Abstract: An autonomous vehicle and related method include, at each corner of the vehicle, a sensor module including a cast frame configured to mount on a corner component of the vehicle, and a plurality of sensors mounted on the cast frame. The plurality of sensors are configured to sense an environment around the autonomous vehicle and to communicate data about the environment to a navigation system of the autonomous vehicle for navigating the autonomous vehicle.

Abstract: An autonomous vehicle and related method include, at each corner of the vehicle, a module including a cast frame configured to mount on a corner component of the autonomous vehicle, and an applique connected directly to the cast frame, wherein the applique covers at least part of the cast frame and defines a portion of an outside surface of the autonomous vehicle.

Abstract: A module support system for a vehicle including exterior paneling defining an interior and exterior of the vehicle, and a frame disposed in the interior of the vehicle, the module support system including a first casting mounted on the frame, where the first casting extends outward from the frame, through the exterior paneling, to the exterior of the vehicle such that the first casting includes an interior portion disposed within the interior of the vehicle and mounted on the frame, and an exterior portion extending outward from the exterior of the vehicle. The module support system includes a first electronic device supported on the exterior portion of the first casting, and a cover fixed with the exterior portion of the first casting such that the cover is disposed over the first electronic device and the exterior portion of the first casting with respect to an external environment.

Abstract: A module support system for a vehicle including exterior paneling defining an interior and exterior of the vehicle, and a frame disposed in the interior of the vehicle, the module support system including a first casting mounted on the frame, where the first casting extends outward from the frame, through the exterior paneling, to the exterior of the vehicle such that the first casting includes an interior portion disposed within the interior of the vehicle and mounted on the frame, and an exterior portion extending outward from the exterior of the vehicle. The module support system includes a first electronic device supported on the exterior portion of the first casting, and a cover fixed with the exterior portion of the first casting such that the cover is disposed over the first electronic device and the exterior portion of the first casting with respect to an external environment of the vehicle.

Abstract: A front side frame member for a vehicle front frame assembly and a method of forming a front side frame member for a vehicle front frame assembly includes an outer frame member having at least one outer frame mating flange and an inner frame member having at least one inner frame mating flange. The at least one inner frame mating flange is fixedly secured to the at least one outer frame mating flange. At least one of the at least one outer frame mating flange and the at least one inner frame mating flange includes a plurality of longitudinally spaced joggles thereon for promoting longitudinal crush of at least one of the outer frame member and the inner frame member.

Abstract: A front side frame member for a vehicle front frame assembly and a method of forming a front side frame member for a vehicle front frame assembly includes an outer frame member having at least one outer frame mating flange and an inner frame member having at least one inner frame mating flange. The at least one inner frame mating flange is fixedly secured to the at least one outer frame mating flange. At least one of the at least one outer frame mating flange and the at least one inner frame mating flange includes a plurality of longitudinally spaced joggles thereon for promoting longitudinal crush of at least one of the outer frame member and the inner frame member.

Abstract: A vehicle frame is provided. The vehicle frame includes a body frame, a subframe mounted to the body frame, and a bumper frame coupled to the body frame. The bumper frame includes a beam having a first end and a second end. The vehicle frame also includes at least one brace coupling the beam to the subframe adjacent to at least one of the beam ends.

Abstract: A vehicle frame is provided. The vehicle frame includes a body frame, a subframe mounted to the body frame, and a bumper frame coupled to the body frame. The bumper frame includes a beam having a first end and a second end. The vehicle frame also includes at least one brace coupling the beam to the subframe adjacent to at least one of the beam ends.

Abstract: Some embodiments are directed to a frame assembly that includes a supplemental beam portion, and a main beam portion adjacent the supplemental beam portion. The main beam portion includes a central portion as well as left and right portions disposed at opposing sides of the central portion. The central portion defines a recessed portion that is shaped such that the left and right portions each define in aggregate a relatively larger cross-sectional area than the central portion. The recessed portion is configured to enable the central portion to be able to at least partially enclose a steering column assembly. A mounting assembly is configured to mount the steering column assembly to the main beam portion with the central portion at least partially enclosing the steering column assembly. The mounting assembly also enhances stiffness of the central portion to thereby at least partially counteract stiffness lost based on the recessed portion.

Abstract: Some embodiments are directed to a frame assembly that includes a supplemental beam portion, and a main beam portion adjacent the supplemental beam portion. The main beam portion includes a central portion as well as left and right portions disposed at opposing sides of the central portion. The central portion defines a recessed portion that is shaped such that the left and right portions each define in aggregate a relatively larger cross-sectional area than the central portion. The recessed portion is configured to enable the central portion to be able to at least partially enclose a steering column assembly. A mounting assembly is configured to mount the steering column assembly to the main beam portion with the central portion at least partially enclosing the steering column assembly. The mounting assembly also enhances stiffness of the central portion to thereby at least partially counteract stiffness lost based on the recessed portion.

Abstract: A vehicle body includes first and second side rails, a first cross member and a second cross member. A multi-piece well configured to house hybrid electronic hardware includes a well floor having a first side, a second side, a first end, and a second. The first end is secured to the first cross member to define a well first end wall. The second end is secured to the second cross member to define a well second end wall. A first frame side support is secured to the first side to define a well first side wall. A second frame side support is secured to the second side to define a well second side wall. The first frame side support is laterally spaced inwardly from and connected to the first side rail and the second frame side support is laterally spaced inwardly from and connected to the second side rail.

Abstract: A vehicle body includes a pair of laterally spaced longitudinal side rails, a first cross member and a second cross member. Each cross members spans between and interconnects the side rails. A multi-piece well includes a well floor having a first side, a second side opposite the first side, a first end, and a second end opposite the first end. A first frame side support is secured to the first side of the well floor and a second frame side support is secured to the second side of the well floor. The first and second frame side supports define opposite side walls of the well. A first frame end support is secured to the first end of the well floor and a second frame end support is secured to the second end of the well floor. The first and second frame end supports define opposite end walls of the well.

Abstract: A bulkhead cover for a vehicle air intake system includes a forward wall defining a bulkhead cover primary port for receiving an air flow admitted through a grille of a vehicle, a first side wall extending from an outer lateral side of the forward wall to an outer lateral side of an intake enclosure, and a second side wall extending from an inner lateral side of the forward wall to an inner lateral side of the intake enclosure. The intake enclosure defines an intake port between the outer and inner lateral sides of the intake enclosure. A bulkhead cover auxiliary port is defined in the second side wall for receiving additional air flow admitted through the grille and thereby reducing snow ingestion through the bulkhead cover primary port.

Abstract: A vehicle air intake system includes a grille disposed along a forward end of a vehicle. The grille has one or more inlet apertures for admitting airflow. A bulkhead extends laterally across the vehicle rearwardly of the grille. An intake enclosure having an intake port is disposed over the bulkhead. A bulkhead cover extends from the bulkhead to the grille. The bulkhead cover has louvers defining airflow passages therebetween for allowing the airflow admitted by the grille to pass to the intake port while inhibiting the passage of particles entrained in the airflow.

Abstract: A vehicle air intake system includes a grille disposed along a forward end of a vehicle. The grille has one or more inlet apertures for admitting airflow. A bulkhead extends laterally across the vehicle rearwardly of the grille. An intake enclosure having an intake port is disposed over the bulkhead. A bulkhead cover extends from the bulkhead to the grille. The bulkhead cover has louvers defining airflow passages therebetween for allowing the airflow admitted by the grille to pass to the intake port while inhibiting the passage of particles entrained in the airflow.

Abstract: A vehicle air intake system includes a grille disposed along the front portion of an engine compartment, a hood disposed over the engine compartment and a bulkhead cover disposed in the engine compartment below the hood. The bulkhead cover has a bulkhead cover intake port and a deflector disposed along and extending forwardly from a lower portion of the bulkhead cover intake port to circuitously redirect airflow passing from the grille to the bulkhead cover intake port.

Abstract: A bulkhead cover for a vehicle air intake system includes a forward wall defining a bulkhead cover primary port for receiving an air flow admitted through a grille of a vehicle, a first side wall extending from an outer lateral side of the forward wall to an outer lateral side of an intake enclosure, and a second side wall extending from an inner lateral side of the forward wall to an inner lateral side of the intake enclosure. The intake enclosure defines an intake port between the outer and inner lateral sides of the intake enclosure. A bulkhead cover auxiliary port is defined in the second side wall for receiving additional air flow admitted through the grille and thereby reducing snow ingestion through the bulkhead cover primary port.

Abstract: A vehicle air intake system includes a grille disposed along the front portion of an engine compartment, a hood disposed over the engine compartment and a bulkhead cover disposed in the engine compartment below the hood. The bulkhead cover has a bulkhead cover intake port and a deflector disposed along and extending forwardly from a lower portion of the bulkhead cover intake port to circuitously redirect airflow passing from the grille to the bulkhead cover intake port.