Abstract: Active material based haptic communication and alert systems are provided. In an embodiment, a haptic alert system comprises: an active material in operative communication with a vehicle surface, the active material being capable of changing at least one attribute in response to an applied activation signal; and a controller in communication with the active material, wherein the controller is configured to selectively apply the activation signal, and wherein the vehicle surface has at least one property that changes with the change in the at least one attribute of the active material.

Abstract: A vent includes a vane configured for spatial movement, and at least one actuator in operative communication with the vane configured to spatially move the vane in at least one direction, wherein the actuator comprises an active material configured to undergo a change in at least one property upon receipt of an activation signal, wherein the change in at least one property is effective to selectively change an orientation of the vane.

Abstract: A system and method for determining vehicle wheel misalignment. The method includes accumulating the hand-wheel position using a hand-wheel sensor over a predetermined sampling period, and then comparing the accumulated hand-wheel position to previously accumulated hand-wheel positions to provide an indication of wheel misalignment. Because a vehicle will typically be driven so that the right turns will substantially equal the left turns over a sufficiently large sampling period, the accumulated hand-wheel position should average out to be about zero, unless there is a wheel misalignment which would cause the vehicle operator to continuously turn the hand-wheel in one direction when driving straight. Therefore, if the accumulated hand-wheel position exhibits a consistent algebraic deviation and shows a progressive increase over multiple sampling periods, the confidence of wheel misalignment will increase.

Abstract: According to the invention a hollow cylindrical shank of electrically conducting metal is connected to a resistance welder. A coolant supply tube passes through the shank and has an interior coolant supply passage. The coolant supply tube has an outer diameter less than the inner diameter of the hollow cylindrical shank. A weld cap seats on the shank and has a cap tip and a cap skirt that depends from the cap tip and is attached to the shank. An underside of the cap tip faces the shank and the supply tube. A coolant receiving bore formed into the underside of the weld cap extends into the cap tip to receive the coolant supply tube part way into the bore. The bore formed into the underside of the cap tip defines a bore sidewall that provides added area of heat transfer contact between the coolant and the cap tip.

Abstract: An improved cooling system for adapting to a two-component welding electrode device having a shank and cap, includes a retractable nozzle tube, a manifold, and an adjustment element for adjustably interconnecting the tube and manifold. A threaded bushing or plunger is attached to the tube and operable to adjust the distance between the interior surface of the cap and the outlet of the tube to a preferred distance. A threaded sleeve interconnects the tube and bushing for additional adjustability. The tube defines an elastically compressible bellows section, and a spacer is removably attached to the distal end of the tube for automatic adjustment of the outlet position by the cap.

Abstract: A step apparatus for a vehicle having a door and a rocker panel includes a step disposed at and in operable communication with the door, wherein the step has a retracted position in response to the door being closed and a deployed position in response to the door being at least partially open. The vehicle has a first ground clearance in response to the door being closed and the step retracted and a second ground clearance in response to the door being open and the step deployed. The first ground clearance, which is defined by the vehicle and is independent of the step apparatus, is equal to or greater than the second ground clearance.

Abstract: A friction stir rivet for use in a friction stir process is disclosed. The rivet includes a body, a mandrel, and a mechanical interface between the body and the mandrel. The body has an elongated shank, a cap at a first end, and an axial hole therethrough. The mandrel has an elongated shaft defining an axis and a head at one end thereof, the head having an effective outside diameter greater than the effective outside diameter of the shaft, the shaft being disposed within the axial hole of the body, the mandrel head being disposed at an opposite end of the body to that of the cap, and the end of the mandrel head having a substantially pointed surface aligned with the axis of the shaft.

Abstract: A reconfigurable clamp for a flexible manufacturing system comprises a body portion, a plurality of pins slidably engaged within sleeves formed in the body portion, a compression spring attached to each shaft of the plurality of pins, a reservoir comprising a magnetorheological fluid in operative communication with the plurality of pins, and an electromagnet in operative communication with the magnetorheological fluid, wherein the electromagnet selectively increases a yield stress property of the magnetorheological fluid; and a matching pressure foot.

Abstract: A load floor assembly includes a load floor and a frame. The frame supports the load floor, and the load floor is movable with respect to the frame between a first position in which the load floor is entirely located within a vehicle cargo area, and a second position in which at least a portion of the load floor extends rearward of a rear body opening. The load floor is preferably movable to a third position forward of the first position in which increased vehicle body floor space is exposed adjacent to the rear body opening. A ramp surface supports the forward portion of the load floor in the third position to prevent a cantilevered condition. The load floor preferably includes two handles that are operative to disengage a latch for selective movement of the load floor between the positions.

Abstract: According to the invention a hollow cylindrical shank of electrically conducting metal is connected to a resistance welder. A coolant supply tube passes through the shank and has an interior coolant supply passage. The coolant supply tube has an outer diameter less than the inner diameter of the hollow cylindrical shank. A weld cap seats on the shank and has a cap tip and a cap skirt that depends from the cap tip and is attached to the shank. An underside of the cap tip faces the shank and the supply tube. A coolant receiving bore formed into the underside of the weld cap extends into the cap tip to receive the coolant supply tube part way into the bore. The bore formed into the underside of the cap tip defines a bore sidewall that provides added area of heat transfer contact between the coolant and the cap tip.

Abstract: A blind rivet assembly is inserted through aligned holes provided in a top member and bottom member. The blind rivet includes a rivet head that abuts the top member and a hollow rivet shank integral with the rivet head. A mandrel includes a mandrel stem that extends thorough the hollow rivet and a mandrel head that abuts the terminal end of the rivet shank. A tool holds the rivet head in contact with the top member and forcibly withdraws the mandrel in the direction to exit the aligned holes to thereby cause the mandrel head of axially collapse and radially expand the terminal end of the rivet shank into engagement with the bottom member to thereby attach the top member and the bottom member together. Weld current is then applied to the rivet head to thereby weld the blind rivet in place.

Abstract: A method of joining a pair of overlapping workpieces, the method includes: inserting a filler material between the pair of overlapping workpieces; applying a pressure to at least one of the workpieces so that the filler material is crushed; and joining the two workpieces together in a region defined by the filler material. A welded joint includes: a pair of overlapping workpieces; and a filler material that is made from a material whose comparability has been established by the American Welding Society, and the filler material is a porous material.

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 sliding load floor assembly for a motor vehicle comprises a sliding platform configured to receive a load floor and slidable along a support frame fixed to the vehicle. The support frame includes upper and lower flanges. An axle extends outward from the sliding platform, with a roller rotatably attached thereto and movable along the upper and lower flanges. The roller configuration elevates the sliding platform above a vehicle floor, while allowing the sliding platform the move between a stowed position and an extended position. A wedge is configured to exert a vertical force upon a portion of the sliding platform in the stowed position, thereby preventing vertical movement of the roller to reduce vibration. At least one detent member and at least one latch member are selectively engageable with one another to restrict movement of the sliding platform with respect to the support rail.

Abstract: A friction stir nut is disclosed. The friction stir nut includes a body, a cap, and an anti-rotation feature. The body has an elongated cylindrical shank extending between a first end and a second end, the cap being disposed at the second end, and the anti-rotation feature being disposed at the cap and/or an outer surface of the body. The body and cap have a blind axial hole extending from the first end to the second end, the first end being blind and the second end being open. The outer surface of the first end has a flat surface oriented substantially perpendicular to the axis of the shank, and the body has a cylindrical wall thickness suitable for receiving internal threads. In response to a mandrel tool friction stir welding the friction stir nut to a workpiece and then being extracted, uniform internal threads result at the body. The anti-rotation feature bonds to the workpiece by metallurgical bonding and/or mechanical bonding.

Abstract: A fixture device generally includes a base member, a reconfigurable pad disposed on the base member, wherein the reconfigurable pad comprises a shape memory material configured to selectively conform to a surface contour of a workpiece, and an activation device in operative communication with the shape memory material.

Abstract: A process generally includes contacting a surface of at least one workpiece with a reconfigurable pad of a fixture device, wherein the reconfigurable pad comprises a shape memory material configured to conform to the surface of the at least one workpiece, and fixturing the contacted workpiece.

Abstract: A latch assembly includes a plunger having a ramp and a lip, with a support member defining an opening through which the plunger extends. A support surface partially defines the opening and supports the plunger. The plunger is selectively movable between an extended position, in which the plunger protrudes a first distance from the opening, and a retracted position, in which the plunger protrudes a second distance from the opening, with the second distance being less than the first distance. In the extended position, the ramp and the lip are on a first side of the opening. In contrast, in the retracted position, the ramp and the lip are on a second side of the opening, with the lip engaging the support member to maintain the retracted position.

Abstract: The present invention is directed to an improved laminated, sound damping resistance weldable composite and a method for its manufacture. The metal composite structure (10) features two metal members (12)(14) sandwiching a viscoelastic layer (26) where the viscoelastic layer entrains electrically conductive particles (28). Barrier elements (32) (34) are disposed between the metal members and the viscoelastic layer to inhibit and/or prevent contaminant migration into the metal from the viscoelastic layer and/or conductive particles during welding.

Abstract: An improved spot welding tip is adapted for welding a set of adjacent members within a heated zone during a welding program, wherein a quantity of energy is produced, and for reducing the final base temperature of the heated zone. The tip presents a distal engaging surface for contacting one of the members and defines a preferably inner space located a preferred distance from the surface. A phase changing body is releasably retained within the space. At least a portion of the body changes from a first phase to a second phase by absorbing at least a portion of the heat energy during the welding program.