Abstract: A method of assembling components of a vehicle is provided that includes locating a node relative to an adjoining component, measuring at least one geometrical feature of the node or the adjoining component, 3D printing an assembly adjustment member based on the measuring, and placing the assembly adjustment member proximate at least one of the node or the adjoining component. The assembly adjustment member is configured to allow relative movement between the node and the adjoining component for subsequent processing operations.

Abstract: A method of assembling components of a vehicle is provided that includes locating a node relative to an adjoining component, measuring at least one geometrical feature of the node or the adjoining component, 3D printing an assembly adjustment member based on the measuring, and placing the assembly adjustment member proximate at least one of the node or the adjoining component. The assembly adjustment member is configured to allow relative movement between the node and the adjoining component for subsequent processing operations.

Abstract: A method of assembling components of a vehicle is provided that includes locating a node (20) relative to an adjoining component (22), measuring at least one geometrical feature of the node or the adjoining component, 3D printing an assembly adjustment member (24) based on the measuring, and placing the assembly adjustment member proximate at least one of the node or the adjoining component. The assembly adjustment member is configured to allow relative movement between the node and the adjoining component for subsequent processing operations.

Abstract: A controller alters a cycle time of a die arrangement, configured to hot stamp metal into components and having an active cooling system, based on an amount of heat transferred from the components to the active cooling system such that a grain structure of the components transitions from an austenitic state to a martensitic state.

Abstract: A vehicle assembly method includes assembling a chassis platform, mounting a floor pan to the platform, mounting a modular interior to the floor pan, assembling a body top-hat separate from the platform and the floor pan, and mounting the body top-hat to the platform and the floor pan after mounting the modular interior to the floor pan.

Abstract: The method of monitoring an operation includes acquiring data from sensors including images of a workspace in which the operation is to be performed, identifying a human operator and a controlled element within the workspace using the acquired images, determining whether the operation has initiated based on a known activation trigger, estimating pose of the human operator using the images, monitoring state of the controlled element based on acquired data, and determining whether an abnormality occurred based on the estimated pose, the state of the controlled element, a duration of the operation, or a combination thereof.

Abstract: The method of monitoring an operation includes acquiring data from sensors including images of a workspace in which the operation is to be performed, identifying a human operator and a controlled element within the workspace using the acquired images, determining whether the operation has initiated based on a known activation trigger, estimating pose of the human operator using the images, monitoring state of the controlled element based on acquired data, and determining whether an abnormality occurred based on the estimated pose, the state of the controlled element, a duration of the operation, or a combination thereof.

Abstract: A vehicle assembly method includes assembling a chassis platform, mounting a floor pan to the platform, mounting a modular interior to the floor pan, assembling a body top-hat separate from the platform and the floor pan, and mounting the body top-hat to the platform and the floor pan after mounting the modular interior to the floor pan.

Abstract: A system and method of verifying that a part is heat treated to strengthen the part. The part is marked with a thermo-chromatic composition before heat treating. The part is then heat treated to strengthen the part and change the color of the thermo-chromatic composition to indicate successful completion of the heat treating process. A detector may act to prevent the inclusion of a non-heat treated part in an assembly by disabling an assembly tool. A controller may also provide data related to the completion of the heat treating process to be recorded in a database.

Abstract: A vehicle assembly method includes assembling a chassis platform, mounting a floor pan to the platform, mounting a modular interior to the floor pan, assembling a body top-hat separate from the platform and the floor pan, and mounting the body top-hat to the platform and the floor pan after mounting the modular interior to the floor pan.

Abstract: A vehicle includes a floor including a top panel and a bottom panel defining a cavity therebetween. At least one of the top panel and the bottom panel includes a polymeric material. A passenger-climate-control duct is disposed in the cavity and is integral with the at least one of the top panel and the bottom panel.

Abstract: This disclosure details electrified vehicles that are equipped with removable generators for increasing the electric range of the vehicles. An exemplary electrified vehicle includes a cargo space, such as a truck bed, and a generator removably positioned within the cargo space. The generator is adapted to selectively supply power for either charging a battery pack of the electrified vehicle or for propelling one or more vehicle drive wheels. In some embodiments, the generator is shaped like, and therefore disguised as, a toolbox.

Abstract: A controller alters a cycle time of a die arrangement, configured to hot stamp metal into components and having an active cooling system, based on an amount of heat transferred from the components to the active cooling system such that a grain structure of the components transitions from an austenitic state to a martensitic state.

Abstract: A vehicle includes an integrated floor and traction battery support assembly. The assembly includes a floor panel and cross-members each having an upper portion attached to a lower surface of the floor panel and extending laterally across the floor panel. The assembly further includes a battery tray attached to lower portions of the cross-members and cooperating with the lower surface to define a battery-pack enclosure. A battery pack is disposed in the enclosure.

Abstract: A vehicle includes a floor including a top panel and a bottom panel defining a cavity therebetween. At least one of the top panel and the bottom panel includes a polymeric material.

Abstract: A vehicle assembly method includes assembling a chassis platform, mounting a floor pan to the platform, mounting a modular interior to the floor pan, assembling a body top-hat separate from the platform and the floor pan, and mounting the body top-hat to the platform and the floor pan after mounting the modular interior to the floor pan.

Abstract: A controller alters a cycle time of a die arrangement, configured to hot stamp metal into components and having an active cooling system, based on an amount of heat transferred from the components to the active cooling system such that a grain structure of the components transitions from an austenitic state to a martensitic state.

Abstract: Systems and methods for reducing or eliminating corrosion in joined materials are disclosed, for example, multi-material joints. The system may include a sealing device including a body and a tip. The tip may be configured to form a seal around a local region of a material having a fastener disposed therein. The sealing device may be configured to apply a sealant material from the tip to the local region and form a cap thereover. The tip of the sealing device may form a cavity between the material and the inner surface of the tip, which may be filled with the sealant material to form the cap. In one embodiment, the sealing device may be configured to couple to the joining device that inserted the fastener. This may allow for accurate and robust placement of the sealant material directly after the fastener is inserted.

Abstract: A battery assembly for a vehicle including a battery pack and a platform supporting the battery pack. A tubular sled runner is longitudinally oriented to absorb collision forces in a frontal collision. The sled runner defines first and second coolant supply channels on opposite lateral sides of a central coolant return channel. A coolant circulation system provides coolant to the first and second coolant supply channels and receives coolant from the central coolant return channel. A coolant loop is disclosed for cooling another heat source with the coolant flowing through the sled runner. Longitudinally extending ribs may be provided on the inner side, outer side, or both sides of the sidewalls of the sled runner to increase crush resistance or heat transfer efficiency.

Abstract: A method of assembling components of a vehicle is provided that includes locating a node (20) relative to an adjoining component (22), measuring at least one geometrical feature of the node or the adjoining component, 3D printing an assembly adjustment member (24) based on the measuring, and placing the assembly adjustment member proximate at least one of the node or the adjoining component. The assembly adjustment member is configured to allow relative movement between the node and the adjoining component for subsequent processing operations.