Abstract: A motor vehicle includes a frame with energy-absorbing zones at outboard corners of the vehicle and a bumper beam mounted to the energy-absorbing zones to transfer force to at least one of the energy-absorbing zones during a collision. The bumper beam includes a center section extending generally laterally across the vehicle between the energy-absorbing zones, and left and right load transfer sections attached to outboard ends of the center section. Each load transfer section extends outboard and rearward such that the free end of each load transfer section is disposed outboard of the frame adjacent a rear end of its respective energy-absorbing zone. In a small-overlap collision, the load transfer section on the side of the impact bends rearward as the energy-absorbing zone deforms, and the free end of the load transfer section contacts the frame to transfer crash loads to the frame.

Abstract: A motor vehicle includes a frame with energy-absorbing zones at outboard corners of the vehicle and a bumper beam mounted to the energy-absorbing zones to transfer force to at least one of the energy-absorbing zones during a collision. The bumper beam includes a center section extending generally laterally across the vehicle between the energy-absorbing zones, and left and right load transfer sections attached to outboard ends of the center section. Each load transfer section extends outboard and rearward such that the free end of each load transfer section is disposed outboard of the frame adjacent a rear end of its respective energy-absorbing zone. In a small-overlap collision, the load transfer section on the side of the impact bends rearward as the energy-absorbing zone deforms, and the free end of the load transfer section contacts the frame to transfer crash loads to the frame.

Abstract: A sleeper cab assembly for a vehicle includes a frame configured to provide a support structure for at least a portion of the sleeper cab assembly. The frame includes a plurality of frame members coupled together. Each of the frame members are formed of a reinforced polymeric material.

Abstract: A sleeper cab assembly for a vehicle includes a frame configured to provide a support structure for at least a portion of the sleeper cab assembly. The frame includes a plurality of frame members coupled together. Each of the frame members are formed of a reinforced polymeric material.

Abstract: Method of welding a metal sheet and metal tubing as well as a welded sheet-to-tube welded structure wherein the tube-to-sheet gage ratio may be reduced to permit use of metal tubing having a reduced wall thickness. One or more intermediate metal bridging members is/are first welded to a metal tube using a relatively rapid welding process that reduces heat input and residual tensile stress imparted to the tube. A metallic sheet then is spot welded directly to the one or more bridging members, rather than to the metallic tube, to form a welded sheet-to-tube structure.

Abstract: A joint assembly for joining first and second tubular members. The first member has flanges extending from walls of an end segment. The walls of the end segment define a receiving opening. The second member has walls and a protrusion having sides extending from the walls to an end of the protrusion. When the members are joined the protrusion is received in the opening of the end segment so that the sides of the protrusion are in facing engagement with the walls of the end segment and the flanges engage the walls of the second member. The members are secured together at some of the engaging surfaces. The protrusion reduces stress on the flanges and increases the mechanical strength of the assembly.

Abstract: A weld gun having a linkage, which relates pivotal motion of a pair of laterally opposed facing electrodes of the weld gun in a predetermined manner. Based upon the predetermined motion of the electrodes a welding robot positions the electrodes of the weld gun on opposite sides of a workpiece to be welded so that the electrodes simultaneously engage the workpiece on opposite sides.

Abstract: This invention provides a method of producing a series of substantially uniform spot welds between two metal parts using a servomotor driven movable electrode and an axially opposing fixed electrode. Target values for electrode displacement in producing a weld indentation and electrode squeeze force are determined for the electrodes and workpieces. During welding operations electrode displacement and electrode force measurements are continually taken and compared with the displacement and force target values. While the measured values are within a tolerance range of the target values, welding is continued using the preset parameters. When either or both of the measured electrode displacement or force value falls outside the target range the total welding current is adjusted in small increments to correct the displacement and/or force values and, thereafter, welding is continued using the new total welding current.

Abstract: Method and apparatus for detecting unacceptable misalignment of welding electrodes. An electrode-alignment station is positioned adjacent a welding station. A robot controls the movement of the electrodes, and occasionally moves the electrodes out of the welding station and into an electrode-alignment station. At the electrode-alignment station, the electrodes are closed on a fixture that transfers electrode-misalignment into movement of a plate that triggers an alarm if the misalignment is greater than a prescribed amount.

Abstract: A weight distributing hitch assembly includes a shank, hitch head, spring bar and lift assembly. The lift assembly is preferably removably mountable to the frame members of a trailer frame while the spring bar extends below the frame members relative to the ground. The lift assembly mounts a hanger assembly which engages a cantilevered segment of the spring bar to drive the spring bar from a free state to a loaded state to distribute the hitch load to a towing vehicle as well as to the trailer. A lever assembly mounts the hanger assembly to the lift assembly and supplies mechanical advantage to assist a user during tensioning of the spring bar. By moving the lever assembly, the cam rotates about a pivot. As the hanger assembly is engaged with the cam, the hanger assembly is driven from a disengaged position to an engaged position which moves the spring bar from its free state to its loaded state with a minimum of user effort.

Abstract: Method and apparatus for detecting unacceptable misalignment of welding electrodes. An electrode-alignment station is positioned adjacent a welding station. A robot controls the movement of the electrodes, and occasionally moves the electrodes out of the welding station and into an electrode-alignment station. At the electrode-alignment station, the electrodes are closed on a fixture that transfers electrode-misalignment into movement of a plate that triggers an alarm if the misalignment is greater than a prescribed amount.

Abstract: A joint assembly for joining first and second tubular members. The first member has flanges extending from walls of an end segment. The walls of the end segment define a receiving opening. The second member has walls and a protrusion having sides extending from the walls to an end of the protrusion. When the members are joined the protrusion is received in the opening of the end segment so that the sides of the protrusion are in facing engagement with the walls of the end segment and the flanges engage the walls of the second member. The members are secured together at some of the engaging surfaces. The protrusion reduces stress on the flanges and increases the mechanical strength of the assembly.

Abstract: A weight distributing hitch assembly includes a shank, hitch head, spring bar and lift assembly. The lift assembly is preferably removable mountable to the frame members of a trailer frame while the spring bar extends below the frame members relative to the ground. The lift assembly mounts a hanger assembly which engages a cantilevered segment of the spring bar to drive the spring bar from a free state to a loaded state to distribute the hitch load to a towing vehicle as well as to the trailer. A lever assembly mounts the hanger assembly to the lift assembly and supplies mechanical advantage to assist a user during tensioning of the spring bar. By moving the lever assembly, the cam rotates about a pivot. As the hanger assembly is engaged with the cam, the hanger assembly is driven from a disengaged position to an engaged position which moves the spring bar from its free state to its loaded state with a minimum of user effort.

Abstract: A method for electrical resistance welding thin metal sheets together is disclosed. In the method, a protrusion is formed upon a first sheet wherein the protrusion includes a planar circular surface and an annular sloping wall. Thereafter, electrodes pass an electrical current through the protrusion as the protrusion is contacted with a second metal sheet for electric resistance welding the first sheet to the second sheet.

Abstract: The lift unit for a weight distributing trailer hitch includes a fixed mounting bracket secured to the trailer tongue and a chain lift bracket that pivots on the mounting bracket to raise and lower a chain for flexing and unflexing a spring bar that distributes weight between the towing vehicle and the trailer with the spring bar in the flexed position. A locking pawl rotatably connected to the lift bracket has a lower arm portion for engagement with a detent in the fixed mounting bracket to releasably latch the lift bracket in a raised position. The locking pawl also includes an upper arm projection. The locking pawl is connected to the lift bracket with the pawl upper arm projection positioned adjacent a tool engagement finger on the lift bracket that is slidably engaged by a tool such as a pipe to aid in raising and lowering the chain lift bracket.

Abstract: A fluid-operated stabilizing apparatus receives an article having loose, wrinkled overlapping surfaces and by use of fluid flow control devices directs flows of fluid to the overlapping surfaces to fluidly shake the surfaces to smooth out wrinkles and any folded portions thereof, and then to align and hold the surfaces for subsequent treatment, such as bonding together. A method is also provided for smoothing and aligning the overlapping surfaces for subsequent treatment.