Abstract: The present invention discloses a high step-down modular DC power supply, belonging to the field of power electronics technology, and the high step-down modular DC power supply includes an upper modular cascade circuit string, a lower modular cascade circuit string, a load, and an input source, where the upper modular cascade circuit string includes i upper sub-module circuits, and the lower modular cascade circuit string includes j lower sub-module circuits. A combination manner of module circuits includes: upper module string cascading, lower module string cascading, and hybrid cascading of the upper module string and the lower module string. The power supply is formed to be a high voltage step-down ratio power supply with high voltage direct current input and low voltage direct current output through modular cascading.

Abstract: An emblem installation system for installing emblems on a work piece includes an end effector for a robotic arm. The end effector has a base and multiple vacuum gripper modules repositionable along the base in different configurations. The vacuum gripper modules are configured to simultaneously grip multiple emblems and individually release the emblems. An emblem installation method includes applying a force within a first range of forces to the multiple emblems individually and in succession via vacuum gripper modules of an end effector on a robotic arm, with the emblems disposed at a first location, applying a vacuum to the vacuum gripper modules to grip the emblems with the vacuum gripper modules, and moving the robotic arm from the first location to a second location adjacent a workpiece with the emblems gripped by the vacuum gripper modules.

Abstract: An emblem installation system for installing emblems on a work piece includes an end effector for a robotic arm. The end effector has a base and multiple vacuum gripper modules repositionable along the base in different configurations. The vacuum gripper modules are configured to simultaneously grip multiple emblems and individually release the emblems. An emblem installation method includes applying a force within a first range of forces to the multiple emblems individually and in succession via vacuum gripper modules of an end effector on a robotic arm, with the emblems disposed at a first location, applying a vacuum to the vacuum gripper modules to grip the emblems with the vacuum gripper modules, and moving the robotic arm from the first location to a second location adjacent a workpiece with the emblems gripped by the vacuum gripper modules.

Abstract: Systems and methods are provided for fixturing hairpins for joining by welding. A fixture system includes an outer structural ring fixed relative to an inner structural ring and mates with the component around its hairpin type conductor ends. Dielectric rings are disposed between conductor pairs. Clamp rings are disposed on opposite sides of the dielectric rings. One clamp ring and one dielectric ring define an opening receiving one conductor pair. Another clamp ring and another dielectric ring define another receiving another conductor pair. The clamp rings are movable toward one another to align and crowd the conductor pairs between the clamp rings and the dielectric rings prior to welding.

Abstract: An end-effector for installation of an emblem assembly is provided. The end-effector includes a support frame, a first splitter, and a second splitter. The first splitter and the second splitter are connected to the support frame. The pneumatically actuated grippers include: a first gripper connected to the first splitter and configured to grab at least a portion of the emblem assembly; and a second gripper connected to the second splitter and configured to peel off one or more layers of the emblem assembly. The roller is connected to the support frame and configured to wet out an adhesive layer of the emblem assembly.

Abstract: An end-effector for installation of an emblem assembly is provided. The end-effector includes a support frame, a first splitter, and a second splitter. The first splitter and the second splitter are connected to the support frame. The pneumatically actuated grippers include: a first gripper connected to the first splitter and configured to grab at least a portion of the emblem assembly; and a second gripper connected to the second splitter and configured to peel off one or more layers of the emblem assembly. The roller is connected to the support frame and configured to wet out an adhesive layer of the emblem assembly.

Abstract: A method includes acquiring a first structural component conforming to a design, producing a first vehicle including the first structural component, and transferring possession of the first vehicle with the first structural component having a first set of mechanical properties. The method further includes acquiring a second structural component conforming to the design, subjecting the second structural component to a heat treatment process so that the second structural component is characterized by a second set of mechanical properties different from the first set of mechanical properties, producing a second vehicle including the second structural component, and transferring possession of the second vehicle with the second structural component having the second set of mechanical properties.

Abstract: A method of welding two or more workpieces employing a motion-controlled electrode that reduces temperature and residual stresses at a workpiece-to-electrode interface is disclosed. During a first period of time, a first electrode force is applied to the workpieces to be welded, and a weld current is applied that causes heating of an associated workpiece-to-workpiece faying surface, the first electrode force being applied at a first electrode stroke. A temperature of the faying surface indicative of a weld nugget formation thereat is determined, and in response thereto the electrode force is reduced to a second level during a second period of time while maintaining a constant electrode stroke. During a third period of time, the electrode force is further reduced to a third level while simultaneously reducing the electrode stroke to a second level. Welding is stopped after the third period of time, resulting in a weld joint having reduced residual stresses and reduced likelihood of stress crack formation.

Abstract: A process for simulating and assembling flexible parts includes creating an ideal path between first and second planes and placing a virtual rigid envelope around the ideal path, and possibly tubular extensions beyond the path. A virtual flexible part is marked with reference features and pulled through the virtual rigid envelope, such that the path of the virtual flexible part is constrained but may rotate. Removing the virtual rigid envelope allows the virtual flexible part to relax, causing it to move to its lowest energy state. Zero-twist end conditions on the virtual flexible part are marked, corresponding to the intersection of the reference features with the planes. Identification marks are placed on a real flexible part, corresponding to the reference strips on the virtual flexible part. The real flexible part may then be assembled by aligning zero-twist marks on mating features to the identification marks on the real flexible part.

Abstract: A method to detect and rank appearance distortions includes creating virtual models of a reference panel and a processed panel, including a first reference patch and the processed panel, respectively. Projecting a first simulated light pattern on the reference panel and the processed panel, and viewing the first reference patch and the first processed patch from a first viewpoint with respect to the first simulated light pattern. The method compares a first reference reflection at the first reference patch with a first processed reflection at the first processed patch, and creates a first index value from optical variations between the appearance of the reference and processed reflections. The first index value is output in a computer readable format. The method may compare the first index value to a predetermined index value and determine whether the processed panel is within an acceptable appearance quality threshold.

Abstract: A method includes acquiring a first structural component conforming to a design, producing a first vehicle including the first structural component, and transferring possession of the first vehicle with the first structural component having a first set of mechanical properties. The method further includes acquiring a second structural component conforming to the design, subjecting the second structural component to a heat treatment process so that the second structural component is characterized by a second set of mechanical properties different from the first set of mechanical properties, producing a second vehicle including the second structural component, and transferring possession of the second vehicle with the second structural component having the second set of mechanical properties.

Abstract: A method to detect and rank appearance distortions includes creating virtual models of a reference panel and a processed panel, including a first reference patch and the processed panel, respectively. Projecting a first simulated light pattern on the reference panel and the processed panel, and viewing the first reference patch and the first processed patch from a first viewpoint with respect to the first simulated light pattern. The method compares a first reference reflection at the first reference patch with a first processed reflection at the first processed patch, and creates a first index value from optical variations between the appearance of the reference and processed reflections. The first index value is output in a computer readable format. The method may compare the first index value to a predetermined index value and determine whether the processed panel is within an acceptable appearance quality threshold.

Abstract: A process for simulating and assembling flexible parts includes creating an ideal path between first and second planes and placing a virtual rigid envelope around the ideal path, and possibly tubular extensions beyond the path. A virtual flexible part is marked with reference features and pulled through the virtual rigid envelope, such that the path of the virtual flexible part is constrained but may rotate. Removing the virtual rigid envelope allows the virtual flexible part to relax, causing it to move to its lowest energy state. Zero-twist end conditions on the virtual flexible part are marked, corresponding to the intersection of the reference features with the planes. Identification marks are placed on a real flexible part, corresponding to the reference strips on the virtual flexible part. The real flexible part may then be assembled by aligning zero-twist marks on mating features to the identification marks on the real flexible part.

Abstract: A method of welding two or more workpieces employing a motion-controlled electrode that reduces temperature and residual stresses at a workpiece-to-electrode interface is disclosed. During a first period of time, a first electrode force is applied to the workpieces to be welded, and a weld current is applied that causes heating of an associated workpiece-to-workpiece faying surface, the first electrode force being applied at a first electrode stroke. A temperature of the faying surface indicative of a weld nugget formation thereat is determined, and in response thereto the electrode force is reduced to a second level during a second period of time while maintaining a constant electrode stroke. During a third period of time, the electrode force is further reduced to a third level while simultaneously reducing the electrode stroke to a second level. Welding is stopped after the third period of time, resulting in a weld joint having reduced residual stresses and reduced likelihood of stress crack formation.

Abstract: A method allowing for the fabrication of tubular structures, such as structural members used in vehicle bodies, from two or more metals or other materials using a hydroforming process. Being able to use two or more metals or other materials, such as, for example, high-strength steel and low-weight aluminum alloy, in body structure design allows for achieving an optimum material solution which combines the desirable attributes of the different materials.

Abstract: A method for manufacturing a complex heat treated tubular structure includes making a tube assembly having tube portions along its length of differing characteristic. The tube assembly is formed by lengthwise tube bending and hydroforming to provide a desired shape. The tube is formed by lengthwise tube bending and hydroforming to provide a desired shape. The tube is supported in a locating fixture having a plurality of supports spaced along the tube to support the tube against distortion. A local region of the tube is heated in at least one local region to a temperature to heat treat the local region. A quenching medium is then flushed through the hollow interior of the tube, and the tube is removed from the locating fixture..

Abstract: A method for manufacturing a complex heat treated tubular structure includes making a tube assembly having tube portions along its length of differing characteristic. The tube assembly is formed by lengthwise tube bending and hydroforming to provide a desired shape. The tube is formed by lengthwise tube bending and hydroforming to provide a desired shape. The tube is fixedly supported in a locating fixture having a plurality of supports spaced along the tube to support the tube against distortion. A local region of the tube is heated in at least one local region to a temperature to heat treat the local region. A quenching medium is then flushed through the hollow interior of the tube, and the tube is removed from the locating fixture.

Abstract: A process that combines tubular body pressure induced shaping at elevated temperatures with a controlled rapid quenching operation using a gaseous quenching medium in a common unit. The achievable cooling rate permits the in-die shaping and quenching of tubular structural components of martensitic steels without requiring the use of a separate discrete quenching.

Abstract: A method is provided for manufacturing a shaped tubular part from a first tube and second tube. The end of the first tube is inserted into the end of the second tube to provide a region of overlapping tube walls. An induction coil is placed around the outer surface of the first and second tubes at the region of overlapped tube walls. The induction coil is energized to make a plurality of longitudinally spaced apart magnetic pulse welds attaching the tubes together to thereby form a multi-tube one-piece composite tubular assembly. The tubular assembly is then subjected to a forming process such as hydroforming, tube bending or stretch bending to form the final shape of the tubular part.

Abstract: A method is provided for forming a tube between a pair of dies. The tube is captured between a pair of dies having die surfaces constructed of an electrically non-conducting material defining a die cavity therein. The ends of the tube are sealed and electrical current is applied to the tube to induce electrical resistance heating of the tube. The interior of the tube is pressurized to expand the tube into the cavity to thereby form the heated tube.