Abstract:
A method and system for detecting edge cracks of an element of a sheet metal product is provided. The method includes calculating a first stress associated with a forming process employing a first die; calculating a second stress associated with a finishing process employing a second die; combining the first stress and the second stress to formulate a total stress; simulating the sheet metal product to produce a benchmark stress; and comparing the total stress and the benchmark stress to determine if the element predictively contains edge cracks.
Abstract:
A process for curing of an adhesive (16) using laser (20) energy. A substrate sandwich assembly (12) is provided with an adhesive (16) interposed between the substrates (14,18). The adhesive (16) used at least partially requires heat to assist in curing of the adhesive (16). The area where the adhesive (16) is found in the sandwich (12) is heated with a laser (20). The laser (20) used is defocused for instance the laser is focused to a point (22) behind the substrates (14,18) to be bonded. Thereafter the defocused laser (20) is used to contact the surface of the substrates (14,18) to be bonded at the location of said adhesive (16) with the out of focus laser (20) energy beam for imparting heat on the bonding area with an effective amount of laser (20) energy sufficient to assist in bond curing of the adhesive (16) at that area.
Abstract:
A crash box includes a body portion extending from a top edge to a bottom edge along a global z-axis (A) and having a pair of side walls disposed in spaced relationship to one another. At least one x- shaped reinforcing web extends between the side walls along a plane (P) disposed transverse to the axis (A). An extension portion is integral with the body portion and extends outwardly from one of the side walls and is disposed along the plane (P). A flange plate is also integral with the body portion and defines at least one flange plate attachment hole for securing the crash box to a frame of a vehicle.
Abstract:
A crash box includes a body portion extending from a top edge to a bottom edge along a global z-axis (A) and having a pair of side walls disposed in spaced relationship to one another. At least one x- shaped reinforcing web extends between the side walls along a plane (P) disposed transverse to the axis (A). An extension portion is integral with the body portion and extends outwardly from one of the side walls and is disposed along the plane (P). A flange plate is also integral with the body portion and defines at least one flange plate attachment hole for securing the crash box to a frame of a vehicle.
Abstract:
A light engine 20 to provide light from a plurality of semiconductor light sources 40 in an automotive lighting system, such as a headlamp, includes a substrate 24 upon which the semiconductor light sources are mounted. The semiconductor light sources are spaced from one another on the substrate for cooling purposes. The substrate also preferably includes at least one layer 48 of heat transfer material which assists in transferring waste heat from the semiconductor light sources to a heat sink or other cooling means. The light engine 20 further includes a transfer device 28 comprising a bundle of fiber optic cables 60, one cable for each semiconductor light source 40, and each cable has a receiving end 32 which is located adjacent a respect one semiconductor light source 40 and an emitter end 36 which is located in close proximity to the emitter end of each other cable emitter end. The substrate 24 can be located in a location which is convenient for the purposes of cooling the semiconductor light sources while the emitter end of the cables of the transfer device can be located adjacent a lens of the headlamp or other automotive lighting system.
Abstract:
A window surround module (10) for installation to the perimeter of a window opening (120, 248) in a motor vehicle door panel (118, 244) comprises individual window surround components that are fabricated into a unitary structure. The individual components include two or more of a header molding (16, 130), a belt molding (18, 132), a mirror base (12, 28, 140), a B-pillar trim piece (14, 134), a glass run channel (150, 260), a wire harness (264), a wire harness support (262), seals (24, 200, 202, 2004), a mirror (30, 114), and a window (122, 246). At least some of the components are molded together to form a unit to which other components are mounted.
Abstract:
A lighting assembly is adapted to be fixedly secured to a motor vehicle for emitting light out therefrom. The lighting assembly includes a frame for supporting and mounting the lighting assembly and a lens (16) fixedly secured to the frame. The lighting assembly also includes a light emitting diode (18) spaced from the lens for emitting light out through the lens. The lighting assemb further includes a reflector (30) extending between the lens and the light emitting diode. The reflector includes a parabolic reflecti surface and a hyperbolic component for directing light emitting from the light emitting diode out toward the parabolic reflective surface at an angle such that the light passes through the lens as collimated light.
Abstract:
A dead front actuating assembly actuates a device in standard ambient light conditions. The dead front actuating assembly includes a housing (36) defining a periphery and an interior volume. A cover plate (28) is fixedly secured to the housing at the periphery. The cover plate defines an inboard surface (44) facing the interior volume and an outboard surface (46) opposite the inboard surface. The outboard surface is opaque in standard ambient light conditions. The dead front actuating assembly also includes a switch that is operatively connected to the inboard surface of the cover plate at a defined location for toggling the device between on and off conditions. The dead front actuating assembly also includes a presence sensor (50) identifying when an operator is disposed adjacent the cover plate. A back light (51) inside the housing illuminates the cover plate such that light passes through the cover plate and out the outboard surface to illuminate the switch for the operator.
Abstract:
A method and apparatus for hydroforming a metal part includes placing a part to be formed (510) within a die (512), closing the die to enclose the part to be formed, and introducing a high pressure fluid to an interior of the die for expanding the part against an interior surface of the die. The high pressure fluid has a pulse applied thereto for increasing a material flow of the part within the die.
Abstract:
A method for forming a bumper beam includes providing an elongated piece of sheet metal having opposing end portions and an intermediate portion, bending the end portions with respect to the intermediate portion until the end portions are substantially perpendicular to the intermediate portion, bending a central section of the intermediate portion to form a protruding bulge in the intermediate portion after the bending the end portions, and bending side sections of the intermediate portion to move ends of the end portions adjacent to one another and adjacent to the protruding bulge after the bending the central section to from the bumper beam. The end portions form front walls of the bumper beam, the protruding bulge forms inner side walls and a web portion of the bumper beam, and the side sections form outer side walls and rear walls of the bumper beam.