Abstract: An energy-dissipating cover for covering a component sensitive to mechanical impulse includes a sheet of selected ferrous or aluminum alloy, the sheet having a top surface, a bottom surface, an outer perimeter, an overall area within the outer perimeter and a nominal thickness of no more than 2.5 mm. The sheet is configured for connection with one or more external structures at a plurality of connection points within the outer perimeter, wherein the overall area comprises a plurality of supported areas and at least one unsupported area. Embossments are formed within the at least one unsupported area and extend outward from the bottom surface. The embossments are shaped, sized and arranged so as to limit orthogonal deflection of the sheet from a mechanical impulse directed normal to the bottom surface of the sheet at the plurality of embossments.

Abstract: A containment system for a rechargeable energy storage device (RESS) is described includes an enclosure having a first compartment adjoining a second compartment. The first compartment is arranged to house a plurality of power electronics devices, and the second compartment is arranged to house a plurality of battery cells. The second compartment includes a tub that defines a bottom portion, and a floor plate. The tub includes opposed end walls and opposed sidewalls. A top plate is arranged overtop of the first compartment and the second compartment. A first one of the end walls and the top plate define a first slot between the first compartment and the second compartment. A first removable panel is arranged to enclose the first compartment. The plurality of battery cells connect to the plurality of power electronics devices via a high-voltage DC power bus that is arranged to pass through the first slot.

Abstract: An injection molded composite component includes a groove extending from a first surface of the composite component and a tubing material placed within the groove and formed integrally with the composite component such that the tubing material forms an integrated conduit on the first surface of the composite component.

Abstract: A reinforced composite assembly includes a first sheet made of carbon fiber and having a first perimeter, a second sheet made of a non-carbon fiber material and having a second perimeter, wherein the second sheet is disposed atop the first sheet within the first perimeter, and a metallic plate having a third perimeter, wherein the metallic plate is disposed atop the second sheet within the second perimeter. The metallic plate has a plurality of holes formed therein about a perimeter of the metallic plate and defining a plurality of respective bridge portions between each of the holes and an adjacent outer edge of the metallic plate, and/or a plurality of extensions extending outward from a main portion of the metallic plate. A first arrangement of thread stitching secures each of the bridge portions and extensions to the second sheet or to the first and second sheets.

Abstract: A method and fixture for welding a battery foil-tab assembly is disclosed. The fixture includes a first clamp member having a first clamping surface defining an opening extending into the first clamp member and a second clamp member having a protrusion surrounding a weld slot. The opening of the first clamp member is configured to receive a portion of the protrusion with the battery foil-tab assembly disposed therebetween. The second clamp member is moveable toward the first clamp member to align the weld slot of the second clamp member with the opening of the first clamp member, thereby causing the protrusion to cooperate with the opening of the first clamp to deflect a portion of the battery foil-tab assembly out of a plane parallel with the battery foil-tab assembly. A laser beam is directed at the out of plane portion to laser weld the battery foil-tab assembly.

Abstract: An injection molded composite component includes a groove extending from a first surface of the composite component and a tubing material placed within the groove and formed integrally with the composite component such that the tubing material forms an integrated conduit on the first surface of the composite component.

Abstract: A rotary electric machine for use with coolant includes a stator and rotor assembly. The rotor assembly includes a rotor, rotor shaft, and first and second end rings. The rotor has inner and outer diameter surfaces and an embedded set of rotor magnets proximate the outer diameter surface. The shaft is connected to the rotor and defines a main coolant passage along an axis of rotation. Radial shaft coolant passages are in fluid communication with the main coolant passage. The end rings are positioned at opposing distal ends of the rotor. The shaft coolant passages direct the coolant into the rotor and/or the end rings such that the coolant flows axially through rotor cavities of the rotor and cools the rotor magnets via forced convection.

Abstract: The present disclosure provides a composite lift gate for a vehicle. The composite lift gate includes a polymer matrix and a fiber assembly. The fiber assembly is embedded in the polymer matrix. The fiber assembly includes a fiber mat and a plurality of substantially-aligned continuous fibers. The plurality of substantially-aligned continuous fibers is directly connected to a portion of the fiber mat. In one aspect, the composite lift gate further includes an electronic component connected to the fiber assembly. In various aspects, the present disclosure provides a method of manufacturing a composite lift gate for a vehicle.

Abstract: A reinforced composite assembly includes a first sheet made of carbon fiber and having a first perimeter, a second sheet made of a non-carbon fiber material and having a second perimeter, wherein the second sheet is disposed atop the first sheet within the first perimeter, and a metallic plate having a third perimeter, wherein the metallic plate is disposed atop the second sheet within the second perimeter. The metallic plate has a plurality of holes formed therein about a perimeter of the metallic plate and defining a plurality of respective bridge portions between each of the holes and an adjacent outer edge of the metallic plate, and/or a plurality of extensions extending outward from a main portion of the metallic plate. A first arrangement of thread stitching secures each of the bridge portions and extensions to the second sheet or to the first and second sheets.

Abstract: A mirror assembly includes a mirror housing and a mirror. The mirror is supported by the mirror housing. The mirror has an outer reflective surface. The mirror is bendable between a flat shape and a fisheye shape. The mirror assembly further includes an actuator assembly coupled to the mirror. Upon actuation, the actuator assembly is configured to bend the mirror between the flat shape and the fisheye shape to adjust a field of view of the mirror.

Abstract: A method and fixture for welding a battery foil-tab assembly is disclosed. The fixture includes a first clamp member having a first clamping surface defining an opening extending into the first clamp member and a second clamp member having a protrusion surrounding a weld slot. The opening of the first clamp member is configured to receive a portion of the protrusion with the battery foil-tab assembly disposed therebetween. The second clamp member is moveable toward the first clamp member to align the weld slot of the second clamp member with the opening of the first clamp member, thereby causing the protrusion to cooperate with the opening of the first clamp to deflect a portion of the battery foil-tab assembly out of a plane parallel with the battery foil-tab assembly. A laser beam is directed at the out of plane portion to laser weld the battery foil-tab assembly.

Abstract: A package for a power semiconductor device includes a housing, a power semiconductor module disposed within the housing, first and second fluidic channels extending through the housing on opposite sides of the power semiconductor module, and first and second arrays of heat transfer elements respectively disposed within the first and second fluidic channels. The first and second arrays of heat transfer elements are respectively physically bonded to first and second major surfaces of the power semiconductor module. A method of manufacturing a package for a power semiconductor device includes (i) respectively bonding first and second arrays of heat transfer elements to first and second major surfaces of a power semiconductor module, (ii) encapsulating the heat transfer elements within a sacrificial material, (iii) forming a housing around the sacrificial material and the heat transfer elements, and (iv) removing the sacrificial material from the housing to form first and second fluidic channels.

Abstract: A roll-and-peel tool includes a frame, a roller, two traction rims, a peeling wheel, and a trailer arm. A roller shaft is supported by the frame, and the roller is rotatable relative to the frame on the shaft. The traction rims are axially-spaced from one another with a roller midportion between the traction rims and the traction rims extending outward of the roller midportion. The peeling wheel is rotatable about a wheel shaft and has two traction hubs axially-spaced from one another and protrusions extending proud at an exterior surface of the peeling wheel between the traction hubs. The trailer arm connects the wheel and roller shafts so that the traction hubs interface with the traction rims and a gap is defined between the roller and the peeling wheel with the protrusions extending into the gap. A method of installing a trim component may be carried out with the tool.

Abstract: An energy-dissipating cover for covering a component sensitive to mechanical impulse includes a sheet of selected ferrous or aluminum alloy, the sheet having a top surface, a bottom surface, an outer perimeter, an overall area within the outer perimeter and a nominal thickness of no more than 2.5 mm. The sheet is configured for connection with one or more external structures at a plurality of connection points within the outer perimeter, wherein the overall area comprises a plurality of supported areas and at least one unsupported area. Embossments are formed within the at least one unsupported area and extend outward from the bottom surface. The embossments are shaped, sized and arranged so as to limit orthogonal deflection of the sheet from a mechanical impulse directed normal to the bottom surface of the sheet at the plurality of embossments.

Abstract: An end-effector assembly comprising a master boom, a crossbar coupled to the master boom, at least one branch rail, and a swing arm is provided. The at least one branch rail is movably coupled to the crossbar by a branch lock. The at least one branch rail has a driving groove formed longitudinally therealong for telescopic movement relative to the crossbar. The branch lock comprises a crossbar clamp and a branch rail clamp. The crossbar clamp is slidably and pivotally disposed about the crossbar for slidable and pivotal movement therealong. The branch rail clamp comprises a body having a primary telescoping lock including a receiving bore formed therethrough and a wedging collet disposed in the receiving bore. The body further comprises a secondary telescoping lock having a ball and a plunger disposed in a ball-plunger cavity of the body.

Abstract: Systems and methods for vehicle-target localization, identification and indication. The system includes a vehicle module operating onboard a vehicle and configured to receive a request for a tether and send the tether responsive thereto, and a target module operating on a target external to the vehicle. The target module can generate target profile data (TPD) comprising location information for the target, such as, a first component that is a function of a detected first WiFi signal having a first signal strength. The request for the tether including the TPD is transmitted to the vehicle module; a tether of secured communications is established between the vehicle module and target module. Real-time TPD is exchanged during the tether and the vehicle module performs the V-T localization as a function of the RT TPD, and commands the vehicle based on V-T localization data.

Abstract: A system and method for determining the presence of a hidden hazard may include identification of an operational scene for a host vehicle, and identification of an operational situation for the host vehicle. Information from a plurality of proximity sensors is collected and classified. A plurality of hidden hazard presence probabilities corresponding to the information from each of the plurality of proximity sensors, the operational scene, the operational situation, and at least one of a comparative process and a dynamic neural network process are estimated. A fusion process may be performed upon the plurality of hidden hazard presence probabilities to determine the presence of a hidden hazard.

Abstract: A multi-tasking end effector system includes a base frame connected to a robot arm of a robot. A first shaft is rotatably supported on the base frame. A first pin-wheel assembly is rotatably mounted to the shaft at a first end of the base frame. Multiple first die assemblies are mounted to the first pin-wheel assembly. A second pin-wheel assembly is rotatably mounted to the shaft at a second end of the base frame. Multiple second die assemblies are mounted to the second pin-wheel assembly and individually oriented in mirror image configuration to one of the multiple first die assemblies. An index motor rotates the first shaft and co-rotates paired and mirror image die assemblies. First and second tab-bending actuators mounted to the base frame are operated to bend opposed cell tabs of a battery cell positioned between the first and second pin-wheel assemblies.

Abstract: An end-effector assembly includes a master boom, a frame rail coupled thereto, and at least one branch rail movably coupled to the frame rail by a swing branch lock. The swing arm is movably coupled to the at least one branch rail by a swing arm lock. Each of the swing branch lock and the swing arm lock further includes a clamp configured to movably secure the branch rail to the frame rail or the swing arm to the branch rail. A pivot shaft extends through the clamp and is configured to rotationally secure the clamp in place. A swing plate is secured to the pivot shaft and is configured for engagement with a configuration tool. A locking fastener extends through the swing plate and into the pivot shaft and is configured to lock and unlock the clamp in position.

Abstract: A system and method for determining the presence of a hidden hazard may include identification of an operational scene for a host vehicle, and identification of an operational situation for the host vehicle. Information from a plurality of proximity sensors is collected and classified. A plurality of hidden hazard presence probabilities corresponding to the information from each of the plurality of proximity sensors, the operational scene, the operational situation, and at least one of a comparative process and a dynamic neural network process are estimated. A fusion process may be performed upon the plurality of hidden hazard presence probabilities to determine the presence of a hidden hazard.