Abstract: A hybrid torsion beam axle assembly is provided, which includes a steel torsion beam. An end cap is fastened to an end portion of the steel torsion beam, and a cast trailing arm is cast about the end portion of the steel torsion beam including the end cap. In this way, the cast trailing arm is positively and rigidly secured to the steel torsion beam.

Abstract: In one aspect of the present invention, a solar energy collection system that includes multiple longitudinally adjacent collectors is described. The collectors are coupled end to end to form a collector row. The collector row extends along a longitudinal axis and is arranged to rotate about a pivot axis to track the sun in at least one dimension. Each collector includes a reflector, one or more solar receivers and a support structure. The support structure includes a tube assembly that underlies the reflector. The tube assemblies of the collector row are arranged end to end along the longitudinal axis. There is a space between the tube assemblies of adjacent collectors in the collector row, where the reflectors of the adjacent collectors extend beyond the underlying tube assemblies to form a substantially continuous reflective surface over the space. A coupling device is positioned in the space between the tube assemblies.

Abstract: A truck box includes front and rear corner brackets and an inner side panel having a first end fixed to the front corner bracket and a second end fixed to the rear corner bracket. A rail longitudinally extends substantially the entire length of the inner side panel and has a first end fixed to the front corner bracket and a second end fixed to the rear corner bracket. The rail has a center portion fixed to the inner side panel. The first and second ends of the rail are transversely offset and spaced apart from the inner side panel.

Abstract: A bumper beam for mounting to a frame assembly of a motor vehicle at one end of the motor vehicle includes opposing end portions adapted to be mounted to the frame assembly of the motor vehicle and a centrally disposed intermediate portion extending between the end portions. The end portions and the intermediate portion define an upper wall, a lower wall, and a central wall between the upper and lower walls. The upper and lower walls each have an elongated arcuate flange that extends from a free end of a respective upper and lower wall along a length of the bumper beam. The arcuate flange of each of the upper and lower walls defines an outwardly facing concave surface and an inwardly facing convex surface.

Abstract: A structure for joining a cross member (2) to a side member (1) of a chassis frame, wherein a flange (4) is formed integrally at an end of the cross member via a flare (3), an extension member (5) inserted into the end of the cross member (2) to project from the afore-mentioned flange (4) is welded to the flare (3), the extension member (5) is passed through an inside hole (9i) formed in an inside part (8i) in the width direction of the vehicle in the closed-section part of the side member (1) and welded to an outside hole (9o) formed in an outside part (8o) in the width direction of the vehicle, and the outer periphery of the flange (4) is welded to the inside part (8i) in the width direction of the vehicle. The closed-section part (8) is formed in a rectangular shape, and the top and bottom parts of the periphery of the flange (4) are located near top and bottom bends (12) of the closed-section part (8).

Abstract: An integrated rear suspension assembly is fixedly secured to a transmission case, rear wheel carriers and frame rails of a motor vehicle. The integrated rear suspension assembly includes a plurality of trailing arms having first and second ends. Each of the first ends is secured to one of the frame rails and each of the second ends is secured to each of the rear wheel carriers. A plurality of control arms is pivotally secured to each of the plurality of trailing arms for controlling the plurality of trailing arms. A compound link member having opposing ends is attached to each of the plurality of trailing arms. The integrated rear suspension assembly also includes a transmission cross member that is fixedly secured to each of the frame rails.

Abstract: A cross member for a motor vehicle includes an elongated, non-cast center structure and first and second castings. The center structure is formed as a one-piece, unitary structure and has a first end, a mid portion, and a second end. The first casting is rigidly connected to the first end of the center structure and the second casting is rigidly connected to the second end of the center structure. Each of the castings is configured and arranged to be attached to a respective motor vehicle element.

Abstract: A motor vehicle frame includes a pair of longitudinal frame members. A cross member is provided to maintain the frame members in a spaced apart condition. The cross member has a first end configured to mount to a first one of the longitudinal frame members and a second end configured to engage a steering gear housing. The second end sandwiches steering gear housing as the second end is fastened to a second one of the frame members.

Abstract: A truck box includes front and rear corner brackets and an inner side panel having a first end fixed to the front corner bracket and a second end fixed to the rear corner bracket. A rail longitudinally extends substantially the entire length of the inner side panel and has a first end fixed to the front corner bracket and a second end fixed to the rear corner bracket. The rail has a center portion fixed to the inner side panel. The first and second ends of the rail are transversely offset and spaced apart from the inner side panel.

Abstract: A module for a frame for a motor vehicle and a method of forming a frame assembly with a pair of laterally spaced, longitudinally extending central side rail structures includes, in one embodiment, using a pair of tubular hydroformed side rail members and a laterally extending connecting structure connected between the pair of side rail members to secure the pair of side rail members in laterally spaced, fixed relation to one another. Each first portion of the pair of side rail members extending longitudinally and each second portion of the pair of side rail members extending laterally relative to the respective first portion and each second portion having an end being constructed and arranged to form a joint with a portion of a respective central side rail structure such that the end of each of the pair of side rail members extends generally laterally through a side of the respective central side rail structure.

Abstract: A bumper beam for mounting to a frame assembly of a motor vehicle at one end of the motor vehicle includes opposing end portions adapted to be mounted to the frame assembly of the motor vehicle and a centrally disposed intermediate portion extending between the end portions. The end portions and the intermediate portion define an upper wall, a lower wall, and a central wall between the upper and lower walls. The upper and lower walls each have an elongated arcuate flange that extends from a free end of a respective upper and lower wall along a length of the bumper beam. The arcuate flange of each of the upper and lower walls defines an outwardly facing concave surface and an inwardly facing convex surface.

Abstract: A traditional twist beam axle found in a vehicle includes a twist beam with a separate torsion beam or a hollow tube formed into an inverted U shape that acts as both the twist beam and the torsion beam.

Abstract: A structure for joining a cross member (2) to a side member (1) of a chassis frame, wherein a flange (4) is formed integrally at an end of the cross member via a flare (3), an extension member (5) inserted into the end of the cross member (2) to project from the afore-mentioned flange (4) is welded to the flare (3), the extension member (5) is passed through an inside hole (9i) formed in an inside part (8i) in the width direction of the vehicle in the closed-section part of the side member (1) and welded to an outside hole (9o) formed in an outside part (8o) in the width direction of the vehicle, and the outer periphery of the flange (4) is welded to the inside part (8i) in the width direction of the vehicle. The closed-section part (8) is formed in a rectangular shape, and the top and bottom parts of the periphery of the flange (4) are located near top and bottom bends (12) of the closed-section part (8).

Abstract: A bumper system for mounting to a frame assembly of a motor vehicle at one end of the motor vehicle includes a bumper beam and an energy absorber. The bumper beam includes an upper beam wall, a lower beam wall, and a central beam wall between the upper and lower beam walls. The energy absorber is mounted to the bumper beam and includes an upper absorber wall, a lower absorber wall, and a central absorber wall between the upper and lower absorber walls. The energy absorber has a height that is greater than a height of the bumper beam such that the upper absorber wall is spaced upwardly above the upper beam wall and the lower absorber wall is spaced downwardly below the lower beam wall.

Abstract: A module for a frame for a motor vehicle with a pair of laterally spaced, longitudinally extending central side rail structures. The module including a pair of tubular hydroformed side rail members and a laterally extending connecting structure connected between the pair of side rail members to secure the pair of side rail members in laterally spaced, fixed relation to one another. Each first portion of the pair of side rail members extending longitudinally and each second portion of the pair of side rail members extending laterally relative to the respective first portion and each second portion having an end being constructed and arranged to form a joint with a portion of a respective central side rail structure such that the end of each of the pair of side rail members extends generally laterally through a side of the respective central side rail structure.

Abstract: A module for a frame for a motor vehicle and a method of forming a frame assembly with a pair of laterally spaced, longitudinally extending central side rail structures includes, in one embodiment, using a pair of tubular hydroformed side rail members and a laterally extending connecting structure connected between the pair of side rail members to secure the pair of side rail members in laterally spaced, fixed relation to one another. Each first portion of the pair of side rail members extending longitudinally and each second portion of the pair of side rail members extending laterally relative to the respective first portion and each second portion having an end being constructed and arranged to form a joint with a portion of a respective central side rail structure such that the end of each of the pair of side rail members extends generally laterally through a side of the respective central side rail structure.

Abstract: A continuous, hydroformed tubular member includes a horizontal member having a first end and a second end. A first vertical member has a first lower end coupled to the first end of the horizontal member. The first vertical member also has a first upper pillar-free end to form a first pillar configured to form a terminal end of an upwardly-open rear bed of a motor vehicle. A second vertical member has a second lower end coupled to the second end of the horizontal member. The second vertical member also has a second upper pillar-free end to form a second pillar configured to form the terminal end of the upwardly-open rear bed of a motor vehicle. The horizontal member, the first vertical member, and the second vertical member together form a one-piece, unitary U-shaped member.

Abstract: An integrated rear suspension assembly is fixedly secured to a transmission case, rear wheel carriers and frame rails of a motor vehicle. The integrated rear suspension assembly includes a plurality of trailing arms having first and second ends. Each of the first ends is secured to one of the frame rails and each of the second ends is secured to each of the rear wheel carriers. A plurality of control arms is pivotally secured to each of the plurality of trailing arms for controlling the plurality of trailing arms. A compound link member having opposing ends is attached to each of the plurality of trailing arms. The integrated rear suspension assembly also includes a transmission cross member that is fixedly secured to each of the frame rails.

Abstract: A welding assembly including a welding gun for providing spaced welds on opposite sides of members being welded. The welding gun includes two welding tips so that both welds can be formed without moving the gun or the members relative to each other. Preferably one weld tip is connected to a force applying mechanism such as a hydraulic cylinder to clamp the members together and improve the connection between the weld tips and the members. The weld gun can be used for making one or two welds while in the engaged position around the members being welded. Also, one of the weld tips can be replaced with a support that merely provides the force applying function.

Abstract: A control arm for an motor vehicle and method of forming the same. The control arm includes a hydroformed member and first and second stamped members. The hydroformed member has a first end forming part of a first joint and a second end. The first stamped member forms part of a second joint and is coupled to the hydroformed member between the first end and the second end thereof. The first stamped member has a section rigidly connected to the hydroformed member and a section adapted to receive a first bushing. The second stamped member forms part of a third joint and is coupled to the second end of the hydroformed member. The second member has a portion rigidly connected to the second end of the hydroformed member and a portion adapted to receive a second bushing.