Abstract: The present invention is a segmented LED lighting system. In particular, the present invention is directed to a set of channel segments connected by a flexible lens sleeve that can be positioned in a variety of ways. A printed circuit board with at least one LED is mounted in each channel segment. Each segment preferably has a base with two ribbed vertical sides. The lens sleeve is preferably coextruded from flexible acrylic and has opaque side grips that grip the ribbed vertical sides and a translucent lens portion with an air gap. Pairs of encapsulated PCB modules are preferably connected in series to allow the system to be cut in the field.

Abstract: Methods and Apparatus to increase the efficiency of roll-forming and leveling systems are described herein. An example strip material processing apparatus are described herein includes a first drive system to drive a first plurality of workrolls and a second drive system to drive a second plurality of workrolls. A controller provides a first command reference to the first drive system. The controller measures a first output parameter of the first drive system when the first drive system operates at the first command reference. The controller determines a second command reference based on the first output parameter and the controller drives the second drive system based on the second command reference.

Abstract: Methods and apparatus to monitor conditioning machines are disclosed herein. An example system includes a plurality of work rolls to process a strip material. A first sensor detects a first distance between an upper surface of the strip material and a first reference location and a second sensor detects a second distance between an upper surface of the strip material and a second reference location. A controller determines a difference value between the first distance and the second distance to detect material curvature of the strip material.

Abstract: Methods of bonding components for fabricating electronic assemblies and electronic assemblies including bonded components are provided herein. In one example, a method of bonding components for fabricating an electronic assembly comprises the steps of disposing a first layer of a first high temperature metal-containing paste adjacent to a first component. A second layer of a second high temperature metal-containing paste is disposed adjacent to a second component. A nanostructured multilayer reactive foil is disposed between the first and second layers. The nanostructured multilayer reactive foil is activated to sinter the first and second layers and bond the first and second components.

Abstract: Methods and apparatus for controlling a hem profile in roll-forming processes are described. An example roll-forming apparatus includes a first plurality of work rolls to form a first hem on a material and a second plurality of work rolls. One of the second plurality of work rolls is adjustable relative to an opposing work roll and to the first plurality of work rolls to adjustably control a profile of the first hem.

Abstract: Methods and apparatus to monitor conditioning machines are disclosed herein. An example system includes a plurality of work rolls to process a strip material. A first sensor detects a first distance between an upper surface of the strip material and a first reference location and a second sensor detects a second distance between an upper surface of the strip material and a second reference location. A controller determines a difference value between the first distance and the second distance to detect material curvature of the strip material.

Abstract: Methods and systems to drive rotary presses are described. In one described example, a rotary press system includes a first rotary press and a second rotary press adjacent to the first rotary press. The first and the second rotary presses are to receive a strip of material. A drive member is operatively coupled to the first and the second rotary presses and a motor coupled to the drive member rotates the drive member to cause the first and second rotary presses to process the strip material.

Abstract: The present invention is a lighting module, in particular, a lighting module that emits warmer color light as it dims. The lighting module preferably has a dimmable power source and a printed circuit board having at least two series of LEDs. The first LED series has a resistor and three LEDs that operate at full brightness at a first voltage, e.g. 12v. The second LED series has a voltage regulator, two capacitors and three LEDs that operate at full brightness at a second voltage, e.g. 6v, less than the first voltage. The first series has a different color light output from the second series. The module produces a linear color shift for a range of voltages, e.g. from seven volts to twelve volts.

Abstract: Methods and apparatus for controlling a hem profile in roll-forming processes are described. An example roll-forming apparatus includes a first plurality of work rolls to form a first hem on a material and a second plurality of work rolls. One of the second plurality of work rolls is adjustable relative to an opposing work roll and to the first plurality of work rolls to adjustably control a profile of the first hem.

Abstract: The present invention is an improved LED lighting module. Preferably, the LED lighting module comprises a first LED base, a central LED base containing a printed circuit board, and a third LED base, where the first and third bases are connected by spacer tubes. Each LED base has an LED pc-board mounted thereon. A main power line runs through the set of three LED bases. A first series connector line connects the printed circuit board to the first LED board and a second series connector line connects the printed circuit board to the third LED board. A first connection line connects the first LED board to the central LED board and a second connection line connects the central LED board to the third LED board. These LED module sets can be connected consecutively to create strings of series wired sets from the same main power lines.

Abstract: A power electronic building block includes a housing; a power module mounted within the housing; a controller mounted within the housing and coupled to the power module; a capacitor assembly coupled to the power module and mounted within the housing; an AC bus bar mounted within the housing; and a DC bus bar coupling the capacitor assembly to the power module and mounted within the housing.

Abstract: The present invention is a segmented LED lighting system. In particular, the present invention is directed to a set of channel segments connected by a flexible lens sleeve that can be positioned in a variety of ways. A printed circuit board with at least one LED is mounted in each channel segment. Each segment preferably has a base with two ribbed vertical sides. The lens sleeve is preferably coextruded from flexible acrylic and has opaque side grips that grip the ribbed vertical sides and a translucent lens portion with an air gap. Pairs of encapsulated PCB modules are preferably connected in series to allow the system to be cut in the field.

Abstract: Electronic assemblies and methods of fabricating electronic assemblies are provided herein. The electronic assembly includes a heat sink, a metal layer, and an electrical insulator layer. The metal layer defines at least a portion of an electrical circuit. The electrical insulator layer is disposed between the heat sink and the metal layer and is directly bonded to the heat sink.

Abstract: Systems and methods are provided for monitoring current in an electric motor. An electrical system includes a (DC) interface, an electric motor, an inverter module coupled between the DC interface and the electric motor, a first current sensor between a first phase leg of the inverter module and a first phase of the electric motor to measure a first current flowing through the first phase of the electric motor, a second current sensor between the first phase leg and the DC interface to measure a second current flowing through the first phase leg, and a control module coupled to the first current sensor and the second current sensor. The control module is configured to initiate remedial action based at least in part on a difference between the first current measured by the first current sensor and the second current measured by the second current sensor.

Abstract: Methods and apparatus for controlling flare in roll-forming processes are disclosed. An example method involves predefining a plurality of position values to adjust a tilt angle of a flange roller and adjusting the tilt angle of the flange roller based on one of the pre-defined position values to change an amount of flare in a zone of a component. The one of the pre-defined position values is associated with the zone of the component.

Abstract: Methods of bonding components for fabricating electronic assemblies and electronic assemblies including bonded components are provided herein. In one example, a method of bonding components for fabricating an electronic assembly comprises the steps of disposing a first layer of a first high temperature metal-containing paste adjacent to a first component. A second layer of a second high temperature metal-containing paste is disposed adjacent to a second component. A nanostructured multilayer reactive foil is disposed between the first and second layers. The nanostructured multilayer reactive foil is activated to sinter the first and second layers and bond the first and second components.

Abstract: The present invention is an improved LED lighting module. Preferably, the LED lighting module comprises a first LED base, a central LED base containing a printed circuit board, and a third LED base, where the first and third bases are connected by spacer tubes. Each LED base has an LED pc-board mounted thereon. A main power line runs through the set of three LED bases. A first series connector line connects the printed circuit board to the first LED board and a second series connector line connects the printed circuit board to the third LED board. A first connection line connects the first LED board to the central LED board and a second connection line connects the central LED board to the third LED board. These LED module sets can be connected consecutively to create strings of series wired sets from the same main power lines.

Abstract: A power converter assembly is provided. The power converter assembly includes first, second, and third power modules. The second power module is coupled to the first power module such that the second power module is separated from the first power module by a first distance. The third power module is coupled to the first and second power modules such that the third power module is separated from the second power module by a second distance and is separated from the first power module by a third distance. The first, second, and third distances are substantially the same.

Abstract: Methods and apparatus for controlling flare in roll-forming processes are disclosed. An example method involves predefining a plurality of position values to adjust a tilt angle of a flange roller and adjusting the tilt angle of the flange roller based on one of the pre-defined position values to change an amount of flare in a zone of a component. The one of the pre-defined position values is associated with the zone of the component.

Abstract: A subcomponent is provided for a power inverter module. The apparatus comprises a capacitor having a terminal and integrated into a housing. A substrate is mounted on the housing. The substrate incorporates a power semiconductor switch and has at least one direct current (DC) tab. The direct current tab is directly connected to the terminal of the capacitor.