Abstract: A modular cargo vehicle for transportation of cargo by a rider. The cargo vehicle includes a tow cycle, a front cargo module, and a trailer cargo module. The tow cycle has a rider seat, a front axle with a front wheel, a rear axle with one rear wheel, and a pedal crank to facilitate driving of the tow cycle by the rider via a pedal crank. A rear end of the front cargo module is coupled to a front end of the tow cycle. The front cargo module has a front axle with a front wheel, a cargo-receiving area, and no rear axle. A front end of the trailer cargo module is coupled to a rear end of the tow cycle. The trailer cargo module has a cargo-receiving area and an axially central axle with two wheels.

Abstract: A system and method for identifying a shape and pose of an object is provided. The system includes a controller and a grasping device. The grasping device includes a plurality of fingers that are moveable relative to a base. The fingers include one or more tactile sensors attached thereto. The tactile sensors are configured to collect data, such as a 2D image or 3D point cloud, based on points of contact with the object when the object is grasped. The grasping device is configured to roll the object within the fingers and collect additional data. The controller may combine the data and determine the shape and pose of the object based on the combined data.

Abstract: A forming system that includes a first die having a first die surface and a second die having a second die surface is provided. The first and the second die surfaces are configured to cooperate to form a die cavity therebetween so as to receive a workpiece therein. Coatings are formed on opposing portions of the first and second die surfaces. The coatings on the opposing portions of the first and the second die surfaces cooperate to be on opposite sides of the workpiece received in the die cavity. A ratio of Vanadium to Tungsten in the coatings is in the range between 0.31 and 0.45. In one embodiment, each of the coatings includes at least two layer configuration. In another embodiment, each of the coatings includes a predetermined thickness.

Abstract: A vehicle frame structure including a pair of elongated mid bay rails with a cross beam extending between rear ends of the pair of mid bay rails. A pair of elongated rear bay rails define an overlapping joint with the pair of elongated mid bay rails, wherein a first pair of reinforcement members connect forward ends of the pair of rear bay rails to the pair of elongated mid bay rails and a second pair of reinforcement members connect rearward ends of the pair of mid bay rails to the pair of elongated rear bay rails.

Abstract: A fixture assembly for supporting a plurality of blanks during a shearing and welding operation. The fixture assembly includes a base frame. A rotating frame is rotatably connected to the base frame. A fixed block is fixed to the rotating frame for supporting a first blank. A moveable block is moveably connected to the rotating frame for supporting a second blank. A first clamp is provided for coupling the first blank to the fixed block. A second clamp is provided for coupling the second blank to the moveable block. A vertical actuator is coupled with the rotating frame and configured to move the moveable block in a vertical direction being perpendicular to a plane of the rotating frame for moving the second blank. A horizontal actuator is coupled with the rotating frame and configured to move the moveable block in a horizontal direction.

Abstract: A method for producing a joining connection between at least two metal sheets or at least two components made of hot-workable sheet metal with a scaling-resistant coating, is provided. The method includes at least one step in which a connection is produced between the at least two metal sheets or sheet-metal components by hot-press soldering, wherein the surface of the metal sheets or components to be connected is pretreated in order to break up the coating.

Abstract: A pillar for a vehicle including at least two different localized areas of different tensile strengths. The pillar includes a body defining a width that merges into sidewalls at a transition. The body having a first tensile strength and the transition has a second tensile strength, wherein the first tensile strength is smaller than the second tensile strength. The variety in tensile strength resulting from at least one of varying the material treatment and varying the gauge. The pillar is press-hardened until it reaches a tensile strength of 1500 MPa to 2000 Mpa.

Abstract: A structural component for a vehicle may include an extrusion that is extruded into a first state and then expanded into a second state. The extrusion in the first state has a reduced size relative to a desired final size. The extrusion in the first state is placed within a die that defines the desired final size. Pressurized water is distributed within internal cells of the extrusion in the first state such that the walls defining the internal cells are expanded into engagement with the surface of the die, thereby creating surface features or sealing interfaces with tight tolerances. The relative shape of the die and the extrusion in the first state defines an open space therebetween, into which the extrusion may expand to define the final shape. Some of the internal cells may be plugged such that they are not provided with pressurized water.

Abstract: A frame assembly for an automobile and method of assembling same. The frame assembly includes a battery housing at least partially integral with an automobile frame. The frame includes longitudinal beams that extend between front frame rails and rear frame rails. The battery housing includes two portions, a upper cover integrated with the longitudinal beams and a base plate that connects to the upper cover or the longitudinal beams with a releasable connection. The base plate includes a connection flange that includes at least one seal. When connected, at least one battery module is enclosed in the battery housing.

Abstract: A stamp tool assembly is provided that includes a forming cavity for shaping a blank into a formed part. The stamp tool assembly includes adjustable block assembly for modifying the amount of material draw-in from subsequently stamped blanks. A draw-in sensor measures the amount of material from the blanks that is not drawn-into the forming cavity during each stroke. Based on the readings from the draw-in sensor, the adjustable block assembly is expanded or reduced. The adjustable block assembly includes a pair of opposing inclined plates having interlocking teeth such that movement of one plate with respect to the other plate changes a vertical extension of the adjustable block assembly. The adjustable block assembly sets the spacing between two opposing draw-in surfaces, which, in turn, changes the amount of draw-in. Multiple adjustable block assemblies and draw-in sensors may be used in conjunction and controlled via a controlling system.

Abstract: The present disclosure is related to a method of welding a component, such as a fastener, with a base metal. The method includes the step of stud welding a component with a base metal to create at least one weld joint using at least one electrode. The method continues with the steps of emitting ultrasonic waves from an ultrasonic sensor on an electrode and receiving reflections of those ultrasonic waves with the ultrasonic sensor. The method proceeds with the step of generating an acoustic map based on the reflections of the ultrasonic waves. The method continues with the step of analyzing the acoustic map to determine a quality of the at least one weld joint.

Abstract: A system for producing components by hot forming includes a conductive post-furnace heat station, a furnace, a computer system, and a press. The computer system comprises one or more physical processors operatively connected with the furnace in and the conductive post-furnace heat station. The one or more physical processors being programmed with computer program instructions which, when executed cause the computer system to control the furnace to heat the blank to a temperature that is below AC3 temperature; and control the conductive post-furnace heat station to heat a portion of the heated blank to a temperature above the AC3 temperature by thermal conduction. The press is constructed and arranged to receive the post-heated blank from the post-furnace heat station and to form the post-heated blank into the shape of the component.

Abstract: An impingement cooling system includes a porous heat spreader and a nozzle configured to direct a fluid as a jet and/or as a spray impinging upon the porous heat spreader. The porous heat spreader is made of a thermally-conductive material such as a metal, metal alloy, carbon/graphite, or ceramic, and is in thermal contact with a heat source. The nozzle may be configured to direct the fluid as a jet comprising a single component liquid or gas (including air) or a liquid mixture such as water-glycol or other coolants. The nozzle may be configured to direct the fluid as a spray comprising a single component liquid or gas (including air) or a liquid mixture such as water-glycol or other coolants. The cooling system may include one or more nozzles, which may direct the cooling fluid orthogonally or at an oblique angle to an impingement plate.

Abstract: The invention provides a component formed of an aluminum alloy for use in a vehicle, for example an automotive vehicle component requiring high strength, light-weight, and a complex three-dimensional shape, and a method of manufacturing the component. The method begins by providing a blank formed of an aluminum alloy which is already solution heat treated and tempered, and thus has a temper designation of about T4. The method further includes heating the blank to a temperature of 150° C. to 350° C., preferably 190° C. to 225° C. The method next includes quickly transferring the blank to a hot or warm forming apparatus, and stamping the blank to form the complex three-dimensional shape. Immediately after the forming step, the component has a temper designation of about T6, but preferably not greater than T6, and thus is ready for use in the vehicle without any post heat treatment or machining.

Abstract: A smart trim die assembly for providing multiple internal operations during a stroke is provided. The smart trim die assembly includes a first die, a second die, and a cavity formed between the first die and second die. A plurality of sensors are located between the first die and the second die for measuring the distance therebetween during a stroke. A series of tools are integrated into one of the first die or second die and each perform one of trimming, piercing, dimpling, and tapping operations. The smart trim die assembly further includes a processor and a memory device for receiving readings from the sensors. The memory device further contains instructions that, when executed by the processor, cause the processor to, in response to the sensor reading a predetermined distance, instruct the series of tools to perform one or more of the operations.

Abstract: A welding electrode for an electric resistance welding process. The welding electrode includes a body extending along a center axis and terminating axially at a weld face for contacting a work face. The weld face defines a center along the axis and defines an outer edge spaced radially from the center. A plurality of senates are defined along the weld face. Each of the serrates projects axially away from the weld face and extends radially from the center axis to the outer edge of the weld face. A higher density of the plurality of serrates is formed proximate to the center axis than proximate to the outer circumference of the weld face. Methods for using the welding electrode and forming the senates on the welding electrode are also provided.

Abstract: An adapter assembly for a robot arm includes: an inner shaft configured to receive a tool supply cable therethrough and configured to attach to the tool supply cable; an outer member disposed annularly around the inner shaft and attached thereto in a telescopic configuration with the inner shaft movable with the tool supply cable between a retracted position and an extended position; and a compression spring configured to bias the inner shaft to the retracted position. A robotic assembly includes: a robotic arm including at least two linkages configured to articulate relative to each other; a tool attached to the robotic arm; a tool supply cable extending along the robotic arm for providing functionality to the tool; and an adapter assembly connected to the robotic arm. The adapter assembly includes a spring bias toward a retracted position, thereby taking-up slack in the tool supply cable.

Abstract: A system and method for inspecting an assembly including components joined by self-piercing rivets by a computerized tomography (CT) scan of the joint is provided. The system includes a source of x-rays, a mounting unit for an assembly including the joint which is subject to the x-rays, and an x-ray detector disposed opposite the source for detecting the x-rays. The x-rays are provided at a high energy level of at least 200 kV to generate images having a resolution of at least 200 micrometers (?m). A computer stitches the images together to form reconstructive images which show details of the joint. The assembly to be inspected is not destroyed or modified prior to the inspection process. The resolution of the images generated by the x-rays is high enough to determine the presence of cracks, if any, the interlock (SH), minimum thickness (Tmin), and overall structure of the unmodified assembly.

Abstract: A motor drive system and method for determining an optimized efficiency of the motor drive system are provided. The motor drive system includes a system controller, a motor drive having includes an inverter configured to generate the AC power upon one or more motor leads, and an electric motor, which is to convert the AC power from the motor leads to rotational energy. A dynamometer may include a load coupled to the shaft and sensors to measure to measure operating characteristics such as torque and speed of the electric motor. The system controller is configured to generate a lookup table, with an entry describing an output current command for operating the inverter and the motor at a maximum system efficiency for a given combination rotational speed and output torque. Motor temperature may also be measured and used as an additional index into the lookup table.

Abstract: A method for force or torque sensing in an electromechanical actuator-driven robot comprising one or more links, one or more joints, an end effector and a controller is provided, the method comprising: estimating a first set of load torques in one or more joints in a given configuration of the robot without external force or load applied to the end effector; identifying gravitational and frictional components in the first set of load torques; estimating a second set of load torques in the one or more joints in the given configuration of the robot with an external force or load applied to the end effector; calculating a difference between the second set of load torques and the first set of load torques, taking into account the identified gravitational and frictional components; calculating an external force or torque acting on the end effector based on the difference between the second set of load torques and the first set of load torques using a Jacobian matrix for the given configuration of the robot; and pr