Abstract: A composite liftgate including an inner panel construction having strengthening channel structure in combination with a ribbing. Structural steel reinforcements are bonded to the inner panel where additional strength is needed. Where the extra structure is needed, a minimum amount of steel is used and the structural reinforcement is bonded in place using adhesive. A plurality of access doors are provided that are removable for easier maintenance and repair.

Abstract: An optical wheel assembly for a laser transmission welding apparatus includes a double-convex optical lens having two spherical surfaces that are joined by a polished side surface extending circumferentially around the lens. Each of the two spherical surfaces has a known spherical diameter. The optical lens is disposed between a pair of dish cup holders, each having a spherical concave surface with the known spherical diameter and engaging the spherical surfaces of the lens. Each dish cup holder has an axial projection extending away from a side of the dish cup holder that is opposite the spherical concave surface. The axial projections are received within respective bearings that are mounted within a housing. The bearings allow the dish cup holders and the optical lens to rotate while pressure is being applied to plastic workpieces during laser transmission welding thereof.

Abstract: The twist axle assembly includes a cross beam that extends along a length between opposite ends, and a pair of trailing arms are fixedly attached with the opposite ends. A spindle plate is fixedly attached with each of the trailing arms. For each spindle plate and trailing arm combination, the spindle plate and trailing arm are provided with cooperating orbital adjustment features which allow an orientation of the spindle plate relative to the trailing arm to be adjusted prior to the spindle plate being fixedly attached with the trailing arm for allowing preselection of a camber angle, a caster angle, and a toe angle for a wheel to be coupled with the spindle plate.

Abstract: A system for making an autonomous connection between a first electrical contact and a second electrical contact includes a first receiver with the first contact therein and a second receiver with a second contact therein. The receivers are at least partially disposed within respective first and second housings. A first cover is disposed over an opening of the first housing and a second cover is disposed over an opening of the second housing. The covers seal the ends of the housings and the ends of the receivers, providing a double seal to the contacts. As the receivers are moved toward each other, the covers are automatically moved out of engagement with the receivers and housing. As the receivers are moved away from each other, the covers are automatically moved back into engagement with the housings and receivers.

Abstract: A locating pin for positioning one or more workpieces on a mounting member is provided. The locating pin includes at least one cam being radially moveable between an extended position and a retracted position. The at least one cam engages the workpiece while in the extended position to hold the workpiece in place. The at least one cam is spaced from the workpiece while in the retracted position to allow the workpiece to be positioned on, or removed from the locating pin.

Abstract: A system and method for automatically moving one or more items between a structure at a source location and a destination using a robot is provided. The system includes first and second vision systems to identify an item and to determine the precise location and orientation of the item at the source location and the precise location and orientation of the destination, which may or may not be in a fixed location. A controller plans the best path for the robot to follow in moving the item between the source location and the destination. An end effector on the robot picks the item from the source location, holds it as the robot moves, and places the item at the destination. The system may also check the item for quality by one or both of the vision systems. An example of loading and unloading baskets from a machine is provided.

Abstract: A pressing device for a laser welding apparatus includes an arm member with opposite mounting and pressing ends. A pressing pad at the pressing end has an opening for allowing a laser beam to irradiate a workpiece assembly that is being pressed by the pressing device. The mounting end has a mounting structure for detachably securing the pressing device to the laser welding apparatus. The arm member is shaped to position the opening at a known fixed distance from a laser source of the laser welding apparatus. The pressing pad has a pressing surface on a workpiece-facing side thereof for applying a joining force to the workpiece assembly at a welding location. At least one of the size, shape and smoothness of the pressing surface allows a sliding-contact movement of the pressing surface along a surface of the workpiece assembly during application of the pressing force.

Abstract: An electric drive module (e-drive module) for an electric motor vehicle and chain driven electric-drive (e-drive) gearbox therefor is provided. The e-drive gearbox has first and second chain members operably coupling an output shaft of an electric motor to a shaft of a driven output member. A first drive gear is rotatable with the output shaft of the electric motor. A first driven gear is coupled to the first drive gear via the first chain member. A second driven gear is coupled to the first driven gear via a common shaft and co-rotatable with the first driven gear. A second drive gear is coupled to the second driven gear via the second chain member. The respective rotational axes of the first and second drive gears and the first and second driven gears are parallel to each other.

Abstract: A system and method for laser cutting a plurality of parts, for example metal chassis components, using a plurality of laser cutting apparatuses is provided. The system includes a plurality of the laser cutting apparatuses disposed in a single enclosed cell for simultaneously trimming multiple parts. The system also includes at least one inner chamber and at least one set of double doors for transferring the parts in and out of the enclosed cell without any light escaping the cell. The parts are conveyed through the first door to the inner chamber while the second door is closed, and through the second door to the enclosed cell while the first door is closed. The system also includes robots continuously preloading and unloading the parts to maximize the laser trimming time.

Abstract: A sheet metal blank is hot-stamped between first and second tool surfaces of first and second die tools, respectively, to form a hot-stamped product. That product is then heat treated between the first and second tool surfaces. An actively cooled portion of the tool surfaces quenches part of the hot-stamped product to form a hardened zone. An actively heated portion of the tool surfaces slows heat transfer from the hot-stamped product to the heated portion, which causes the hot-stamped product to have a soft zone. A matrix of insulating gaps is formed in the heated portion to further slow the rate of heat transfer from the hot-stamped product to the heated portion. The insulating gaps may facilitate the use of a lower-temperature heated portion, which may consequently save energy and result in the heated portion having greater wear resistance and longer life.

Abstract: A crossmember for a bumper includes an extruded profile base frame with at least two connecting areas, for attaching the crossmember to a vehicle structure, and which are set at a distance from each other along a longitudinal direction. An extruded reinforcing element is fixedly secured to a rear side of the extruded profile base frame between the at least two connecting areas. The crossmember is weight-optimized and which can be produced in a cost-effective manner.

Abstract: A compact deployable/retractable running board assembly for a motor vehicle including a running board, linkage coupled to the running board, and a motor assembly coupled to an actuator, the running board moveable between at least one stowed position and at least one deployed position. The linkage includes a drive arm connected to a pivot shaft within a housing at a location on the pivot shaft between two bushings that are coupled to the pivot shaft within the housing. The linkage also includes an idler arm connected to a pivot shaft within an idler housing. The actuator is operably coupled to the linkage to cause rotation of the linkage to move the running board between the at least one stowed position generally under the motor vehicle and at least one deployed position to provide a step surface for a user.

Abstract: A dimensionally stable B-pillar for an automotive vehicle including tailored material properties is provided. The B-pillar includes at least one localized soft zone surrounded by a hard zone. The hard zone typically has a yield strength of 950 MPa to 1700 MPa; a tensile strength of 1200 MPa to 2100 MPa; and an elongation of greater than 4%. The soft zones each have a yield strength of 340 MPa to 780 MPa; a tensile strength of 400 MPa to 980 MPa; and an elongation of greater than 10%. The microstructure of the hard zone is martensite, and the microstructure of the soft zones is tempered martensite, ferrite pearlite bainite, ferrite pearlite austenite, ferrite pearlite, ferrite bainite, cementite austenite, and/or cementite bainite. The soft zones of the B-pillar are manufactured with a slow cooling step, which can be conducted in air outside of the dies.

Abstract: The vehicle door assembly includes an outer panel which has a rocker sill area and a beltline area. A reinforcement member, which is made of one or more pieces, is attached with the outer panel along at least a portion of an outer periphery of the outer panel. The door assembly further includes a module which is made as a single integral piece and is fixedly attached with the reinforcement member. The module has an inner beltline reinforcement and supports a pair of window channels and a window regulator for controllably raising and lowering a window between an open position and a closed position.

Abstract: A dynamic lens for projecting different output beam shapes includes a first light source of laser diodes generating a first light beam toward a target. A projector generates a second light beam with a different wavelength than the first light beam. A beam combiner combines the first light beam together with the second light beam and directs the combined beams to a focusing plane that includes a lensing array to focus the first light beam into the output beam shape on the target. The lensing array includes a plurality of photoactive cells including at least one photoreactive group which changes molecular shape in response to light energy from the second light beam, thereby changing the orientation of adjacent liquid crystal molecules, which in turn alters the index of refraction of the photoactive cell. A method of operating the dynamic lens to generate the output beam shape is also disclosed.

Abstract: A shock tower for a vehicle includes a body having an upper portion and a lower portion. The body includes a hub disposed along the upper portion and a rim extending along the lower portion. A plurality of first spokes extend between the hub and the rim for carrying or distributing a load from the shock tower to a portion of the vehicle. A plurality of second spokes extend at least partially around the body and transversely to respective ones of the first spokes to define a plurality of spoke junctions for allowing the distributed load to change directions at each intersection of the second spokes with the first spokes. A plurality of third spokes each extend angularly from one of the first spokes to the rim. The spokes collectively define voids for removing material from the shock tower and reducing an overall weight of the shock tower component.

Abstract: A metasurface lens assembly to perform chromatic separation includes a first layer with a plurality of nanofins extending transversely there from and each being optically anisotropic and transmissive to light in the visible spectrum and having an optical characteristic that is set according to a phase profile. A second layer is spaced apart from the first layer and includes a plurality of photosensitive subpixels each associated with a different color. In operation, many beams of light may be directed onto the metasurface lens from a source with each beam of light having a plurality of component colors. The nanofins may function in combination with one another according to the phase profile to bend and focus the beams of light onto the second layer with each of the component colors being bent and focused differently to direct the component colors onto corresponding ones of the photosensitive subpixels.

Abstract: A riveted assembly includes a first panel member having a first surface and a second surface opposite to the first surface; a second panel member having a first surface and a second surface opposite to the first surface; and a rivet. The first and second panel members are positioned such that at least a portion of the second surface of the first panel member is in contact with at least a portion of the first surface of the second panel member. The rivet extends into and engages the first surface of the first panel member, and has an outwardly flared portion about which a portion of the first panel member and the second panel member are deformed, such that the rivet mechanically connects the first panel member to the second panel member at a connection region. The second surface of the second panel member has a differential height surface portion at least at the connection region.

Abstract: A system for producing components by hot forming includes a pre-heat station, a furnace, and a press. The pre-heat station is configured to receive a blank; and to pre-heat at least a portion of the blank to a pre-heat temperature by thermal conduction. The furnace is constructed and arranged to receive the pre-heated blank from the pre-heat station and to heat the entire blank to a deformation temperature. The deformation temperature is higher than the pre-heat temperature. The press is constructed and arranged to receive the heated blank from the furnace and to form the heated blank into the shape of the component.

Abstract: A compact deployable/retractable running board assembly for a motor vehicle including a running board, linkage coupled to the running board, and a motor assembly coupled to an actuator, the running board moveable between at least one stowed position and at least one deployed position. The linkage includes a drive arm connected to a pivot shaft within a housing at a location on the pivot shaft between two bushings that are coupled to the pivot shaft within the housing. The linkage also includes an idler arm connected to a pivot shaft within an idler housing. The actuator is operably coupled to the linkage to cause rotation of the linkage to move the running board between the at least one stowed position generally under the motor vehicle and at least one deployed position to provide a step surface for a user.