Abstract: An additive manufacturing system includes a powder delivery system, an area scanning laser, a build chamber, and a controller. The powder delivery system provides a predetermined amount of powder material to the build chamber, and includes a material dispenser, a dispensing head, and a scraper. The scanning laser selectively sinters the powder material, and includes a mirror galvanometer for raster scanning. The build chamber has an annular configuration, and includes an inner annular wall that defines a central portion disposed inward of the build chamber. A portion of the delivery system and the laser are located in the central portion. The chamber continuously rotates under the head and under a sintering zone generated by the laser as the delivery system continuously dispenses the material. The laser continuously raster scans the material at the sintering zone in a raster pattern to sinter a layer of material directly to a preceding layer.

Abstract: A method for adjusting a vehicle seat onboard a vehicle is provided. The method obtains vehicle status data, by a processor communicatively coupled to a plurality of sensors onboard the vehicle; detects a current actuation state of the vehicle seat based on the vehicle status data, by the processor, wherein the current actuation state comprises at least one of a user input actuation state and an emergency actuation state; calculates seat adjustments, by the processor, based on the current actuation state; and actuates the vehicle seat based on the seat adjustments, via an electromagnetic vehicle seat rail device communicatively coupled to the processor.

Abstract: Additive manufacturing systems, area scanning laser systems, and methods for performing an additive manufacturing process are provided. An exemplary additive manufacturing system includes a laser generation device for producing a laser beam. Further, the additive manufacturing system includes an optic element for forming a first portion of the laser beam with a first polarization and a second portion of the laser beam with a second polarization different from the first polarization to encode an image in the laser beam. Also, the additive manufacturing system includes a selective beam separator configured to direct the first portion of the laser beam onto a material to be sintered or melted. The additive manufacturing system includes a recycling system for receiving the second portion of the laser beam.

Abstract: A method for adjusting a vehicle seat onboard a vehicle is provided. The method obtains vehicle status data, by a processor communicatively coupled to a plurality of sensors onboard the vehicle; detects a current actuation state of the vehicle seat based on the vehicle status data, by the processor, wherein the current actuation state comprises at least one of a user input actuation state and an emergency actuation state; calculates seat adjustments, by the processor, based on the current actuation state; and actuates the vehicle seat based on the seat adjustments, via an electromagnetic vehicle seat rail device communicatively coupled to the processor.

Abstract: An additive manufacturing system has a powder delivery system for presenting a powder material to a build chamber. A laser selectively sinters the powder material in the build chamber. The build chamber is presented in an annular configuration with the powder delivery system and laser arranged within a central portion thereof.

Abstract: Additive manufacturing systems, area scanning laser systems, and methods for performing an additive manufacturing process are provided. An exemplary additive manufacturing system includes a laser generation device for producing a laser beam. Further, the additive manufacturing system includes an optic element for forming a first portion of the laser beam with a first polarization and a second portion of the laser beam with a second polarization different from the first polarization to encode an image in the laser beam. Also, the additive manufacturing system includes a selective beam separator configured to direct the first portion of the laser beam onto a material to be sintered or melted. The additive manufacturing system includes a recycling system for receiving the second portion of the laser beam.

Abstract: A spring aid for a vehicle suspension includes a compliant tower attachable to elements undergoing suspension travel. The tower defines an axis of travel or center axis and includes a plurality of rings and a plurality of window frames connecting the rings. The rings are perpendicular to, and spaced along, the axis, and define a cylindrical cavity. The window frames define a plurality of windows between the rings. The suspension element may also include a core, which substantially fills the cylindrical cavity of the compliant tower. A rod may be disposed within the core and movable within the hole of the shelf.

Abstract: A seal assembly is disclosed for providing a seal against a body. The assembly includes an elastically-deformable sealing member with a sealing surface facing a surface of the body. The assembly also includes a shape memory alloy biasing member. The biasing member is configured to bias the sealing surface to different positions with respect to the surface of the body or with different pressures against the surface of the body in response to a displacement response of the shape memory alloy to thermal stimulus. The body can be dynamic relative to the sealing member such as a rotatable shaft, static relative to the sealing member such as a case or housing, or can be either static or dynamic in response to the SMA displacement such as a snubber assembly.

Abstract: Methods, systems, and vehicles are provided for controlling an angle of a wheel assembly for vehicle events. In accordance with one embodiment, the vehicle includes a wheel assembly, a structural member, a detection unit, an actuator, and a processor. The detection unit is configured to detect an event for a vehicle that has a wheel assembly. The processor is coupled to the detection unit, and is configured to utilize an actuator to adjust an angle of the wheel assembly in a manner that guides energy absorption or transference from the event toward the structural member.

Abstract: A spring aid for a vehicle suspension includes a compliant tower attachable to elements undergoing suspension travel. The tower defines an axis of travel or center axis and includes a plurality of rings and a plurality of window frames connecting the rings. The rings are perpendicular to, and spaced along, the axis, and define a cylindrical cavity. The window frames define a plurality of windows between the rings. The suspension element may also include a core, which substantially fills the cylindrical cavity of the compliant tower. A rod may be disposed within the core and movable within the hole of the shelf.

Abstract: Methods, systems, and vehicles are provided for controlling an angle of a wheel assembly for vehicle events. In accordance with one embodiment, the vehicle includes a wheel assembly, a structural member, a detection unit, an actuator, and a processor. The detection unit is configured to detect an event for a vehicle that has a wheel assembly. The processor is coupled to the detection unit, and is configured to utilize an actuator to adjust an angle of the wheel assembly in a manner that guides energy absorption or transference from the event toward the structural member.

Abstract: Vehicles, systems and a method for mitigating power hop in a vehicle are provided. The vehicle, for example, may include, but is not limited to a drivetrain, an electronic limited slip differential mechanically coupled to the drivetrain, and a controller communicatively coupled to the electronic limited slip differential, wherein the controller is configured to determine when the vehicle is experiencing a power hop event or when the vehicle may experience a future power hop event, and cause, when the vehicle is experiencing the power hop event or when the vehicle may experience the future power hop event, the electronic limited slip differential to apply torque differentiation pulses to the drivetrain.

Abstract: A sealing boot assembly comprises a flexible boot having a first end in sealing engagement with an outer surface of a shaft to define an inner chamber therein. A venting orifice extends from the inner chamber through the flexible boot to ambient and a moisture-blocking, vapor-breathable membrane is disposed across the venting orifice between the inner chamber and ambient to vent gas from the inner chamber during high temperature operation of the shaft and to allow air to returns to the inner chamber upon cooling thereof.

Abstract: A helical LSD includes a case defining an inner cavity and a plurality of grooves disposed around the inner cavity. In addition to the case, the helical LSD includes a plurality of pinion gears. Each pinion gear is disposed in one of the grooves and includes a plurality of gear teeth. Each gear tooth has a top land. The helical LSD further includes at least one helical output gear disposed in the inner cavity of the case. The helical output gear meshes with the pinion gears, and the pinion gears are disposed around the helical output gear. The top land has a surface profile characterized by raised portions and indentations in order to minimize noise and vibration when the pinion gears rotate relative to the case. The surface profile can also be applied to contact surfaces of power transfer units and transfer cases.

Abstract: A sealing boot assembly comprises a flexible boot having a first end in sealing engagement with an outer surface of a shaft to define an inner chamber therein. A venting orifice extends from the inner chamber through the flexible boot to ambient and a moisture-blocking, vapor-breathable membrane is disposed across the venting orifice between the inner chamber and ambient to vent gas from the inner chamber during high temperature operation of the shaft and to allow air to returns to the inner chamber upon cooling thereof.

Abstract: Vehicles, systems and a method for mitigating power hop in a vehicle are provided.

Abstract: A helical LSD includes a case defining an inner cavity and a plurality of grooves disposed around the inner cavity. In addition to the case, the helical LSD includes a plurality of pinion gears. Each pinion gear is disposed in one of the grooves and includes a plurality of gear teeth. Each gear tooth has a top land. The helical LSD further includes at least one helical output gear disposed in the inner cavity of the case. The helical output gear meshes with the pinion gears, and the pinion gears are disposed around the helical output gear. The top land has a surface profile characterized by raised portions and indentations in order to minimize noise and vibration when the pinion gears rotate relative to the case. The surface profile can also be applied to contact surfaces of power transfer units and transfer cases.

Abstract: A method of operating a RESS thermal system in a vehicle having a coolant loop for directing a coolant through a RESS and a refrigerant loop configured to selectively cool the coolant flowing through a chiller in the coolant loop, including: determining a current target temperature range for the RESS based on a current vehicle operating mode and ambient temperature; determining a temperature of the RESS; determining if the temperature of the RESS needs to increase or decrease to be within the current target temperature range; if the determination is made that the temperature of the RESS needs to increase, determining if an active heating or a passive heating of the coolant will be employed, the active heating using a greater amount of energy over a shorter time period than the passive heating; and activating the determined active heating or passive heating of the coolant.

Abstract: Methods and systems for dynamically estimating the core temperature of at least one cell in a battery during an operative period. The method includes receiving by at least one controller the surface temperature, the current, the voltage, the state of charge, and the period of time from the initiation of a rest period to the termination of the rest period, determining an initial value of the lumped internal resistance of the at least one cell, determining subsequent values of the lumped internal resistance recursively in real-time based on the initial value, the current, and the voltage, and determining the core temperature of the at least one cell based on the surface temperature, the current, the obtained time, and the lumped internal resistance.

Abstract: A method of operating a RESS thermal system in a vehicle having a coolant loop for directing a coolant through a RESS and a refrigerant loop configured to selectively cool the coolant flowing through a chiller in the coolant loop, including: determining a current target temperature range for the RESS based on a current vehicle operating mode and ambient temperature; determining a temperature of the RESS; determining if the temperature of the RESS needs to increase or decrease to be within the current target temperature range; if the determination is made that the temperature of the RESS needs to increase, determining if an active heating or a passive heating of the coolant will be employed, the active heating using a greater amount of energy over a shorter time period than the passive heating; and activating the determined active heating or passive heating of the coolant.