Abstract: A method of forming a relatively low cost motor provides a motor rotor and/or stator which has a generally solid body. The core of the body is formed of a less conductive material, and a more conductive material is at circumferentially spaced locations on the core. In one embodiment, the conductive material and the less conductive material are co-extruded. In a second embodiment, the core material is formed by powdered metal technology, and the conductive material is deposited onto the core.

Abstract: An AC motor is utilized to drive a closure on a vehicle. The use of the AC motor provides valuable benefits with regard to cost and size. Further, a three-phase AC motor may be utilized, and the pulses in its power supply monitored to determine an obstruction in the path of the closure. Frequency control may also be utilized to provide optimum control of the drive of the component at both start-up and stop.

Abstract: In the disclosed embodiment of this invention, sets of straight wire bundles are molded or otherwise encased about a cylindrical rotor casing. The straight wire bundles lie parallel to the axis of the cylindrical rotor casing. This process is an alternative to a traditional type of electric motor armature which uses a wire that is coiled around the cylindrical rotor casing. Since the wire bundles are straight and not pulled from a single wire roll, breaking and stretching of the wire is greatly reduced. The straight wire bundles are connected at their ends using a circuit cap to form a complete electrical circuit.

Abstract: A brake shoe assembly includes a backing plate and a brake lining. The brake lining has an interface surface abutting the backing plate and a wear surface for contacting a vehicle. A pair of temperature sensors are positioned adjacent to the interface surface and spaced unequal distances from the wear surface for determining the thickness of the brake lining. The pair of temperature sensors may be embedded directly in the brake lining or encapsulated in one of a plurality of housing embodiments packaged in the brake lining. In a preferred embodiment, a unique brake lining temperature sensor assembly is attached to the brake shoe assembly. The unique temperature sensor assembly includes a body of material having a proximate end positioned adjacent to the backing plate and a distal end for contacting the vehicle concurrently with the wear surface of the brake lining. A heat pipe, disposed within the body of material, extends from the distal end toward the proximate end.

Abstract: A system for setting vehicle operator preferences is provided. The system includes a vehicle control module for controlling a vehicle component such as an HVAC unit. A data link is connected to the vehicle control module and may be an infrared signal receiver, a radio frequency signal receiver, a vehicle communications bus, or any other suitable data link. A portable handheld computing device includes a program having vehicle preferences stored in a memory. Preferably, the vehicle preferences may be input by the operator into the portable handheld computing device. The portable handheld computing device may be a Handspring® device, a Palmpilot® device, or any other suitable portable computing device. The portable handheld computing device sends the vehicle preferences to the vehicle control module through the data link to control the vehicle component. The vehicle preferences are sent by IR, RF, or any other suitable means. The system may be used to control an HVA system, for example.

Abstract: A distributed propulsion system is provided for a multi-unit articulated road train. The distributed propulsion system includes a tractor having a first propulsion system for propelling the tractor. A trailer is secured to the tractor at an articulated joint, such as a fifth wheel or draw bar connection. The tractor has a second propulsion system for substantially propelling the trailer. A load sensor for detecting a load between the tractor and the trailer, preferably the tensile load, is associated with the articulated joint. The load sensor produces a load signal. An input device produces a request signal for actuating the second propulsion system. An electronic control mechanism is electrically connected to the input device and the load sensor for coordinating the various sensors and inputs. The control mechanism commands the second propulsion system in response to the load signal and the request signal such that the trailer is propelled in a controlled manner relative to the tractor.

Abstract: A vehicle brake assembly includes a sensor that detects the amount of movement of certain components within the brake assembly. In the preferred embodiment, a rotary sensor is coupled directly with the generally S-shaped cam member and provides signals that indicate the total amount of rotary movement of the cam member during braking applications. These signals provide information indicative of the amount of slack or stroke during braking applications and provide indications of the conditions of brake linings associated with the brake shoes within the brake assembly.

Abstract: A vehicle data storage system is provided which includes a plurality of sensors for sensing vehicle operating conditions, such as engine temperature. A control module receives the vehicle operating conditions and translates the vehicle operating conditions into vehicle information. A portable hand held computing device, such as a Handspring® or Palmpilot®, has a data storage device or memory that receives the vehicle information. The data storage device is limited by a particular memory capacity. A secondary storage device receives the vehicle information from the data storage device from the portable hand held computing device when the memory capacity reaches a desired memory capacity level, such as when there is only 10% of the memory left in the data storage device. Additionally, one of the vehicle operating conditions in one of the subsystem control modules may comprise a triggering event. The triggering event may be detecting a high engine temperature in an engine temperature sensor.

Abstract: A system for determining an out of balance wheel condition on a vehicle incorporates a wheel speed signal such as provided by ABS systems. The wheel speed signal is associated with acceleration information from an accelerometer on the axle. If a particular acceleration profile is repeated across several rotational cycles of the wheels, then an indication is made that an out of balance condition exists.

Abstract: A vehicle brake assembly includes a sensor that detects the amount of movement of certain components within the brake assembly. In the preferred embodiment, a rotary sensor is coupled directly with the generally S-shaped cam member and provides signals that indicate the total amount of rotary movement of the cam member (during braking applications. These signals provide information indicative of the amount of slack or stroke during braking applications and provide indications of the conditions of brake linings associated with the brake shoes within the brake assembly. The sensor information preferably is communicated to a vehicle operator in a manner that indicates whether an inspection or maintenance of the braking system is advisable.

Abstract: A method and system for optimizing performance of vehicle control systems based on the dynamics of the specific vehicle include a sensor for sensing a predetermined parameter associated with any one of the vehicle control systems during a predetermined trigger event. A control logic determines a critical vibration mode characteristic for the vehicle control system based on the sensed parameter and operates the vehicle control system based on the determined critical vibration mode characteristic.

Abstract: An device for controlling a level of lubricant in a gear housing of an automotive vehicle that has a sealed interior portion containing lubricant. A gear is rotatably mounted in the housing and rotates through the lubricant. The housing includes at least one wall secured to a bottom portion of the sealed interior portion. The wall defines a first and second space wherein the gear rotates in the first space and displaces the lubricant over the wall into the second space as the gear rotates at high speeds. The wall has an opening of a predetermined size that allows the lubricant to flow back into the first space at a rate greater than the displacement rate at low speeds and less than the displacement rate at high speeds. The gear and housing may be an axle housing, a transmission or other gears and housings.

Abstract: Systems are provided which retard rotation of a driveline at times associated with an engine firing pulse from an engine driving the driveline to reduce torque peaks. In one system, a control monitors rotation of a drive shaft, to provide an indication of when an engine firing pulse should occur. The control selectively closes a switch to power a coil such that the coil retards rotation of the driveline, and generates electricity for use elsewhere. In a second embodiment, circumferentially spaced magnets are mounted on a driveline and move past a coil at a selected circumferential location. The coil resists the rotation of the shaft, retarding torque peaks. The embodiments thus reduce or eliminate imbalances in rotation of the shaft due to engine firing pulses.

Abstract: A brake shoe assembly includes a backing plate and a brake lining. The brake lining has an interface surface abutting the backing plate and a frictionally engaging surface that frictionally contacts a vehicle. The brake lining is provided with a temperature measuring system embedded therein which may measure the temperature directly on the frictionally engaging surface of the brake lining material by way of a heat pipe. The temperature measuring device communicates with a control that activates a signal when a predetermined abnormal degree of heat is generated on the frictionally engaging surface of the brake lining. Thus, a fault in the braking mechanism is indicated.

Abstract: A vehicle break assembly includes a sensor that detects the amount of movement of certain components within the brake assembly. In the preferred embodiment, a rotary sensor is coupled directly with the generally S-shaped cam member and provides signals that indicate the total amount of rotary movement of the cam member during breaking applications. These signals provide information indicative of the amount of slack or stroke during braking applications and provide indications of the conditions of brake linings associated with the brake shoes within the brake assembly. The sensor information preferably is communicated to a vehicle operator in a manner that indicates whether an inspection or maintenance of the braking system is advisable.

Abstract: An improved method of removing heat from a lubricant in an axle housing includes the use of a deflector in the axle housing. The deflector is positioned on a cover secured to the housing bowl. Lubricant is thrown against the deflector by a ring gear in the bowl. The lubricant is directed by the deflector outwardly to the axle ends of the axle assembly. In this way, the lubricant is exposed to a greater surface area, and the cooling efficiency of this system is greatly improved.

Abstract: An isolator to prevent transmitted vibrations includes a ring which fits within a shaft opening of a housing. A bearing is received within the isolator and a shaft is received within the bearing. The vibrations are decoupled from a vibration transmission path by the different material of the isolator. The isolator is preferably manufactured of a rigid laminate material dissimilar to the housing material. Another embodiment of the present invention integrates the isolator directly into the bearing assembly. By manufacturing the outer member of the bearing assembly of the laminated material, the outer member similarly breaks the transmission path of vibrations without the need of the additional member. Noise is thereby substantially prevented from reaching, and from being amplified by, the housing. This greatly reduces the resulting noise and vibration.

Abstract: A system for determining the amount of material in a brake lining includes a frictional brake surface and a brake lining having a sensor for producing an output signal indicating the temperature of the sensor. A brake actuation system actuates the brake lining against the frictional brake surface and, thereafter, releases the brake lining from the frictional brake surface. A timer measures a time period beginning when the brake lining is released from the frictional brake surface and ending when the sensor output signal reaches a return point indicative of the brake lining having cooled. A controller compares the measured time period to electronically stored predetermined values to determine the thickness of the brake lining. The invention further includes a method for determining the amount of brake lining material based upon this structure.

Abstract: A brake shoe assembly includes a brake lining and a brake lining wear sensor. The brake lining has a predetermined thickness which gradually wears away as the brake shoe assembly is used to brake a vehicle. The brake lining wear sensor has a pair of spaced electrical conductors and an electrical resistance located across the pair of spaced conductors for indicating the thickness of the brake lining. The brake lining wear sensor is positioned to wear away concurrently with the brake lining, thereby continuously changing the electrical resistance across the pair of spaced conductors. In this manner, the electrical resistance across the pair of spaced conductors is used to determine the thickness of the brake lining. The brake lining wear sensor can be assembled in alternative embodiments as disclosed.

Abstract: A brake shoe assembly includes a brake lining and a housing. The brake lining has a predetermined thickness which gradually wears away and increases in temperature during a vehicle braking application. The housing is positioned to wear away and increase in temperature concurrently with the brake lining. An electrical wear loop circuit is encapsulated in the housing for directing power from a power source to a remote indicator in response to a wear opening in the loop circuit. A thermally sensitive switching element is encapsulated in the housing and connected in electrical series with the wear loop circuit for directing power from the power source to the remote indicator in response to the temperature of the housing exceeding a predetermined temperature threshold.