Abstract: An RFID tag system and method. An RFID tag is encapsulated within a protective material and formed as a ball. The RFID ball is then mixed with a material that is to be deposited on a particular work piece, such as a coating being deposited on a piece of sheet metal. The RFID ball can later be read when the work piece is in the production environment using a suitable RFID reader. In this manner, the RFID ball forms a permanent part of the work piece and is able to be interrogated at any occasion during the assembly of a product.

Abstract: Methods, program products, and computer systems for estimating a stress of a toughened structural adhesive polymer are provided. One method comprises selecting a strain, a strain rate, a temperature, or a combination thereof at which the stress is to be estimated. A value of a strain-hardening stress of the toughened structural adhesive polymer is determined, wherein the value of the strain-hardening stress is dependent on the temperature and the strain. A value of a non-strain-hardening stress of the toughened structural adhesive polymer is determined, wherein the value of the non-strain-hardening stress is dependent on the strain, the strain rate, and the temperature. The value of the strain-hardening stress is added to the value of the non-strain-hardening stress to obtain an estimated total stress.

Abstract: A rivet configured to provide a strengthened rivet joint capable of acting as a load-bearing joint, such as in a vehicle, is provided. A method of joining a multiple member work-piece utilizing the rivet is also provided. The rivet includes a head portion and an annular body portion extending from the head portion. The body portion has an open end opposite the head portion. The head portion and the annular body portion define an interior cavity that opens at the open end. The annular body portion has an inner surface at the interior cavity and an outer surface opposite the interior cavity. The body portion has passages extending through the body portion from the inner surface to the outer surface, and grooves running along the outer surface intersecting with the passages.

Abstract: A fastener is provided for attachment to a workpiece by a friction stir process. The fastener includes a base having an underside adapted to seat upon the workpiece and a fastener portion attached to the top side of the base. An anchor portion projects from the underside of the base and is adapted to be rotated and advanced at high speed and inserted into the workpiece by friction stirring of the workpiece. The anchor portion is embedded in the workpiece upon cooling of the workpiece. The anchor portion has an indent in the surface thereof enabling the softened stirred material to flow into the indent and thereby mechanically capture the anchor portion within the solidified workpiece.

Abstract: A closure panel assembly includes an inner and an outer panel, the inner panel having a crimped edge surface feature and a textured surface feature such as a set of radial projections or asperities. Adhesive material is applied between the panels, and the outer panel is hemmed and adhesively bonded to the inner panel. The surface features affix the panels together without induction or intermediate heat curing of the adhesive material. The outer panel has a hemmed edge enclosing the crimped surface feature, with the adhesive material positioned therebetween to form a seal of a relatively low shrinkage rate. A method of forming the closure panel assembly includes forming a first and second surface feature on the inner panel, such as by using swaging and coining, respectively, applying adhesive material therebetween, and hemming the panels to form a hem seam.

Abstract: A method and apparatus inspect a quality of an adhesive material used for joining a pair of work surfaces during a weld-bonding process. A pair of work pieces are at least partially bonded by a layer of the adhesive material, and the dynamic displacement of one or both electrodes is measured through a duration of the resistance welding process to determine relative moisture content of the adhesive. A control action is executed when the dynamic displacement exceeds a stored threshold value. The apparatus includes a welding device having a pair of electrodes for providing a clamping force and an electrical current necessary for forming the welded joint, a sensor for measuring a dynamic displacement of at least one of the pair of electrodes and/or another portion of the welding device during formation of the welded joint. A controller has an algorithm for determining a relative moisture using the dynamic displacement.

Abstract: A method of joining a multiple member work-piece includes stacking the members of the work-piece on a die such that a first of the members rests on the die. Next, a rivet is driven into the second member until the rivet penetrates the members and deforms. The rivet is then welded to the first member to strengthen the riveted joint. Different mechanisms may be used to accomplish the welding. For example, a laser beam may be directed through a passage in the first die to target the area of the riveted joint to be welded. Alternatively, the die set, rivet, and first member may be arranged to form an electrical circuit that welds the joint via resistance heating. An assembly of a multiple member work-piece and a rivet made according to the method is also provided.

Abstract: A fastener is provided for projection resistance welding to a panel. The fastener includes a base having a fastening element, such as a threaded stud or a nut integral therewith. Multiple projections formed integral with the base extend therefrom to engage with the panel to be welded to the panel by electric resistance welding. A groove is provided in the base facing the panel and is filled with a heat activated expandable sealer material. Upon heating of the base during the electric resistance welding, or in an oven, the sealer expands to fill and seal any gap between the base and the panel.

Abstract: An improved spot welding system for clamping and welding a plurality of workpieces at predetermined datum locations includes a clamping element, and at least one electrode. The preferred electrode(s) and element are concentrically alignable during engagement, and configured to produce an annular weld about the datum location. More preferably, the workpieces define an opening at the datum location, the element includes an insulated pin at least a portion of which is configured to pass-through the opening, and the electrode defines an inner space configured to receive the portion of the pin, when the electrode and element fully engage the workpieces.

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 for testing adhesive bond quality includes subjecting an adhesively-bonded workpiece to a known loading function. The loading function may be cyclic, linear, or nonlinear, and configured not to damage the workpiece. Response characteristics of the workpiece are measured during the loading. Measured response characteristics are compared with baseline or nominal characteristics and the adhesive bond quality is determined from the resulting comparison. A differential signal may be generated based upon the comparison of measured response and baseline characteristics and used to determine the adhesive bond quality, possibly with an algorithm. Being within the acceptable range is indicative of acceptable adhesive bond quality. The root cause of failure may be determined and a course of action based thereupon; including: localized curing, inspection, repair, and destruction. Following corrective courses of action, the workpiece may be re-tested and compared again to the baseline.

Abstract: A method for improving energy efficient operation of a vehicle includes monitoring vehicle operating characteristics, modeling operation of the vehicle by utilizing the vehicle operating characteristics to estimate energy consumption rates of the vehicle across an allowable vehicle operating range, and generating a control output to the vehicle on the basis of the energy consumption rates.

Abstract: An enhanced head-and-neck restraint system is provided for use with a vehicle having a passenger compartment with a seat assembly and a safety belt assembly mounted therein. The restraint system includes first and second collar straps each having an inflatable cushion integrated thereto. A first end of each collar strap is attached to a headrest portion of the seat assembly to transition between a retracted position, in which the collar straps are substantially inside the headrest portion, and a use position, in which each collar strap attaches to a belt webbing of the safety belt system. A fluid dispensing apparatus is in fluid communication with the inflatable cushions, and operable to selectively transition the inflatable cushions from a non-expanded state to an expanded state when the collar straps are in the use position.

Abstract: A closure assembly with a shape memory polymer seal is provided for use with a vehicle. The closure assembly includes a frame member configured for attachment to the vehicle body to selectively transition from a closed position to an open position. The seal structure includes a base portion elongated along and attached to a peripheral edge of the frame member or the vehicle body, and a flexible contact portion extending integrally from the base portion and configured for sealing communication with an opposing surface. A thermally-activated smart material (TASM), namely a shape memory polymer member, is disposed inside a cavity within the contact portion. A thermoelectric device is in thermal communication with the TASM, and is characterized by a thermal differential when current flows therethrough. The TASM is activated in response to the thermal differential of the thermoelectric device, thereby altering at least one physical property of the TASM.

Abstract: A method is provided for monitoring and controlling the process consistency of an arc welding process. The weld voltage signal is monitored and analyzed to determine the occurrence of the detachment of a weld droplet. The weld droplet detachment is determined via statistical techniques as having occurred at a normal interval following a prior detachment indicating consistent weld process or as a sporadic detachment having occurred at an irregular interval with respect to the prior detachment and indicating inconsistent weld process. The weld process is adjusted by controlling the weld process variables to maximize the predominance of droplet detachment at normal intervals and minimize the occurrence of the sporadic detachments.

Abstract: A system and method for self-piercing riveting including an alignment mechanism comprising laser diodes and sensors for facilitating alignment of a rivet gun and a back-up located on opposite sides of sheet metal parts to be joined, and an oscillation piercing technique for reducing force loads on structures, particularly robotic structures, carrying the rivet gun and the back-up.

Abstract: A staple for attaching together first and second metal sheets is made of a length of round wire bent at the ends to form spaced apart depending metal legs, each having a metal piercing point at the end thereof adapted to pierce completely through the first sheet and at least partially through the second sheet and also adapted to spread the legs further apart during the piercing to a spread position in which the legs are anchored within the metal sheets and thereby attach the metal sheets together. The metal piercing points each having an outside bevel surface on the outside of the leg, an inside bevel surface on the inside of the leg, and a blunt end surface between the inside and outside bevel surfaces.

Abstract: A method to diagnose weld integrity in a welding process includes monitoring a weld indentation characteristic, comparing the monitored weld indentation characteristic to a threshold weld indentation characteristic, and identifying a discrepant weld when the weld indentation characteristic comparison shows the monitored weld indentation characteristic violates the threshold weld indentation characteristic.

Abstract: A method to diagnose a failed weld in a welding process includes monitoring a location of a weld created on a plurality of work pieces, diagnosing the weld as a failed weld based on said location with respect to a closest edge of one of the work pieces, and identifying said failed weld based on the diagnosing.

Abstract: A sheet metal assembly includes first and second resistance weldable metal sheets having flanges extending from the sheets. The flanges overlap in parallel for a dimension. A resistance weldable metal shim is disposed between the flanges and extends to the outer edges thereof. A weld joins the metal sheets through the shim. The shim increases the mechanical strength of the assembly. The increase in mechanical strength from the shim allows for reductions to the flange width. As a result, a lighter assembly of equivalent strength is produced.