Abstract: Techniques control a utility vehicle. Such techniques involve storing electric power in a lithium battery of the utility vehicle. Such techniques further involve operating a motor controller of the utility vehicle in a normal mode in which the motor controller provides electric power from a lithium battery of the utility vehicle to an electric motor of the utility vehicle to turn one or more ground engaging members of the utility vehicle. Such techniques further involve, after operating the motor controller in the normal operating mode, operating the motor controller in a walkaway mode in which the motor controller configures the electric motor to provide braking torque.

Abstract: One exemplary embodiment discloses a bipolar plate assembly including a cathode plate and an anode plate. Each of the cathode plate and the anode plate includes a core material, a first surface material coupled to a first side of the core material, and a second surface material coupled to a second side of the core material, wherein the first surface material and the second surface material have a different composition from the core material.

Abstract: A bipolar plate used in a fuel cell and a method of making a bipolar plate. The sheet is made from a ferritic or austenitic stainless steel, and defines an undulated surface pattern such that the patterned sheet may be formed into the bipolar plate. In one configuration, a stamping or related metal forming tool operation will further deform the patterned sheet into the bipolar plate shape such that the wall thickness is substantially uniform throughout the surface. In this way, there is a substantial reduction in stretching/thinning/necking at an intersection between bends and side walls that define the undulations of the pattern. In one form, the pattern defines a repeating serpentine shape. In a particular embodiment, the bends may include surface modifications to reduce the effects of sheet-to-tool misalignment.

Abstract: A bipolar plate used in a fuel cell and a method of making a bipolar plate. The sheet is made from a ferritic or austenitic stainless steel, and defines an undulated surface pattern such that the patterned sheet may be formed into the bipolar plate. In one configuration, a stamping or related metal forming tool operation will further deform the patterned sheet into the bipolar plate shape such that the wall thickness is substantially uniform throughout the surface. In this way, there is a substantial reduction in stretching/thinning/necking at an intersection between bends and side walls that define the undulations of the pattern. In one form, the pattern defines a repeating serpentine shape. In a particular embodiment, the bends may include surface modifications to reduce the effects of sheet-to-tool misalignment.

Abstract: The microstructure of a low alloy steel workpiece for cold forming may be beneficially modified by heating the workpiece to a temperature just above its austenite transformation temperature (Ac3 temperature). The steel workpiece is then cooled just below its Ac3 temperature to promote ferrite formation on and between the austenite grains. Heating and cooling, above and below the Ac3 temperature, is repeated a determined number of times to refine the austenite grains before the workpiece is quenched below its martensite transformation temperature to form a mixture of martensite with increased retained austenite. The workpiece may be further heated in its martensite region to increase the proportion of retained austenite before quenching the steel workpiece to an ambient temperature. The formability of the workpiece is improved, as is the strength of its formed shape.

Abstract: The microstructure of a low alloy steel workpiece for cold forming may be beneficially modified by heating the workpiece to a temperature just above its austenite transformation temperature (Ac3 temperature). The steel workpiece is then cooled just below its Ac3 temperature to promote ferrite formation on and between the austenite grains. Heating and cooling, above and below the Ac3 temperature, is repeated a determined number of times to refine the austenite grains before the workpiece is quenched below its martensite transformation temperature to form a mixture of martensite with increased retained austenite. The workpiece may be further heated in its martensite region to increase the proportion of retained austenite before quenching the steel workpiece to an ambient temperature. The formability of the workpiece is improved, as is the strength of its formed shape.

Abstract: An impact beam assembly includes a beam of high-strength steel, and a pair of end brackets constructed of a dissimilar material than the high-strength steel. The brackets are locally deformed onto the beam to thereby surround a portion of the beam. Once deformed, the brackets define a flat section suitable for welding to a vehicle door panel, as well as a section for retaining the beam. The beam can include a surface feature suitable for retaining the beam to the end brackets. A method of reinforcing a vehicle door assembly includes positioning the beam with respect to the end brackets such that the brackets surround a portion of the beam, and then activating a magnetic pulse coil (MPC) to deform an overlapping portion of the brackets onto the beam. The brackets are then attached to a surface of the door assembly to reinforce the door assembly.

Abstract: Electromagnetic forming methods suitable for creating surface features on a shape memory alloy are described. Features may be created over a range of scales, including those suitable for the generation of holographic images. Features, images, or patterns may be made capable of reversibly appearing and disappearing as a result of changes in temperature and may include temperature sensitive displays for automotive and other applications.

Abstract: Articles are often formed from a tubular workpiece in a process which does not usefully shape the ends of the tube. In an embodiment of the invention, tube ends may be mechanically reduced in cross section and then expanded against a secondary forming surface(s) using an electromagnetic force to obtain desired shapes for the tube ends and minimize scrapping of workpiece material.

Abstract: A multi-layer driver plate is disclosed for use in electromagnetic sheet metal forming operations. In one embodiment, the driver plate comprises a first layer characterized by low electrical resistivity and thickness for inducement and application of a suitable electromagnetic forming force, a second layer comprising an elastomeric material for compressing a sheet metal workpiece against a die surface and then regaining its original pre-forming structure, and a third layer interposed between the first layer and the second layer to protect the EMF force providing layer and to provide overall strength and durability to the EMF driver plate.

Abstract: Electromagnetic forming methods suitable for creating surface features on a shape memory alloy are described. Features may be created over a range of scales, including those suitable for the generation of holographic images. Features, images, or patterns may be made capable of reversibly appearing and disappearing as a result of changes in temperature and may include temperature sensitive displays for automotive and other applications.

Abstract: An impact beam assembly includes a beam of high-strength steel, and a pair of end brackets constructed of a dissimilar material than the high-strength steel. The brackets are locally deformed onto the beam to thereby surround a portion of the beam. Once deformed, the brackets define a flat section suitable for welding to a vehicle door panel, as well as a section for retaining the beam. The beam can include a surface feature suitable for retaining the beam to the end brackets. A method of reinforcing a vehicle door assembly includes positioning the beam with respect to the end brackets such that the brackets surround a portion of the beam, and then activating a magnetic pulse coil (MPC) to deform an overlapping portion of the brackets onto the beam. The brackets are then attached to a surface of the door assembly to reinforce the door assembly.

Abstract: One exemplary embodiment discloses a bipolar plate assembly including a cathode plate and an anode plate. Each of the cathode plate and the anode plate includes a core material, a first surface material coupled to a first side of the core material, and a second surface material coupled to a second side of the core material, wherein the first surface material and the second surface material have a different composition from the core material.

Abstract: Articles are often formed from a tubular workpiece in a process which does not usefully shape the ends of the tube. In an embodiment of the invention, tube ends may be mechanically reduced in cross section and then expanded against a secondary forming surface(s) using an electromagnetic force to obtain desired shapes for the tube ends and minimize scrapping of workpiece material.

Abstract: A multi-layer driver plate is disclosed for use in electromagnetic sheet metal forming operations. In one embodiment, the driver plate comprises a first layer characterized by low electrical resistivity and thickness for inducement and application of a suitable electromagnetic forming force, a second layer comprising an elastomeric material for compressing a sheet metal workpiece against a die surface and then regaining its original pre-forming structure, and a third layer interposed between the first layer and the second layer to protect the EMF force providing layer and to provide overall strength and durability to the EMF driver plate.

Abstract: Apparatus and methods are disclosed for applying electromagnetic force (EMF) to flanging and hemming metal panels to form a hemmed panel assembly. First and second apparatus and method steps use a translating EMF coil to flange a sheet and to finish a hem by progressive non-planar bending. An alternate embodiment uses EMF hemming for difficult-to-hem portions of a flange and optionally precedes this with conventional hemming of straight hem portions.

Abstract: A scheme for electromagnetic formation of fuel cell plates is provided. In accordance with one embodiment of the present invention, a method of forming a flow field plate is provided where an electromagnetic actuator is arranged opposite a profiled surface of a die portion. The profiled surface of the die portion is configured to at least partially define a network of flow field plate flow passages. The electromagnetic actuator is configured to generate a magnetic field upon activation and a sheet of material is positioned between the electromagnetic actuator and the profiled die surface. The sheet of material is characterized by an electrical conductivity sufficient to yield a repulsive electromagnetic force between the actuator and the sheet upon activation of the actuator. The passages are formed by driving the electromagnetic actuator such that the repulsive force is of sufficient intensity to deform the sheet against the profiled die surface.

Abstract: Nonmagnetized permanent magnet material is heated in a pattern by a laser beam to a localized temperature above the Curie point or a temperature sufficient to reduce the coercivity sufficiently for an external field to magnetize the pattern in the direction of the field. Magnets so produced can have very high pole density, digital encoding and analog patterns having gradually varying local field strength. Alternating pole magnets of this type can be used for stepper motor magnets.

Abstract: A method and apparatus for detecting an engine crankshaft angular position which provides for fast starting of the engine. A target wheel and sensor combination generate an analog signal which is convened into a 24 bit digital output which repeats every 360.degree. rotation of the crankshaft. Each bit represents a particular angular position of the crankshaft. Any 6 sequential bits in the repeating 24 bit digital output sequence form a unique pattern. By monitoring the first six bits generated (90.degree. of crankshaft rotation) during startup, a crankshaft angular position can be determined, thereby enabling fast starting of the engine.

Abstract: An article comprising first and second bodies of permanent magnet material, each of said first and second bodies consisting substantially of a substrate of permanent magnet material being magnetized substantially uniformly to a predetermined flux density in a range from zero flux to 100% flux saturation of the permanent magnet material; each of the first and second bodies also comprising a pattern of at least one affected volume in a surface of the body, wherein each affected volume has a magnetic flux density that varies from the substantially uniform predetermined flux density and wherein the first and second bodies are stacked and fixedly attached so that the pattern on each body aligns with the pattern on the other body, wherein at least one affected volume on the first body is aligned with at least one affected volume on the second body and wherein the aligned affected volumes comprise a pole detectable by a magnetic sensor.