Abstract: An electrohydraulic actuator assembly for use in a brake-by-wire hydraulic brake system. The electrohydraulic actuator assembly includes a pair of electrohydraulic actuator EHA units. One EHA unit provides fluid to front brakes and the other EHA unit provides fluid to rear brakes. Each EHA unit includes an electric motor, a reduction gear unit, a pair of magnetorheological clutches, and a pair of fluid pumps. The system further including an ECU that actuates the electric motor and controls engagement of the clutches to cause the fluid pump to pump brake fluid to at least one of the front and rear brakes. The system further includes a regeneration system for providing supplemental electricity to the electric motors.

Abstract: An electrohydraulic actuator assembly for use in a brake-by-wire hydraulic brake system. The electrohydraulic actuator assembly includes a pair of electrohydraulic actuator EHA units. One EHA unit provides fluid to front brakes and the other EHA unit provides fluid to rear brakes. Each EHA unit includes an electric motor, a reduction gear unit, a pair of magnetorheological clutches, and a pair of fluid pumps. The system further including an ECU that actuates the electric motor and controls engagement of the clutches to cause the fluid pump to pump brake fluid to at least one of the front and rear brakes. The system further includes a regeneration system for providing supplemental electricity to the electric motors.

Abstract: A system for opening and closing a closure of a vehicle, such as a door or a tailgate, is provided. The system includes a motor such as an electric motor which may be coupled to the closure via an output linkage, with the output linkage mechanically coupled to the closure and operable to move the closure between a closed position and an open position. The output linkage may include a driven pulley which may be coupled to the motor. The output linkage may include a driven pulley and a cable. The output linkage may include a leadscrew threadedly engaging a nut. A high-bandwidth MR clutch having a high dynamic response may selectively couple the motor with the closure to provide a haptic or tactile feedback to a user interacting with the closure as it is opened or closed.

Abstract: A system and method for orienting a workpiece on an assembly line to prepare the workpiece for an operation is provided. The method includes positioning a flexible fixture on the assembly line. The flexible fixture has a base and at least one adjustable component. The workpiece is positioned on the flexible fixture. A first orientation of the workpiece relative to the flexible fixture is detected with a detection device and transmitted to a calibrator. The calibrator determines a difference between the detected first orientation of the workpiece and a predetermined fixture orientation and transmits instructions from the calibrator to the flexible fixture to move the workpiece from the detected first orientation to the predetermined fixture orientation. The workpiece is moved with the at least one adjustable component into the predetermined fixture orientation and is fixedly held with the adjustable component.

Abstract: A system and method for orienting a workpiece on an assembly line to prepare the workpiece for an operation is provided. The method includes positioning a flexible fixture on the assembly line. The flexible fixture has a base and at least one adjustable component. The workpiece is positioned on the flexible fixture. A first orientation of the workpiece relative to the flexible fixture is detected with a detection device and transmitted to a calibrator. The calibrator determines a difference between the detected first orientation of the workpiece and a predetermined fixture orientation and transmits instructions from the calibrator to the flexible fixture to move the workpiece from the detected first orientation to the predetermined fixture orientation. The workpiece is moved with the at least one adjustable component into the predetermined fixture orientation and is fixedly held with the adjustable component.

Abstract: An austempered structural steel component for an automotive vehicle, and a method for manufacturing the component, is provided. The structural component can be a twist axle, spring link, control arm, pillar, trailer hitch, bumper, body or suspension attachment bracket for a truck frame, or other chassis, body in white, or safety-related component. The structural component is at least partially formed of medium carbon steel having a bainitic microstructure. The medium carbon steel can include 0.2 to 1.0 wt. % carbon, 0.1 to 3.0 wt. % manganese, not greater than 2.0 wt. % silicon, 0.0 to 0.010 wt. % boron, not greater than 0.1 wt. % sulfur, and not greater than 0.2 wt. % phosphorous. The medium carbon steel provides a yield strength of 900 to 1500 MPa. The structural component is also lighter and can potentially be manufactured with reduced costs, compared to structural components formed from other steel materials.

Abstract: A sub-frame assembly for attachment to a unibody of a vehicle and for supporting at least one vehicular component is provided. The sub-frame assembly includes a pair of longitudinal members which are spaced from one another in a lateral direction and extend in a longitudinal direction between first and second ends. The longitudinal members at least partially converge towards one another from the first ends to the second ends such that the second ends are closer to one another than the first ends. A cross-member is coupled with and extends laterally between the longitudinal members. Each of the longitudinal members and the cross-member has a single and no more than one body mount for connection with the unibody of the vehicle such that the sub-frame assembly has exactly three body mounts in total.

Abstract: A sub-frame assembly for attachment to a unibody of a vehicle and for supporting at least one vehicular component is provided. The sub-frame assembly includes a pair of longitudinal members which are spaced from one another in a lateral direction and extend in a longitudinal direction between first and second ends. The longitudinal members at least partially converge towards one another from the first ends to the second ends such that the second ends are closer to one another than the first ends. A cross-member is coupled with and extends laterally between the longitudinal members. Each of the longitudinal members and the cross-member has a single and no more than one body mount for connection with the unibody of the vehicle such that the sub-frame assembly has exactly three body mounts in total.

Abstract: Systems and methods that facilitate vehicle passenger protection during side impact events and, more particularly, to systems and methods which increase the survival space between the vehicle side structure and a vehicle passenger located in the vehicle passenger compartment while maintaining reasonable vehicle structure deceleration levels. The systems and methods enable the seat structure assemblies to move inboard during side impact events by coupling the seat structure assemblies to a deformable cross bar or beam. The embodiments include a deformable cross-car beam that is deformable in one or more locations along its length using changes in geometry and/or changes in material to initiate controlled deformation under a cross-car load due to a side impact event.

Abstract: Systems and methods that facilitate vehicle passenger protection during side impact events and, more particularly, to systems and methods which increase the survival space between the vehicle side structure and a vehicle passenger located in the vehicle passenger compartment while maintaining reasonable vehicle structure deceleration levels. The systems and methods enable the seat structure assemblies to move inboard during side impact events by coupling the seat structure assemblies to a deformable cross bar or beam. The embodiments include a deformable cross-car beam that is deformable in one or more locations along its length using changes in geometry and/or changes in material to initiate controlled deformation under a cross-car load due to a side impact event.

Abstract: Systems and methods that facilitate vehicle passenger protection during side impact events and, more particularly, to systems and methods which increase the survival space between the vehicle side structure and a vehicle passenger located in the vehicle passenger compartment while maintaining reasonable vehicle structure deceleration levels. The systems and methods enable the seat structure assemblies to move inboard during side impact events by coupling the seat structure assemblies to a deformable cross bar or beam. The embodiments include a deformable cross-car beam that is deformable in one or more locations along its length using changes in geometry and/or changes in material to initiate controlled deformation under a cross-car load due to a side impact event.

Abstract: A hybrid component for lightweight, structural uses, including a steel member formed of a high strength steel; and a cast coupling member cast on a portion of the steel member by casting-in-place a semi-solid aluminum about the portion of the steel member, thereby positively and rigidly securing the coupling member to the steel member. A method of forming a hybrid component for lightweight, structural uses, including: forming a steel member formed of a high strength steel into a predetermined configuration; and casting a coupling member on a portion of the steel member by casting-in-place a semi-solid aluminum about the portion of the steel member, thereby positively and rigidly securing the coupling member to the steel member.

Abstract: A hybrid component for lightweight, structural uses, including a steel member formed of a high strength steel; and a cast coupling member cast on a portion of the steel member by casting-in-place a semi-solid aluminum about the portion of the steel member, thereby positively and rigidly securing the coupling member to the steel member. A method of forming a hybrid component for lightweight, structural uses, including: forming a steel member formed of a high strength steel into a predetermined configuration; and casting a coupling member on a portion of the steel member by casting-in-place a semi-solid aluminum about the portion of the steel member, thereby positively and rigidly securing the coupling member to the steel member.