Abstract: A system for opening and closing a sliding vehicle door includes a vehicle door that engages with the body in the closed position. A longitudinal track is fixedly mounted to an interior of the vehicle door. A hinged bracket is fixedly mounted to the vehicle body adjacent an opening defined by the vehicle body. The hinged bracket has a laterally compressed shape when the door is closed, and expands laterally outward when the door is opened. The door and the track fixed thereto slide longitudinally along the opened hinged bracket when the door is opened. The interface between the hinged bracket and the track remains at the same generally location relative to the vehicle body, and shifts relative to the vehicle door when the door is opened.

Abstract: A motor drive system for an electrified vehicle includes a DC source, such as a battery, and an inverter, which includes one or more phase drivers, each configured to switch current from the DC source to generate AC power upon one or more output terminals using a hybrid of two or more different solid-state switches, each having a corresponding voltage rating. A nine-switch inverter includes three phase drivers, each including high, low, and middle solid-state switches, with Si-MOSFET high and low switches having a first voltage rating of half of the rated voltage of the system, and with Gallium Nitride (GaN) transistors rated to block a full rated voltage of the system used for the middle switches. A delay driver synchronizes timing between two different solid-state switches by energizing control terminals at different rates. The inverter can be operated using near-state pulse-width modulation (NSPWM) to reduce switching losses.

Abstract: A vehicle seat system is provided that includes heating, cooling, and occupant sensing functionality in a single unit. The system includes carbon nanotube (CNT) elements disposed adjacent the seat surface. The CNT elements may be woven or stitched to a vehicle seat cover, or may be disposed in a mat that is placed between a seat cushion and the seat cover. The CNT elements may be used for heating, cooling, and occupant sensing, without requiring separate units or circuits. The system may include Peltier elements attached to the CNT elements, with the Peltier elements transferring heat between the CNT elements and a heat bank. The heat bank may be in the form of a heat sink, or the heat bank may be the seat rails of the vehicle seat, with the Peltier elements attached to the seat rails.

Abstract: An improved aluminum alloy for blending with a recycled aluminum alloy to form a material for high pressure vacuum die casting is provided. The improved aluminum alloy includes 10 to 12 wt. % silicon, 0.65 to 0.85 wt. % manganese, less than 0.05 wt. % iron, less than 0.05 wt. % magnesium, 0.2 to 0.4 wt. % strontium, less than 0.05 wt. % titanium, and less than 0.02 wt. % copper, based on the total weight of the improved aluminum alloy. The recycled aluminum alloy typically includes 0.60-1.0 wt. % silicon, ?0.35 wt. % iron, ?0.20 wt. % copper, 0.05-0.20 wt. % manganese, 0.40-0.8 wt. % magnesium, ?0.20 wt. % chromium, ?0.15 wt. % zinc, ?0.05 wt. % titanium, ?0.05 wt. % others (each), and ?0.15 wt. % others (total). The material meets the specifications for an Aural 5S alloy.

Abstract: A system for modifying the structure of a unibody vehicle includes a vehicle body having a unibody construction and a first module attached to the vehicle body. The first module is removable from the vehicle body and replaceable with a second module having a different size and/or functionality. A rear portion of the first module may be removed from the first module and attached to the second module. The first module may be a stock cargo module, and the second module may be an aftermarket module. The rear portion may be a stock tail tamp and/or sensor module. The rear portion may be removed before or after removing the first module from the vehicle body, and may be attached to the second module before or after attaching the second module to the vehicle body.

Abstract: A cradle for being used in automotive vehicles for supporting various automotive components includes a structure with variable thickness, defining a variable gauge cradle. The variable gauge cradle has a minimum thickness and maximum thickness, with various other thicknesses therebetween. The minimum thickness is less than an original thickness of a reference cradle in which the thickness is the same. The variable gauge cradle allows specific locations to be locally increased in thickness to achieve the desired stiffness at the areas requiring the increased stiffness, while leaving areas requiring a lower stiffness at a lesser thickness. The variable gauge cradle therefore may have a lower mass than the reference cradle. The thickness may be increased relative to the minimum thickness using patches that are bonded to a base layer or panel of the cradle. The patches may be distributed at different locations to create different thicknesses.

Abstract: A system for modifying the range capability of an electric vehicle includes a vehicle body having a front axle and a rear module secured to the vehicle body. The rear module includes a rear axle and the rear module is detachable from the vehicle body and replaceable with another rear module. The rear modules may include different range extension capabilities. The rear modules may include a battery or a combustion engine that may supplement the standard battery and electric motor of the vehicle. A pair of laterally translatable pins of the rear module may be moveable into and out of engagement with the vehicle body. The rear module may also include vertically extending posts that engage with the vehicle body. The vehicle body may be raised to disengage the posts from the vehicle body.

Abstract: An insert for a steel shot sleeve of a high-pressure die casting assembly used to form aluminum vehicle components is provided. The insert is formed by additive manufacturing, for example laser sintering, and is located opposite a pouring hole of the shot sleeve. The insert includes multiple layers formed of metals and ceramic designed to reduce damage to the shot sleeve caused while casting the components. For example, a cylindrical body of the shot sleeve can be formed of steel, and the insert can include a base layer formed of the steel. The insert can include middle layers formed of a mixture of the steel; an alloy of chromium, iron, and molybdenum; and zirconium oxide. The insert can also include an inner layer formed of the zirconium oxide. The amount of ceramic increases and the amount of metal decreases in the direction moving toward the inner layer.

Abstract: A system and method for an improved material flow through an extrusion machine by altering the material properties in a magnetic field are provided. The electromagnetic extrusion system includes a ram that is moved into a chamber containing an extrusion material to force the extrusion material out of an opening defined, at least in part, by a die to create an extrusion with a cross-sectional shape corresponding to the predetermined shape of the opening. An electromagnetic winding of electrically conductive material is embedded within a tool retainer block surrounding the container and is helically wound about the chamber and carries a DC electrical current to generate a magnetic field having a magnetic flux density of at least 2 Tesla within the extrusion material to dissipate dislocation defect structures in the extrusion material being extruded via the magnetoplasticity effect. The magnetic field therefore provides for reduced flow stress on the tooling.

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: A power converter includes an integrated multi-layer cooling structure. The power converter includes a plurality of printed circuit boards (PCBs) stacked together in a generally vertical arrangement. A liquid cooling mechanism is attached to a lower-most PCB, and high loss circuitry components are attached to an opposite side of the lower-most PCB. Low loss circuitry components are attached to further PCBs. Magnetic components may be attached to the further PCBs. The high loss components are actively cooled by the liquid cooling mechanism and the low loss components and magnetic components are passively cooled. The liquid cooling mechanism may be a cold plate heatsink. The power converter may include intermediate PCBs disposed between the upper-most PCB and the lower-most PCB, with low loss circuitry components attached to the intermediate PCBs.

Abstract: A method for improving a hemispherical dome test includes calculating a forming limit diagram (FLD) based on a plurality of simulated data associated with a sheet metal transformation technique. The method also includes performing zero friction analysis on the sheet metal transformation technique. The method also includes shifting the FLD based on the zero friction analysis.

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 system for transferring waste heat from a range extender module of an electric vehicle to a cabin module includes a cooling circuit in the range extender module and a heating circuit of the cabin module. The cooling circuit is thermally coupled to the heating circuit. The cooling circuit includes a thermal coupler and the heating circuit includes a corresponding thermal coupler. The thermal coupler of the cabin module heating circuit may be disposed at the rear of the cabin module, and the thermal coupler for the cooling circuit of the range extender module may be disposed at the front of the range extender module. The thermal coupler of the range extender module may be longitudinally adjustable.

Abstract: A method for conditioning a welded vehicle body assembly is provided. The method includes welding the vehicle body member to at least one additional vehicle body member together to form the welded vehicle body assembly, the welded vehicle body assembly includes a weld area; and laser annealing a weld heat affected zone adjacent to the weld area to soften material in the weld heat affected zone.

Abstract: A vehicle door system includes a door with a door module and a hinge module. The hinge module is attached to the vehicle body. The door module is attached to the hinge module. The hinge module includes a hinge bracket attached to the vehicle body, and a pair of arms extending from the hinge bracket that can pivot relative to the hinge bracket and a cross brace attached at the ends of the arms. The door module attaches to the cross brace. The door module moves along with the cross brace, which moves along with the arms as they pivot relative to the hinge bracket. The door module includes a latch mechanism at a bottom edge, with the latch mechanism engaging with the vehicle body. A lateral edge of the door may seal against a lateral edge of the second door without a latch interface.

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 coating for vehicle components, such as frame assemblies and cradle assemblies formed of steel, is provided. The coating includes a first layer including a high phosphate composition applied to the substrate, and a second layer including wax applied to the first layer. For example, the first layer can include a first inorganic acid, an inorganic salt, a second inorganic acid, nickel salt, and ammonium bifluoride; and the second layer can include petroleum, carbon black pigment, and a corrosion inhibitor, the corrosion inhibitor including magnesium. The coating has been found to improve corrosion resistance when applied to steel substrates, compared to wax coatings which are currently applied to steel substrates.

Abstract: A system and method for integrated charging a vehicle includes a hybrid excitation machine, operable as a traction motor and including a rotor separated by an air gap from a stator with AC windings. An AC utility line power supply is connected to the AC windings providing an electrical current to the vehicle and inducing a magnetic flux across the air gap and in the rotor. A short circuit, an open circuit, or a DC voltage may be applied to a DC winding in the stator to reduce the magnetic flux into the rotor. A field coil in the rotor may be excited with a DC voltage using a secondary coil on the rotor in a traction mode. The secondary coil is excited by the stator windings using field-oriented control in a “self-excited machine” embodiment, and is directly excited by a separate primary coil in an “externally-excited machine” embodiment.

Abstract: A fixture assembly for supporting a plurality of blanks during a welding operation. The fixture assembly includes a frame. A plurality of electromagnets are positioned on the frame for supporting the blanks and for drawing the blanks toward the electromagnets to secure the blanks into a desired position. A plurality of intensifiers are moveably connected to the frame for selectively overlying the top face of one of the electromagnets for clamping the blank against the electromagnet to intensify a magnetic force provided by the electromagnet. A plurality of electromagnet adjusters are each coupled with the frame and with at least one of the electromagnets for moving the electromagnets relative to the frame. A plurality of adjusting pins are each connected to the frame and moveable relative to the frame for adjusting a position of the blanks.