Abstract: A method of joining multiple components is disclosed. The method includes arranging a first component having a first surface, an opposing second surface, and a feature, in contact with a second component having a first surface, an opposing second surface, and defining an aperture. When so arranged, the first surface of the first component is adjacent to the second surface of the second component. The method also includes positioning a fastener on the first surface of the second component and in contact with the feature of the first component, such that at least a portion of the fastener overlaps the aperture on the first surface of the second component. The method additionally includes abutting and fusing the fastener to the feature of the first component to thereby affix the first component to the second component.

Abstract: A modified dual-duplex fail-operational control system. A primary controller includes a first processing unit and a second processing unit for executing a function. A first comparative module comparing the function results from the first and second processing unit to determine an error the first controller. A second controller includes a first processing unit and second processing unit. The first processing unit executes the function. The second processing unit operating in a non-redundant state and not executing the function while in the non-redundant state. A second comparative module determines whether an error is present in the second controller.

Abstract: An automatically-shiftable transaxle includes an input member configured to receive an external power-source torque and rotate about a first axis. The transaxle also includes torque transmitting device(s) and a gear-train, each operatively connected to the input member for selecting transaxle speed ratios, and a first transfer gear operatively connected to the gear-train and rotatable about the first axis. The transaxle also includes an intermediate shaft rotatable about a second axis, and a second transfer gear rotatably fixed to the intermediate shaft and meshed with the first transfer gear. The transaxle additionally includes an electric motor arranged on a third axis for providing a torque input to the second transfer gear. Furthermore, the transaxle includes a differential assembly operatively connected to the intermediate shaft and rotatable about a fourth axis to thereby transmit a transaxle output torque to drive the load. All four transaxle rotational axes are arranged in parallel.

Abstract: An automated method for discovering features in a repeatable process includes measuring raw time series data during the process using sensors. The time series data describes multiple parameters of the process. The method includes receiving, via a first controller, the time series data from the sensors, and stochastically generating candidate features from the raw time series data using a logic block or blocks of the first controller. The candidate features are predictive of a quality of a work piece manufactured via the repeatable process. The method also includes determining, via a genetic or evolutionary programming module, which generated candidate features are most predictive of the quality of the work piece, and executing a control action with respect to the repeatable process via a second controller using the most predictive candidate features. A system includes the controllers, the programming module, and the sensors.

Abstract: A vehicle includes a vehicle body having a structure and a wheel maintaining contact with a road surface. A suspension supports the structure and includes one or more suspension corner assemblies connecting the wheel to the structure and configured to maintain contact between the wheel and the road surface. A secondary actuation system cooperates with the suspension system and is operable to selectively change at least one vehicle operating property. The secondary actuation system includes at least one actuator device operatively connected to the structure at a first end and the one or more suspension corner assemblies at a second end to selectively change at least one vehicle operating property and a spring assembly in fluid communication with the at least one actuator device selectively actuated to adjust an amount of fluid in the at least one actuator device to selectively change the at least one vehicle operating property.

Abstract: A vehicle has first and second portions, with a front aerodynamic element located in the first portion and a rear aerodynamic element located in the second portion. The front and rear aerodynamic elements are each independently movable to respective deployment positions between respective stowed positions and respective fully-extended positions. A controller is operatively connected to each of the front and rear aerodynamic elements and has a processor and tangible, non-transitory memory. The controller is programmed to obtain a front target position (Tf,n) for the front aerodynamic element at a current time step (n) based at least partially on at least one vehicle state parameter at a previous time-step (n?1) and a detected position (Dr,n-1) of the rear aerodynamic element at the previous time-step (n?1).

Abstract: A vehicle telematics device for a vehicle that includes an electronic processor, a wireless chipset for wireless communication to and from the vehicle, and a bus interface for receiving bus messages from a communications bus in the vehicle. The vehicle telematics device includes computer readable memory storing program code that, upon execution by the processor, causes the vehicle telematics device to: (a) monitor for messages received by the bus interface from the communications bus; (b) detect a communication failure of the communication bus based on the monitoring; (c) determine a vehicle movement that is indicative of a vehicle crash; and (d) initiate a communication with a remote facility in response to both the detection of the communication failure and the determination of the vehicle movement that is indicative of a crash a notification.

Abstract: Disclosed are rack-and-pinion mounting devices, methods for making and methods for using such devices, and motor vehicles with storage containers secured by rack-and-pinion mounting devices. A mounting device is disclosed for attaching an accessory to a surface. The mounting device includes a latch housing that mounts to the accessory (or surface). A bolt latch, which is slidably coupled to the housing, includes a linear gear bar and locking pins. These locking pins engage tie-down loops attached to the surface (or accessory). A pinion gear is rotatably coupled to the housing and intermeshed with the gear bar. Spinning the pinion gear in one direction slides the bolt latch to disengage the locking pins from the loops and detach the accessory from the surface. Spinning the pinion gear in the opposite direction slides the bolt latch to engage the locking pins with the loops and attach the accessory to the surface.

Abstract: A cooling plate for a battery pack with a plurality of battery cells is provided. The cooling plate includes a cooling fin with a substantially planar surface and a perimeter. The cooling plate includes a frame abutting the cooling fin and forming a seal with the cooling fin adjacent the perimeter of the same. The frame and the cooling fin define at least one fluid inlet, at least one fluid outlet, and a flow channel therebetween. The at least one fluid inlet and the at least one fluid outlet are disposed through the seal and are in fluid communication with the flow channel. The flow channel is disposed adjacent the perimeter and in heat transfer communication with the substantially planar surface of the cooling fin. A battery pack with the cooling plate, and a method for controlling a temperature of the battery pack, are also provided.

Abstract: A rotor casting includes a lamination stack and a cast structure including proximal and distal cast end rings respectively adjacent proximal and distal end faces of the lamination stack. Cast axial ribs are distributed radially on a peripheral surface of the lamination stack and extend between the proximal and distal cast end rings. Cast feed members extend axially from the proximal cast end ring and are respectively positioned radially between an adjacent pair of axial ribs. In one example, cast bar segments integral to the proximal and distal cast end rings are formed in axial slots of the lamination stack. In one example, a bar insert in each axial slot has insert ends that extend respectively from the proximal and distal end faces of the lamination stack and are fully encapsulated respectively in the proximal and distal cast end rings. A method of forming the rotor casting is provided.

Abstract: An automotive battery pack enclosure, assembly and method of housing battery pack cells within an enclosure. The enclosure includes a tray that defines a mounting surface for the various individual battery cells, as well as an upstanding wall, while the assembly further includes numerous individual battery cells aligned along a stacking axis within the enclosure. The wall is made from a continuous extruded preform with periodically-spaced miters that permit bending such that the wall can assume any shape defined by the various panels. The panels cooperative with the peripheral edges of the tray to define a battery container with a footprint shape generally similar to that of the tray. By being formed from a substantially one-piece preform, all of the corners—save the one formed where wall ends are brought into adjacent cooperation with one another—define a continuous structural seal without the need for sealants, welds or other supplemental closure approaches.

Abstract: An active spoiler system for a vehicle includes a spoiler body having an airfoil shape in a cross-sectional view. The vehicle includes a vehicle body arranged along a longitudinal body axis and having a first vehicle body end configured to face oncoming ambient airflow and an opposing second vehicle body end. The spoiler body is configured to be moveably mounted between the first vehicle body end and the second vehicle body end to generate an aerodynamic downforce on the vehicle body when the vehicle is in motion. The spoiler system also includes a first mechanism configured to selectively translate the spoiler body along the longitudinal body axis to thereby adjust along the longitudinal body axis a location of the aerodynamic downforce generated by the spoiler body.

Abstract: A vehicle propulsion system includes an engine and a first electric machine each configured to selectively provide torque to propel the vehicle. The propulsion system also includes a second electric machine coupled to the engine and configured to start the engine from an inactive state. A controller is programmed to execute a first control algorithm while output speed of the second electric machine is less than a first speed threshold. The controller is also programmed to execute a second control algorithm while output speed of the second electric machine is greater than the first speed threshold and less than a second speed threshold.

Abstract: A final drive assembly for a vehicle drive axle having first and second axle-shafts that are configured to rotate about a common first axis. The final drive assembly includes a first gear-set configured to be operatively connected to the first axle-shaft. The final drive assembly also includes a second gear-set configured to be operatively connected to the second axle-shaft. The final drive assembly additionally includes an electric motor configured to provide an electric motor torque input to each of the first and second gear-sets and arranged on a second axis that is parallel to the first axis.

Abstract: A beltline reinforcement member for a door of a vehicle includes a body that extends along a longitudinal axis, between a first end and a second end. The body includes, an inner belt wall extending generally parallel to the longitudinal axis, an outer belt wall extending generally parallel to the longitudinal axis and spaced apart from the inner belt wall for receiving a window between the inner belt wall and the outer belt wall, a first end wall interconnecting the inner belt wall and the outer belt wall at the first end of the body, and a second end wall interconnecting the inner belt wall and the outer belt wall at the second end of the body. The inner belt wall, the outer belt wall, the first end wall, and the second end wall are integrally formed together as a single, unitary structure, such as by a casting process.

Abstract: A torque converter is provided. The torque converter, or torque converter assembly, operatively connects a primary mover and a transmission, and includes an input rotationally connected to the primary mover and an output rotationally connected to the transmission. The torque converter includes a fluid coupling having impeller blades and turbine blades. The fluid coupling transfers torque between the impeller blades and the turbine blades when the input and the output are rotating at different speeds. A mini damper is disposed in line with the fluid coupling between the input and the output. A torque converter clutch is configured to selectively slip or selectively lock, such that torque may be transferred directly between the input and the output. A primary damper is disposed between the input and the output.

Abstract: A system and method for operating a wireless device installed in a vehicle. The method carried out by the system includes: determining one or more services utilized by the wireless device; receiving a signal indicating one or more services currently available from a wireless access point installed in the vehicle; determining if the one or more services utilized by the wireless device are currently available from the wireless access point; and based on the determinations deciding whether to connect the wireless device to the wireless access point or, if already connected, whether to disconnect so as to free up the wireless access point for use by other wireless devices on the vehicle.

Abstract: A powertrain includes a propulsion system having first and second torque sources, and first and second drive axles respectively connected to and independently driven by the first and second torque sources. A permissible range of torque contribution from the torque sources to the respective first and second drive axles is defined by a component torque window. The powertrain includes sensors for detecting a dynamic driving maneuver of a vehicle having the powertrain. A controller executes a method to adjust a size and/or orientation of a chassis torque window during the detected dynamic driving maneuver, determine an optimally efficient axle torque operating point that falls on a torque line within the component torque window in proximity to the chassis torque window, and command the torque contribution via transmission of torque control signals to the first and second torque sources to achieve the optimally efficient axle torque operating point.