Abstract: An auxiliary step and hand hold system for accessing a vehicle. The system includes at least one auxiliary step, at least one hand hold shaped to assist a climb into the trailer, and at least one pocket shaped to removably receive the at least one hand hold. The auxiliary step may be a rotating-retractable step that rotates between a use position and a stowed position. The hand hold is shaped to assist a climb into the cargo bay and may be inserted into the pockets in a use position and a stowed position. One or more stationary steps can also be used in connection with a preferred embodiment of the present invention. The hand holds, pockets and auxiliary steps may be used alone or in combination to assist with access to a vehicle.

Abstract: A box-type frame member assembly, and a method for assembling the box-type frame member. A first section, having a web, a pair of flanges and a number of holes with locators, is placed onto a fixture assembly with the holes fitting onto pilots. A spacer is placed over each of the pilots and engaged with the locator of the respective hole in the first section. A second section, having a web, a pair of flanges, and a number of holes with locators, is then placed onto the fixture assembly with the holes fitting onto the pilots, and second end of each spacer is engaged with the locator associated with the web of the second section. Finally, the flanges of the first and second sections are secured together.

Abstract: A pocket mounts just below a trailer's rear door to securely anchor a post. This mounting provides a solid three or four-point-contact when climbing into a trailer. A second pocket mounted to the inside of the trailer door provides easy and convenient storage. The handle-post may simply be lifted from one pocket, and dropped into the other, thus clearing passage for the door swing, while storing the handle post right at the point-of-use.

Abstract: An auxiliary step and hand hold system for accessing a vehicle. The system includes at least one auxiliary step, at least one hand hold shaped to assist a climb into the trailer, and at least one pocket shaped to removably receive the at least one hand hold. The auxiliary step may be a rotating-retractable step that rotates between a use position and a stowed position. The hand hold is shaped to assist a climb into the cargo bay and may be inserted into the pockets in a use position and a stowed position. One or more stationary steps can also be used in connection with a preferred embodiment of the present invention. The hand holds, pockets and auxiliary steps may be used alone or in combination to assist with access to a vehicle.

Abstract: A frame rail assembly configured for use in various applications, including automotive vehicles. The frame rail assembly includes two rail portions. The rail portions include apertures each encompassed by a mounting boss. In addition, the frame rail includes spacers sized and configured to receive the mounting bosses in a snug fit to help with alignment. The spacers include at least one dimple in order to guide a mounting bolt though the apertures. The mounting bolt may be employed to hold the frame rail assembly together and attach other components to the frame rail assembly.

Abstract: Link arms for use in suspension systems are produced through an extrusion and friction stir welding process. Blocks having an eye and a planar body section are formed through an extrusion process. These sections are then paired together and joined through friction stir welding. The welded joint(s) is/are positioned in such a location so as to not impact the structural integrity of the completed component. Through this process it is possible to construct cost competitive link arms having the same or better structural integrity as previously employed steel link arms while achieving dramatic weight reductions.

Abstract: A versatile vehicle frame and method of making which includes a plurality of substantially straight, horizontal members connected with connecting hips having complex geometries. All contours and curves are incorporated into these hips, thus allowing the remainder of the frame to utilize substantially straight members. The vehicle frame permits a variety of frame lengths and widths by providing a variety of straight members having differing lengths. This versatility results in significantly reduced manufacturing costs and model flexibility mid-program.

Abstract: A rear vehicle frame is formed by placing a plurality of sheet members in a die in a press. At least some of the sheet members partially overlap other of the members. The press is then closed, thereby interlocking the members to form a rear vehicle frame having first and second siderails and at least one crossmember extending between the siderails. The method may include other steps and/or features. After the step of forming a rear vehicle frame, the respective rear siderails may be attached to first and second front siderails. The first and second siderails may overlap a portion of the first and second front rails, at least one of the first and second front rails comprising a scallop at the overlapped portion. The front siderails may each have an upper front siderail and a lower front side rail. There may be a step in between the center siderails and the lower front siderails. At least one of the upper front siderails has a scallop at one edge.

Abstract: A multi-piece siderail is fabricated for use as a truck frame which has potential cost and weight reductions while also providing superior weight loading characteristics. Each section of the multi-piece siderail includes a webbed portion having longitudinal ribs that form alternating protruding and recessed sections. An upper and a lower flange are provided on each section and each flange is formed with a stepped, lipped configuration. The unique structure of each section provides increased rigidity and support to that section and also allows for a nesting arrangement between each of the three components. Furthermore, this structure provides multiple attachment zones throughout the frame—two zones on each flange and three zones on the front and rear section webs and five zones on the center section web. Each of these attachment zones are surrounded by a work hardened corner to provide reinforcement.

Abstract: A method of connecting elements in a vehicle frame includes fixing the elements in a desired orientation, positioning dies to surround a portion of each element, and introducing material into the die cavity thereby casting a node around the elements.

Abstract: A method of welding together a motor vehicle structural assembly is available. The vehicle structural assembly includes a boxed member including an outboard wall, a top wall, a bottom wall and an inboard wall spaced from the outboard wall. The inboard wall has an opening therein. The motor vehicle structural assembly also includes a cylindrical support including a first end and a shoulder spaced from the first end at least the distance the boxed member inboard wall is spaced from the boxed member outboard wall. The method comprises spinning the support and advancing the support through the inboard wall opening so that the support first end is friction welded to the outboard wall and so that the support shoulder is friction welded to the inboard wall.

Abstract: A method for forming a structural member, the method comprising the steps of placing a first sheet member having a length dimension greater than a width dimension in a press, placing a second sheet member having a length dimension greater than a width dimension in the press, the second member only partially overlapping the first member, the first member only partially overlapping the second member, and the direction of the length dimension of the second member being angled relative to the direction of the length dimension of the first member, and closing the press to shape the first member and the second member.

Abstract: A method for forming a structural member, the method comprising the steps of placing a first sheet member having a length dimension greater than a width dimension in a press, placing a second sheet member having a length dimension greater than a width dimension in the press, the second member only partially overlapping the first member, the first member only partially overlapping the second member, and the direction of the length dimension of the second member being angled relative to the direction of the length dimension of the first member, and closing the press to shape the first member and the second member.

Abstract: A vehicle frame (200) has a rear portion with a rear siderail (204) of hat-shape cross-section, and a front portion with a front siderail (202) of C-shape cross-section received within the hat-shaped rear side-rail. The siderails are attached to each other at a joint (206) and have respective vertical sections (208) and (210) in overlapped contact with each other at the joint and providing a first mounting pad (230) of increased stock thickness. A cross member (226) is attached to the siderails at the joint and has a vertical flange (228) in overlapped contact with a respective vertical section (214) of the rear siderail to provide a second mounting pad (232) of increased stock thickness. A spring hanger (218) is mounted to and extends horizontally between the mounting pads.

Abstract: A manufacturing method and facility for applying a coating to vehicle structural components such as frames, provides unloading and stacking below the unloading station. Oscillation of the vehicle structural component in the coating liquid in the dip tank provides accelerated heat transfer, and also improves coating by eliminating air pockets. A bent carousel arm or a parallelogram linkage provides uniform coating action. Reverse travel sequencing minimizes space requirements.

Abstract: A manufacturing method and facility for applying a coating to vehicle structural components such as frames, provides unloading and stacking below the unloading station. Oscillation of the vehicle structural component in the coating liquid in the dip tank provides accelerated heat transfer, and also improves coating by eliminating air pockets. A bent carousel arm or a parallelogram linkage provides uniform coating action. Reverse travel sequencing minimizes space requirements.

Abstract: A manufacturing facility (20) has substantially reduced space requirements for applying a coating to vehicle structural components such as frames (22, 24). A rotary carousel (28) in a building (26) has a central hub (30) rotatable about a vertical axis and has one or more arms (32) thereon swingable about pivot points (60) on the hub to lower and raise the frames. A loading station (36), preheat wash station (46), rinse station (48), coating station (38), post heat drip station (50) and unloading station (44) are peripherally spaced around the hub such that rotation of the hub moves the arms between the stations for respective functions.

Abstract: A manufacturing method and facility for applying a coating to vehicle structural components such as frames, provides unloading and stacking below the unloading station. Oscillation of the vehicle structural component in the coating liquid in the dip tank provides accelerated heat transfer, and also improves coating by eliminating air pockets. A bent carousel arm or a parallelogram linkage provides uniform coating action. Reverse travel sequencing minimizes space requirements.

Abstract: A truck frame (10) supports the non-continuous structural components of a truck, including a front cab (12) and a rear load box (14). The truck frame includes a front frame (16) supporting the front cab, and a rear frame which is split into a front portion (70) supporting the front cab (12) and the rear load box (14), and a rear portion (72) supporting the rear load box (14). The front and rear portions of the truck rear frame have siderails (74, 76, 78, 80) which are separately formed structural components attached to each other at joints (82, 84) at the rear spring front hangers (48, 54).

Abstract: A manufacturing facility (200) has substantially reduced space requirements for applying a coating to vehicle structural components such as frames (202). A coating tank (204) has a housing (234) with a specially configured slot (238) allowing passage therethrough of a cable (218) of a winch pulley (216) which translates along a support beam (214) of a jib crane (208) having a central hub (210) rotational about a vertical axis (212). An arm (220) pivots about a horizontal pivot axis (232) at the hub (210) below the support beam (214) to lower and raise the frame (202) into and out of the horizontal coating tank (204).