Abstract: A vibration welding system includes vibration welding equipment having a welding horn and anvil, a host device, a check station, and a robot. The robot moves the horn and anvil via an arm to the check station. Sensors, e.g., temperature sensors, are positioned with respect to the welding equipment. Additional sensors are positioned with respect to the check station, including a pressure-sensitive array. The host device, which monitors a condition of the welding equipment, measures signals via the sensors positioned with respect to the welding equipment when the horn is actively forming a weld. The robot moves the horn and anvil to the check station, activates the check station sensors at the check station, and determines a condition of the welding equipment by processing the received signals. Acoustic, force, temperature, displacement, amplitude, and/or attitude/gyroscopic sensors may be used.

Abstract: An exhaust aftertreatment system for treating an exhaust gas feedstream of an internal combustion engine includes a catalytic converter, a fluidic circuit and a Stirling engine. The Stirling engine is configured to transform thermal energy from a working fluid heat exchanger to mechanical power that is transferable to an electric motor/generator to generate electric power. The Stirling engine is configured to transform mechanical power from the electric motor/generator to thermal energy transferable to the working fluid heat exchanger.

Abstract: An apparatus for joining a wire pair of a stator coil. The apparatus includes a tool having a pair of electrodes and control equipment. The control equipment is configured to control the electrodes to apply force to the wire pair to push adjacent wires of the wire pair toward each other and cause current to pass between the pair of electrodes, and so through the wire pair pushed together, at a time at which the force is being applied to the wire pair.

Abstract: An ultrasonic welding system for securing a first work piece to a second work piece includes a welding assembly and a loading assembly disposed adjacent to the welding assembly. The welding assembly includes an ultrasonic controller, an ultrasonic transducer, and a welding tip. The ultrasonic transducer is configured to impart an ultrasonic vibration to the welding tip in response to an electrical signal received from the ultrasonic controller. The loading assembly is configured to generate a pressure load between the welding tip and the first work piece, and includes a first actuator and a second actuator. The first actuator is configured to apply a substantially constant load to the welding assembly, and the second actuator is configured to apply a dynamically variable load to the welding assembly.

Abstract: An ultrasonic welding system for securing a first work piece to a second work piece includes a welding assembly and a loading assembly disposed adjacent to the welding assembly. The welding assembly includes an ultrasonic controller, an ultrasonic transducer, and a welding tip. The ultrasonic transducer is configured to impart an ultrasonic vibration to the welding tip in response to an electrical signal received from the ultrasonic controller. The loading assembly is configured to generate a pressure load between the welding tip and the first work piece, and includes a first actuator and a second actuator. The first actuator is configured to apply a substantially constant load to the welding assembly, and the second actuator is configured to apply a dynamically variable load to the welding assembly.

Abstract: A stator for an electric motor includes a stator coil including a wire pair with respective ends that are joined with a ring. The ring is positioned around the wire pair and joined to the wire pair by a metal joining process.

Abstract: A battery module includes a plurality of stacked electrochemical battery cells, each having a positive cell tab and a negative cell tab. The positive cell tabs and the negative cell tabs are electrically connected through an interconnecting member. The interconnecting member includes a substrate supporting a plurality of connecting elements and defining a first slot and a second slot adjacent each of the connecting elements. The tabs of the electrochemical battery cells extend through the slots and are bent into a parallel relationship relative to the connecting elements. A fastening mechanism, such as a rivet, a bolt a screw, a clip or a weld, fastens the tabs to their respective connecting element.

Abstract: A method for diagnosing a fault in an electrical component using a diagnostic system having a plurality of sensors. The method includes positioning the electrical component in a predetermined position adjacent the diagnostic system and at a predetermined orientation with respect to the diagnostic system. The method also includes causing a predetermined level of electrical current to flow to the electrical component, the stationary sensors sensing electrical discharge emitted by the electrical component at an area of the fault, and the tangible computerized controller receiving sensor data from the sensors. The method further includes the tangible computerized controller executing the computer-readable instructions to process the sensor data to generate test information including a location of the electrical component at which the fault is occurring in at least two dimensions.

Abstract: An apparatus for joining a wire pair of a stator coil. The apparatus includes a tool having a pair of electrodes and control equipment. The control equipment is configured to control the electrodes to apply force to the wire pair to push adjacent wires of the wire pair toward each other and cause current to pass between the pair of electrodes, and so through the wire pair pushed together, at a time at which the force is being applied to the wire pair.

Abstract: An exhaust aftertreatment system for treating an exhaust gas feedstream of an internal combustion engine includes a catalytic converter, a fluidic circuit and a Stirling engine. The Stirling engine is configured to transform thermal energy from a working fluid heat exchanger to mechanical power that is transferable to an electric motor/generator to generate electric power. The Stirling engine is configured to transform mechanical power from the electric motor/generator to thermal energy transferable to the working fluid heat exchanger.

Abstract: A stator for an electric motor includes a stator coil including a wire pair with respective ends that are joined with a ring. The ring is positioned around the wire pair and joined to the wire pair by a metal joining process.

Abstract: A method of forming a cylindrical magnetic motor core having predetermined magnetic properties includes recording a 3D geometrical model, translating the geometry of the model into control parameters, and positioning magnetic material within a staging area surrounded by independently-controllable magnetic field generators. The control parameters are transmitted to the field generators to generate 3D magnetic fields, which are controlled to magnetically shape the material into a motor core substantially conforming to the model. After shaping, the core may be solidified to form a finished core. A system for forming the magnetic motor core includes a host computer controlling the position and motion of each field generator. The 3D model is used by the host computer to control the magnetic field generators and shape the MR material into the magnetic motor core.