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 method of welding and a projection weld bond system is disclosed. A first workpiece is provided that is made of a material that conducts electricity, and a second workpeiece is provided that is made of a material that conducts electricity and has a plurality of projections formed therein. A materail is applied between each projections of plurality of projections, the material having electrical conductivity that is lower than the conductivity of the second workpiece. An area of the first workpiece is disposed at the plurality of projections of the second workpiece, and electricity is conducted through the first workpiece and through at least one of the plurality of projections of the second workpiece.

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 blind rivet system including a number of parts to be joined that have aligned holes. A tubular rivet body is disposed in the aligned holes and includes a rivet head portion and a sleeve portion. The head portion and sleeve portion include a longitudinal bore. A mandrel having a head portion greater in diameter than the bore and a shaft portion is disposed within the longitudinal bore. An adhesive is disposed in an annular space defined by the interior surface of the bore and an exterior surface of the shaft portion. An installation tool having a seal intersects with the rivet head portion such that when the head portion is drawn within the bore during installation, the adhesive is maintained within the tubular rivet body and extruded from the annular space to a region between faying surfaces of the parts to be joined.

Abstract: A friction stir rivet is rotated and driven through a first fusible workpiece into an engaged second fusible workpiece, causing local portions of the first and second workpieces to plasticize. A slideable cap contacts the exposed surface of the first workpiece shortly after the process begins. The contact causes the cap to act as a retaining element, limiting the escape of plasticized material from stir site. Once the rivet is driven into the first and second workpieces, rotation ceases and the plasticized material hardens around the rivet. A weld is thus created, joining the workpieces and encompassing the rivet, which provides additional mechanical strength.

Abstract: A layered switch assembly permits more than one electric circuit function to be obtained from each of a set of switches used to control electric circuit functions such as the operation or adjustment of seats, mirrors or other components in an automotive vehicle passenger compartment. A group of switches for operator control is embedded in an armrest, console, or the like. Overlying the discrete switches are two or more flexible sheet or membrane layers for selective activation of one or more of the switches. Illuminated indicia on each switch activation layer identify the underlying switch operation. The uppermost layer controls the electrical switch function unless that layer has been moved aside to expose the next lower switch function activation layer.

Abstract: A seat belt status monitoring system for use with one or more seat belts of an automotive vehicle. The system includes a status monitor incorporated into the seat belt buckle and has a receiver and operator signaling device located in the instrument panel. The status monitor utilizes a piezoelectric element to generate an electrical signal that is fed to a transmitter to generate a wireless signal from the buckle. A mechanical sensing member is used to activate the piezoelectric element to generate its electrical signal by imparting a mechanical force on the piezoelectric during insertion and removal of the seat belt tongue from the buckle. A microswitch in the buckle is used by the transmitter to determine whether the seat belt is latched or unlatched, and this information is conveyed by the transmitted wireless signal.

Abstract: A friction stir rivet having a body, a mandrel, and a mechanical interface therebetween, is disclosed. The body has an elongated cylindrical 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 flat surface oriented substantially perpendicular to the axis of the shaft. The mechanical interface between the body and the mandrel is such that the body rotates in response to rotation of the mandrel.

Abstract: A method for adjusting a plurality of vehicle cockpit devices via a two-part process that utilizes device position constraints to determine candidate arrangements and then, ultimately, recommended arrangements of the vehicle cockpit devices to determine a desired setting of the various devices. The position constraints are determined using positioning data obtained from an occupant. An exploratory search routine is used to determine the candidate arrangements with the cockpit devices being moved to each candidate arrangement so that the occupant can be queried concerning the desirability of each such arrangement. The occupant's responses are then stored for later retrieval. Thereafter, a plurality of recommended arrangements of the cockpit devices are determined using a meta-heuristic pattern search along with a neural network search accelerator that permits screening of each recommended arrangement.

Abstract: Friction stir fastener equipment and method in which a series of friction stir rivets are rotatably mounted in a supply station and a computer controlled arm terminating in a rotating working head having special gripping jaws that precisely locates and grips a selected rivet. The arm then moves the rotating rivet and progressively drives it into the work until a frictionally heated and plasticized zone of material around the shank of the rivet begins to solidify. The jaws then release the rivet from the drive so that the rivet rotation decelerates to zero. Sufficient hardening of the zone effects the completion of one stir riveting cycle which may be automatically repeated.

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: A reconfigurable clamp for providing support for a variety of different body panel configurations employed in the vehicle assembly without requiring manual adjustment or reprogramming. The clamp includes an adjustable contact portion comprising a plurality of pins slidably engaged within sleeves formed in a body portion. The pins include a head portion and a shaft portion extending from the head portion, wherein the shaft portion has an engageable portion. The clamp further comprises a plurality of slidably mounted rods disposed generally transverse to the movement of the pins within the sleeves. The slidably mounted rods have a complementary engageable portion that lockingly engages the engageable portion of the shaft portion upon contact therewith to selectively prevent further movement of the pins within the sleeves, such as may be desired once a workpiece is loaded onto the clamp.

Abstract: Reconfigurable clamps, clamp systems are disclosed herein that are suitable for a flexible manufacturing process such as, for example, in the manufacture of automotive body panels. The reconfigurable clamp generally includes a body comprising a sleeve extending into a stationary portion and through a rotatable portion, wherein the rotatable portion includes a slot opening coaxially aligned with the sleeve, and wherein the slot opening comprises a termination point; a shaft fixedly attached to the rotatable portion; and a pin disposed in sliding engagement with the sleeve, wherein the pin comprises a head, a shaft extending from the head, and a compression spring in operative communication with the shaft and the stationary portion, wherein the shaft further comprises an engageable portion adapted to lockingly engage the termination point upon rotation of the rotatable portion.

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: Disclosed herein is a strut assembly 10 comprising a housing 2; a piston 3 in slideable communication with the housing 2; an actuator 16 in operative communication with the piston 3 and/or the housing 2; wherein the actuator 16 is adapted to change the location of the housing 2 from a first position to a second position and/or change in a stroke length of the piston 3. Disclosed herein too is a method for changing the strut length of a strut assembly 10 comprising activating an actuator 16 that is in operative communication with a housing 2 or a piston of the strut assembly 10; and changing in the location of the housing 2 from a first position to a second position and/or changing a stroke length of the piston 3.

Abstract: A rivet and method for riveting metal members, and particularly, metal sheets is disclosed. The apparatus includes a rivet assembly for driving a piercing rivet into stacked metal sheets and a die for assisting in supporting the sheets during driving of the rivet and for assisting in securing the rivets to the sheets. The rivet of the invention includes an adhesive that is forced through passages in the rivet for assisting in fastening the rivet to the sheets and for assisting in fastening the sheets to each other with greater strength.

Abstract: A layered switch assembly permits more than one electric circuit function to be obtained from each of a set of switches used to control electric circuit functions such as the operation or adjustment of seats, mirrors or other components in an automotive vehicle passenger compartment. A group of switches for operator control is embedded in an armrest, console, or the like. Overlying the discrete switches are two or more flexible sheet or membrane layers for selective activation of one or more of the switches. Illuminated indicia on each switch activation layer identify the underlying switch operation. The uppermost layer controls the electrical switch function unless that layer has been moved aside to expose the next lower switch function activation layer.

Abstract: A method of welding includes: providing a first workpiece that is made of a material that conducts electricity; providing a second workpiece that is made of a material that conducts electricity and has a plurality of projections formed therein; applying a material between each projection of the plurality of projections, the material having an electrical conductivity that is lower than the conductivity of the second workpiece; disposing an area of the first workpiece at the plurality of projections of the second workpiece; and conducting electricity through the first workpiece and through at least one of the plurality of projections of the second workpiece.

Abstract: Friction stir fastener equipment and method in which a series of friction stir rivets are rotatably mounted in a supply station and a computer controlled arm terminating in a rotating working head having special gripping jaws that precisely locates and grips a selected rivet. The arm then moves the rotating rivet and progressively drives it into the work until a frictionally heated and plasticized zone of material around the shank of the rivet begins to solidify. The jaws then release the rivet from the drive so that the rivet rotation decelerates to zero. Sufficient hardening of the zone effects the completion of one stir riveting cycle which may be automatically repeated.

Abstract: This invention provides a design of an adhesive encapsulated blind rivet for joining an assembly of overlying parts having an accessible side and an inaccessible side. The rivet comprises a rivet head and tubular rivet body. A mandrel is inserted through the open end of the tubular rivet body and through a mandrel hole in the rivet head. A mandrel head engages the end of the tubular body. The tubular body is filled with a mass of latent adhesive around the mandrel. The rivet body is longer than the thickness of the parts to be joined to accommodate a substantial amount of adhesive for expulsion through holes in the rivet body located within the thickness of the assembled parts. The portion of the rivet body extending beyond the blind side of the assembled parts is weakened in a pattern of corrugations or other bands for folding of the end of the tubular body in setting the blind side of the rivet and expelling the larger quantity of adhesive against and between the riveted parts.