes a fuel injector responsive to a fuel command. The method comprises the steps of determining an ON/OFF status of the fuel command and determining the generator torque. The generator torque provides an indication of the actual engine torque. An engine running flag is set ON when the fuel command is ON and the generator torque value is greater than a predetermined value. Otherwise, the engine running flag is set OFF.

Abstract: A vehicle tailgate limiter system for a vehicle includes a cargo bed, a tailgate pivotally attached to the cargo bed operable between a closed vertical position and a deployed horizontal position, a fixed pin having a head portion and a base portion, and a slotted bracket having a middle portion and end portions adapted to receive the pin when the tailgate is in the deployed position.

Abstract: A miniaturized solid-oxide fuel cell and process for making the same are provided. A fuel cell is provided that contains an electrolyte material, electrodes, and interconnects. Manifolds can be placed either within the electrodes or within the interconnects. Techniques common to the microelectronic industry are used to manufacture a miniaturized fuel cell. The miniaturized fuel cell is created by stacking individual fuel cells over one another to maintain a sufficient level of power density and durability.

Abstract: The present invention relates to a method of assembling a vehicle. The method comprises providing an open-top cab module comprising a metallic base frame, a plurality of exterior body panels secured to the base frame, and interior cab module trim component. A roof assembly is then provided. The roof assembly comprises a light metallic roof frame, at least one roof panel supported on the roof frame, glass components comprising at least a front windshield supported on the roof frame, and interior roof assembly trim components supported on the roof frame. The roof assembly is then secured to the cab module.

Abstract: A stability control system (24) for an automotive vehicle as includes a plurality of sensors (28-39) sensing the dynamic conditions of the vehicle and a controller controls a steering force to reduce a tire moment so the net moment of the vehicle is counter to the roll direction. The sensors may include a speed sensor (30), a lateral acceleration sensor (32), a roll rate sensor (34), a yaw rate sensor (20) and a longitudinal acceleration sensor (36). The controller (26) is coupled to the speed sensor (30), the lateral acceleration sensor (32), the roll rate sensor (34), the yaw rate sensor (28) and a longitudinal acceleration sensor (36). The controller (26) determines a roll angle estimate in response to lateral acceleration, longitudinal acceleration, roll rate, vehicle speed, and yaw rate. The controller (26) changes a tire force vector using by changing the direction and/or force of the steering actuator in response to the relative roll angle estimate.

Abstract: A system and method for powertrain testing of a powertrain under load using a computer network includes a plurality of computer nodes for monitoring and adjustably controlling the powertrain and applied load for acquiring powertrain data relating to powertrain performance. A shared memory is connected to the plurality of computer nodes for receiving in real time the powertrain data generated by each of the plurality of computer nodes. An integrating computer node is connected to the shared memory for receiving in real time powertrain data and is arranged to send different commands to the plurality of computer nodes as part of a powertrain testing process. Further, the present invention allows for the powertrain testing of a powertrain in deterministic real time to develop the powertrain, as well as create a powertrain calibration.

Abstract: A rocker arm assembly having an adjustably located cam roller that permits modification of valve timing for an internal combustion engine. An adjustment control shaft having an adjustment cam operates through a linkage to move the cam roller along the rocker arm and relative to the cam shaft of the engine.

Abstract: A method and system for controlling the operation of an internal combustion engine, wherein exhaust gas generated by the engine is directed through an emission control device, includes determining instantaneous rates of storage for a constituent of the exhaust gas, such as NOx, as well as the capacity reduction of the device to store the exhaust gas constituent as a function of a calculated value representing an amount of SOx which has accumulated in the device since a prior device-regeneration (desulfation) event. The calculated accumulated SOx value is also preferably used to schedule a device-regeneration event, as when the calculated accumulated SOx value exceeds a predetermined threshold value.

Abstract: A method for purging a catalyst containing oxidants operates the engine at different air-fuel ratios during different intervals. The intervals are adaptively adjusted based on a model that predicts an amount of fuel needed to perform the purging. The intervals are also responsive to an exhaust gas sensor located downstream of the catalyst.

Abstract: A method for operating a hybrid vehicle and a hybrid vehicle 10 which operates in accordance with the method. Particularly, the hybrid vehicle 10 includes a pair of torque generators 12, 14 which provide torque by moving in dissimilar directions as the hybrid vehicle 10 is started and stopped, thereby reducing inertia related noise and vibration.

Abstract: An engine control system for managing lean NOx trap decontamination uses associated fuel economy impacts to determine when decontamination is enabled. In particular, a maximum achievable benefit provided by lean operation with a decontaminated NOx trap, a present fuel economy benefit being provided by lean operation, and a fuel economy penalty for performing decontamination are used. When a resulting benefit is greater than a penalty, decontamination is enabled.

Abstract: Systems and methods for controlling an internal combustion engine during and shortly after starting include controlling combustion burn location via ignition timing to improve engine stability while reducing feedgas emissions. Open or closed loop control based on observed or measured mass fraction burned or cumulative released heat allows maintenance of a lean air/fuel ratio charge with significantly retarded ignition timing to reduce catalyst light-off time and temperature and reduce engine feedgas emissions.

Abstract: A method of sensing crankshaft position for use with an engine (16) having a combined starter/alternator assembly (18). The crankshaft position sensor assembly includes a tone ring (38) with a sensor (36), mounted near the rotor (30) of the combined starter/alternator assembly (18), that produces an initial crankshaft position signal. A bandpass filter (46) receives this initial signal and a cylinder identification input from a camshaft sensor (48) and filters the initial signal. Then, a gain limiter (54) performs an additional filtering process to produce a crankshaft rotational position signal. The filtered crankshaft position signal can then be input into a vehicle system controller (58) and an inner loop controller (60).

Abstract: A variable damper assembly 10 is provided for use with a vehicle power steering system and includes a variable orifice valve 20 which controls the flow of fluid between one chamber side 30 of the damper assembly to another chamber side 32 of the damper assembly. Variable orifice valve 20 is communicatively coupled to a source of pressurized fluid 110 by use of a conduit 112 and an electronically controlled valve assembly 114. The pressurized fluid received through conduit 112 controls the operation of valve 20. Based upon the pressure of the received fluid, valve 20 selectively increases and reduces the fluid flow rate between chamber sides 30 and 32, thereby causing the damper assembly 10 to have enhanced damping characteristics during certain vehicle operating conditions (e.g., during relatively high vehicle speed operating conditions).

Abstract: A direct injection engine is coupled to a vacuum brake booster wherein vacuum created from engine pumping is used to supplement driver braking force. The brake booster is coupled through a check valve to the engine intake manifold. A method for estimating pressure in the brake booster uses various engine and vehicle operating conditions. A method for estimating operating parameters uses measured brake booster pressure. Further, a method for diagnosing degradation, or monitoring, a brake booster pressure sensor is based on engine or vehicle operating conditions. In addition, a method for diagnosing degradation in other vehicle and engine sensors uses measured brake booster pressure.

Abstract: An electronic throttle control system is described where a throttle position sensor has multiple slopes depending on the operating region. At low throttle positions, a greater slope, and thus a greater sensitivity is provided, thereby increasing control resolution. At greater throttle positions, a lower slope, and thus lower sensitivity is provided. In this way, an output signal that varies across the entire operating region of the throttle is provided for monitoring and control, while improved performance at low throttle angles can be simultaneously achieved. A method of making the sensor is also described.

Abstract: A method and an assembly 10 for increasing the likelihood that a certain function or operation will be performed in a desired manner. In one embodiment, the assembly 10 measures the amount of material 22 which has been applied to an object 23 and provides several sensory stimulation signals in response to the measurement, effective to provide positive feedback to an operator of the performance of the operation.

Abstract: A method of manufacturing electric machines comprising the steps of kinetically spraying a powdered admixture of magnetic material and ductile binder material on to a substrate and applying a concentrated magnetic field to the sprayed admixture to cause magnetic dipole alignment in the sprayed admixture. The magnets of the present invention may be integrally formed atop carriers to form electrical machines such as motors, generators, alternators, solenoids, and actuators. The manufacturing techniques used in this invention may produce highly defined articles that do not require additional shaping or attaching steps. Very high-purity permanent and soft magnetic materials, and conductors with low oxidation are produced.

Abstract: A method of manufacturing a permanent magnet by the steps of preparing an admixture of magnetic material and binder material, the admixture material having a particle size of less than 325 mesh. Then heating a carrier gas to a temperature substantially below the melting point of either component of the admixture. The admixture is introduced into the carrier gas and the admixture is sprayed atop a ductile carrier. The admixture adheres to the carrier and forms a solid permanent magnet. An electric field is applied to the sprayed admixture to create a permanent magnetic moment.

Abstract: An electric machine made from kinetically sprayed permanent magnet material and a binder material form a composite admixture having microstructure of permanent magnet material embedded in the binder material. The admixture has a permanent magnetic moment. The magnets of the present invention may be integrally formed atop carriers to form electrical machines such as motors, generators, alternators, solenoids, and actuators. The manufacturing techniques used in this invention may produce highly defined articles that do not require additional shaping or attaching steps. Very high-purity permanent and soft magnetic materials, and conductors with low oxidation are produced.

Abstract: A method and system for controlling the operation of a lean-burn engine whose exhaust gas is directed through an emission control device and a downstream reductant-concentration sensor, wherein a stored value for the device's instantaneous capacity to store a selected exhaust gas constituent, such as NOx, is periodically adaptively updated when the sensor's output signal falls outside a predetermined range during a device purge event. A device purge event is scheduled when an accumulated measure of instantaneous feedgas NOx concentration during lean engine operation exceeds the stored NOx-storage capacity value. The purge event is discontinued when the sensor's output signal exceeds the upper limit of the predetermined range, or when a determined value representing a cumulative amount of excess fuel supplied to the engine during the purge event exceeds a threshold value calculated based upon previous values for stored NOx and stored oxygen.

Abstract: An engine control system for managing lean operation of an internal combustion engine coupled to a lean NOx trap uses an indication of vehicle activity. A target amount of tailpipe emission per distance is adjusted based on the vehicle activity indication. Then, engine air-fuel ratio is controlled based on the adjusted target amount of tailpipe emission per distance. Also, the indication of vehicle activity is used to enable decontamination cycles of the lean NOx trap.

Abstract: A method of braking an electric or hybrid vehicle 7 is provided. The vehicle (7) has electric regenerative brakes and friction brakes (94). In a normal braking situation regenerative brakes are applied. If a wheel (42) slip condition is sensed, a selectively operable clutch (76) tortionally connects an undriven axle (60) to the driven axles (44, 45) to alleviate the slip condition. The alleviation of the slip condition prevents the electric regenerative brakes from being shut off in favor of an antilock friction brake application.

Abstract: Occupant sensing system (12) for detecting the presence of an occupant within an automotive vehicle (10) includes a seat belt sensor (14) for detecting a buckled condition of the seat belt. An ignition sensor (24) generates an ignition-off signal. An indicator (30) is coupled to a controller (20), the seat belt sensor (22), and the ignition sensor (18). The controller controls the indicator in response to the seat belt buckled signal and ignition-off signal.

Abstract: A torque based monitor method, apparatus, and system, for a torque splitting hybrid electric vehicle (HEV) powertrain and regenerative brake 54 system. The preferred powertrain configuration includes an internal combustion engine 20, generator 32, and electric traction motor 36 combined to produce the vehicle's output shaft torque. The invention has a set of vehicle state sensors and communication interfaces connected independently to a main controller 200 and an independent plausibility check (IPC) 202. The IPC monitors and mitigates the powertrain output shaft torque (OST) by reducing powertrain torque when the detected OST is greater than the desired OST. The IPC has a second mode of operation to shut down the powertrain OST of the HEV powertrain when a fault or failure is detected. Additional features include a quizzer 204 function to continuously verify the functionality of the IPC.

Abstract: A method for controlling an engine having both an electronically controlled inlet device, such as an electronic throttle unit, and an electronically controlled outlet device, such as a variable cam timing system is disclosed. The method of the present invention achieves cylinder air charge control that is faster than possible by using an inlet device alone. In other words, the method of the present invention controls cylinder air charge faster than manifold dynamics by coordination of the inlet and outlet device. This improved control is used to improve various engine control functions.

Abstract: An internal combustion engine having variable camshaft timing that incorporates a method of determining the position of the variable cam timing phasing system for controlling the flow of intake and exhaust gases during the combustion process. The method includes the steps of creating a model for estimating a calculated cam position and a calculated rate-of-change of the cam position. The method also includes the step of measuring a measured cam position and a measured rate-of-change of the cam position. The calculated cam position is compared to the measured cam position and calculated rate-of-change of the cam position and measured rate-of-change of the cam position that are blended based upon a comparison of the two values. The engine controller is adjusted dependent upon the blended rate-of-change of the cam position.

Abstract: A method and an apparatus 34 for inferring the amount of pressure resident within a fuel delivery member 8 by measuring the voltage delivered to a pump 24 and by calculating a desired fuel flow rate.