Abstract: An automated inspection system comprises a camera configured to capture an image of a subject item, and a processor in communication with the camera and programmed to recognize the subject item in the image. The processor is configured to determine, from the image, the presence, location, or other properties of a feature of the subject item. The processor may present an augmented reality display as an overlay onto a live image of the subject item. The system may include a portable computing device including the camera and a display screen presenting the augmented reality display with one or more overlays onto a live image of the subject item. The overlays may include icons indicating a feature being recognized as being present and non-defective, or an error icon indicating a missing or defective feature. The portable computing device may include an internal illuminator and/or an external illuminator.

Abstract: A vehicle structural component is provided having a substrate with one or more patches applied thereto. The thickness of the structural component is thicker and has added stiffness at the locations of the patches. The patches are bonded to the substrate via full surface bonding. The full surface bonding may be achieved via brazing, resistance seam welding, or adhesive bonding. A bonding layer may be disposed between the patches and the substrate. The patches and the substrate may be bonded via resistance seam welding, where a current and pressure are applied by weld wheels. The patches may be applied to the substrate in the form of a blank, or may be applied after the substrate has been formed and shaped into the vehicle component. The fully bonded patches provide comparable stiffness as a solid material having the same thickness.

Abstract: A bumper system including a bumper beam being cast from metal having a front panel and a back panel, extending between a first bumper beam end and a second bumper beam end. A plurality of reinforcing ribs integrally cast with the bumper beam extends between the front panel and the back panel defining a non-uniform cross-sectional profile along a portion of the bumper beam. The front panel includes a front center portion disposed between a pair of front side portions. The back panel includes a back center portion disposed between a pair of back side portions. The front center portion has a front center portion thickness greater than a back center portion thickness. Each of the front side portions has a front side portion thickness being less than a back side portion thickness of adjacent one of the back side portions. Method of manufacturing the bumper system is provided.

Abstract: A bumper system including a bumper beam being cast from metal having a front panel and a back panel, extending between a first bumper beam end and a second bumper beam end. A plurality of reinforcing ribs integrally cast with the bumper beam extends between the front panel and the back panel defining a non-uniform cross-sectional profile along a portion of the bumper beam. The front panel includes a front center portion disposed between a pair of front side portions. The back panel includes a back center portion disposed between a pair of back side portions. The front center portion has a front center portion thickness greater than a back center portion thickness. Each of the front side portions has a front side portion thickness being less than a back side portion thickness of adjacent one of the back side portions. Method of manufacturing the bumper system is provided.

Abstract: A bumper system including a bumper beam being cast from metal having a front panel and a back panel, extending between a first bumper beam end and a second bumper beam end. A plurality of reinforcing ribs integrally cast with the bumper beam extends between the front panel and the back panel defining a non-uniform cross-sectional profile along a portion of the bumper beam. The front panel includes a front center portion disposed between a pair of front side portions. The back panel includes a back center portion disposed between a pair of back side portions. The front center portion has a front center portion thickness greater than a back center portion thickness. Each of the front side portions has a front side portion thickness being less than a back side portion thickness of adjacent one of the back side portions. Method of manufacturing the bumper system is provided.

Abstract: A vehicle bumper assembly includes a bumper beam and a crash box. At least one of the bumper beam or the crash box is cast from metal, such as aluminum or magnesium, to reduce weight, reduce manufacturing process steps, and improve performance characteristics of the bumper assembly. In an embodiment, both of the bumper beam and the crash box are cast from metal to establish an integral connection therebetween. One of the bumper beam or the crash box can be open along a top and bottom portion of the bumper assembly and include at least one reinforcing rib cast integral therewith. In an embodiment, both of the bumper beam and the crash box can be open along a top and bottom portion of the bumper assembly and each include at least one reinforcing rib cast integral therewith.

Abstract: A twist axle assembly (20) of a vehicle includes a pair of trailing arms (22) and a twist beam (24) extending along an axis (A) between first and second twist beam ends (26, 28). The twist axle assembly (20) further includes a bushing (38) interconnected to each one of the first and second twist beam ends (26, 28) and a respective trailing arm (22) for establishing a weld-less joint between the twist beam (24) and the trailing arm (24). In an embodiment, the twist beam (24) and bushings (38) are tubular, and the bushings (38) are press-fit or molded onto the respective first or second twist beam ends (36, 38). In a further embodiment, the trailing arms (26) define an orifice (40) aligned on the axis (A), and the tubular bushings (38) are press-fit into the orifices (40) of the trailing arms (26) to establish the weld-less joint.

Abstract: A bumper system including a bumper beam being cast from metal having a front panel and a back panel, extending between a first bumper beam end and a second bumper beam end. A plurality of reinforcing ribs integrally cast with the bumper beam extends between the front panel and the back panel defining a non-uniform cross-sectional profile along a portion of the bumper beam. The front panel includes a front center portion disposed between a pair of front side portions. The back panel includes a back center portion disposed between a pair of back side portions. The front center portion has a front center portion thickness greater than a back center portion thickness. Each of the front side portions has a front side portion thickness being less than a back side portion thickness of adjacent one of the back side portions. Method of manufacturing the bumper system is provided.

Abstract: A twist axle assembly (20) of a vehicle includes a pair of trailing arms (22) and a twist beam (24) extending along an axis (A) between first and second twist beam ends (26, 28). The twist axle assembly (20) further includes a bushing (38) interconnected to each one of the first and second twist beam ends (26, 28) and a respective trailing arm (22) for establishing a weld-less N joint between the twist beam (24) and the trailing arm (24). In an embodiment, the twist beam (24) and bushings (38) are tubular, and the bushings (38) are press-fit or molded onto the respective first or second twist beam ends (36, 38). In a further embodiment, the trailing arms (26) define an orifice (40) aligned on the axis (A), and the tubular bushings (38) are press-fit into the orifices (40) of the trailing arms (26) to establish the weld-less joint.

Abstract: A vehicle bumper assembly includes a bumper beam and a crash box. At least one of the bumper beam or the crash box is cast from metal, such as aluminum or magnesium, to reduce weight, reduce manufacturing process steps, and improve performance characteristics of the bumper assembly. In an embodiment, both of the bumper beam and the crash box are cast from metal to establish an integral connection therebetween. One of the bumper beam or the crash box can be open along a top and bottom portion of the bumper assembly and include at least one reinforcing rib cast integral therewith. In an embodiment, both of the bumper beam and the crash box can be open along a top and bottom portion of the bumper assembly and each include at least one reinforcing rib cast integral therewith.