Abstract: A hybrid electrical power assist system (EPAS) for an automotive vehicle that utilizes the advantages of a conventional EPAS system to provide power assist based upon several distinct sensor inputs, in a heavy duty vehicle that requires significantly more assistance forces than a conventional EPAS can provide. The hybrid system utilizes a hydraulic amplifier that is connected to receive the torque output from an EPAS motor actuator and responsively provide a fluid under differential pressure through a pair of high pressure lines to a steering piston.

Abstract: A system and method for assembling a mesh model for engineering analysis by a user is provided. The system includes a user computer system, a remotely located computer system and a data storage means. The method includes the steps of selecting a plurality of component parts having a best practice mesh model format and selecting a predetermined property for each of the selected component parts, wherein the predetermined property is selected from a best practice library stored on the data storage means. The method also includes the steps of determining if the mesh model for each of the selected component parts meets a predetermined mesh quality condition using a best practice mesh quality checking software program.

Abstract: A method of manufacturing metallic components consisting of at least two different materials, one of them being an iron-based alloy and the other an aluminum-based alloy, and involving the steps of: depositing a metallic layer onto the body made from the iron-based alloy, said layer being an aluminum-based alloy, preferably based on Al—Si or Fe, placing the coated body in a casting mold and casting an aluminum-based alloy about the coated body. Prior to placing the body in the casting mold, the metallic layer of the body is sprayed and/or blasted with silicon powder and/or Borax (Na2B4O7—10H2O, hydrated sodium borate).

Abstract: An innovative robotic foam application process that integrates system communications, non-contact vehicle insertion point locations, and applications controls to accurately dispense a two-component structural foam at a high volume and flow rate. The process begins by first inserting a baffle within the support structure. After an electrocoat application and bake, the baffles expand and are sealed within the support structure to form cavities having a fill hole. A hydraulic driven robotic dispensing system equipped with a high-pressure static mixer senses the respective fill hole, moves a robotic arm to a location sensed, and injects a high volume of mixed two-component viscous material within each of the respective located fill holes at a high fill rate. After dispensing, the viscous material undergoes an exothermic curing reaction to cure and is expanded to substantially fill each cavity.

Abstract: An automotive vehicle is provided having a body being assembled by a joining process line from a plurality of workpieces joined into a plurality of subassemblies according to the steps of providing templates arranged in a predetermined alignment to form a process line, with each template being generated from a defined set of standardized task stations which are operative to perform a joining process on a workpiece of the subassemblies, fixturing workpieces in a workpiece presenter provided in the task stations, at least one workpiece presenter including a tooling plate removably connected and precision located on a platform of a workpiece presenter, and sequentially joining the workpieces together to form the body.

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: The invention relates to a cylinder block of the closed-deck type, which can be produced by die-casting. The cylinder block includes a water jacket surrounding the cylinders adapted to be open to the side. The lateral opening can be closed by a cover, which is additionally shaped on its inside in such a way as to promote flow distribution or heat dissipation.

Abstract: There is disclosed herein an apparatus for electromagnetic forming, joining or welding a workpiece, the apparatus including at least two multi-turn solenoid coils wound in a manner that cooperatively encircles the workpiece to be formed. The apparatus also includes an electrically insulative shell encasing each coil and an electromagnetic current source electrically connected to the coils that generates an electromagnetic field. A hinge mechanism connects the insulative shells and a locking mechanism secures the shells and coils around the workpiece during electromagnetic field generation. A conductive rod joins the solenoid coils and permits series current flow between the coils. The apparatus further includes a shaper that encircles the workpiece and which restricts movement of the workpiece during electromagnetic forming. The shaper concentrates the generated electromagnetic field on the workpiece.

Abstract: This invention relates to the fabrication of veneer faced panels (10), in particular veneer faced panels (10) for mounting in the passenger compartment of a motor vehicle. A blank (14) is shaped and trimmed by placing it in a first press (20) having a tool with a flat peripheral pressing surface (30) and then placed in a second press (40) also having a flat peripheral pressing surface (31) following which a layer of veneer (16) is placed over the blank (14) before being pressed against the blank (14), so that a veneered panel (10) is formed with flat and parallel end face (18).

Abstract: A method and tool for forming a hem flange pre-hem and a final hem on a sheet metal panel wherein elastomeric tooling elements are used to apply radial compression during a forming operation. The elastomeric tooling elements are compressed and apply pressure to a side of the sheet metal panel, for example an aluminum panel, that is stretched during a forming process step. A foil layer may be placed between the sheet metal blank and the elastomeric tooling element to reduce friction and further improve forming performance.

Abstract: A component part container delivery rack used in manufacturing operations. An E-frame defining at least two compartments that are open on at least one side that extends between the front and back ends of the rack. The frame is supported on a plurality of wheels and is adapted to receive a dolly in the compartment. Each dolly is removably received in one of the compartments and locked in place when placed in the delivery rack. The locking element includes a pivoting lever that is rotated to lock and unlock the dolly within the compartment. The dolly is supported on roller guide elements that guide the dollies as they are moved into and out of the compartment. The dollies are raised above the floor so that the wheels of the dollies do not contact the floor as it is transported by the rack.

Abstract: The invention relates to a method for compensating steering-torque disturbances caused by unequal torque distribution at the front wheels of a motor vehicle with front-wheel drive or all-wheel drive and an active differential. In this arrangement, the magnitude of the steering-torque disturbance is determined from the torque distribution, the total torque and the steering lever and a compensation torque is exerted on the steering system by means of an active steering-servo device.

Abstract: A single-step heat treating and surface coating process is provided for steel self-piercing rivets for joining 5xxx and 6xxx aluminum panels. In this process, two coats of zinc and aluminum flakes in an inorganic binder are applied to the steel rivets. After each coating, the rivets are heated to set and cure the coats and to achieve the desired microstructure and hardness level for joining 5xxx and 6xxx aluminum panels. The coating curing step combines the heat treatment with surface coating into a single-step procedure.