Ford Global Technolgoies, LLC

Gerald J Heath

Michael Musa Azzouz

John Wayne Jaranson

Larry Dean Elie

Timothy Jay Potter

Robert F Novak

Jeff A Wallace

David Anthony Wagner

Evangelos P Skoures

Xiaoming Chen

Jeffrey Michael Hatt

John Joseph Uicker

Sunil K Kasaragod

Sanjay Mehta

Patrick Marchena

Allen Li

Jeffrey A Wallace

Harvey Krage

Jeff Michael Hatt

Tsung-Hsiun Li

An inner mandrel for forming a variable taper component includes a plurality of interlocking pieces and a brace. Each interlocking piece defines opposed tapered edge faces, a first surface, and a tapered second surface opposite the first surface. One of the edge faces defines a locking feature and another of the edge faces defines a receiving feature engaging the locking feature of an adjacent interlocking piece. The first surface defines a variable taper and a plurality of recesses. The brace secures the plurality of interlocking pieces to each other in a concentric arrangement about a central axis. A maximum width of each of the interlocking pieces is smaller than a minimum width of an end portion of the variable taper component. A central portion of the variable taper component is wider than the end portions.

Permanent tooling for composite coil spring compression molding

An inner mandrel for forming a variable taper component includes a master insert and a plurality of interlocking pieces. The master insert includes opposed tapered edge faces, each tapered edge face defining at least one locking feature, a first surface having a variable taper and a plurality of recesses configured to receive a portion of the variable taper component, and a tapered second surface opposite the first surface. Each interlocking piece includes opposed tapered edge faces, one of the opposed tapered edge faces defining a locking feature and another of the opposed tapered edge faces defining a receiving feature to engage the locking feature of an adjacent interlocking piece, a first surface defining a variable taper and a plurality of recesses configured to receive a portion of the variable taper component, and a tapered second surface opposite the first surface.

A friction stir welded assembly includes a first workpiece having an interior portion with opposed interior walls, a second workpiece having an interior portion with opposed interior walls, and an insert positioned within the interior portion of the first workpiece and the interior portion of the second workpiece. The insert extends between and abuts at least one of the opposed interior walls of the first workpiece and the opposed interior walls of the second workpiece and a friction stir weld is between the first workpiece to the second workpiece. A joining end of the first workpiece and a joining end of the second workpiece form a butt joint or a lap joint between the first and second workpieces, and the friction stir weld is a butt weld or a lap weld, respectively, between the first and second workpieces.

Inserts to enable friction stir welding joints and methods of forming friction stir welded assemblies

Tooling for use in forming a variable taper component is provided. The tooling includes an inner mandrel and an outer mandrel disposed around the inner mandrel. The inner mandrel includes a master insert defining opposed tapered edge faces, an external surface having a variable taper and a plurality of recesses configured to receive at least a portion of the variable taper component, and a tapered internal surface. The inner mandrel also includes a plurality of interlocking pieces arranged concentrically around the master insert, and a tapered inner sleeve disposed against the tapered internal surfaces of the plurality of interlocking pieces and the master insert. The outer mandrel defines a corresponding plurality of recesses configured to receive at least a portion of the variable taper component, wherein a maximum width of the interlocking pieces and the master insert is smaller than a minimum width of ends of the variable taper component.

A vehicle door system is disclosed. The system comprises an actuator, a power source, and a controller. The actuator is configured to adjust a position of a door. The controller is configured to control the actuator with energy provided by the power source. The controller is further configured to identify a charge level of the power source and compare the charge level to at least one threshold. In response the charge level being less than the at least one threshold, the controller is configured to output a warning signal.

Power management for vehicle door system

A hinge assembly for mounting a door to a frame of a motor vehicle includes (a) a hinge bracket, having a first receiver and a second receiver, (b) a hinge pin pivotally connecting the door to the hinge bracket at the first receiver, (c) an actuator, having an output shaft, (d) a retention feature, connecting the output shaft to the hinge bracket at the second receiver, and (e) an actuator mounting feature securing the actuator to the door. A method of assembling an actuator in a hinge assembly that mounts a door to a frame of a motor vehicle is also provided.

Hinge assembly and method of assembling an actuator to a hinge assembly

A door assist system for a vehicle is disclosed. The system comprises an actuator configured to control a position of the door about a hinge assembly. An interference sensor forms a portion of a door opening seal and is configured to detect an obstruction in a plurality of detection regions. The system further comprises a controller configured to control the actuator in response to a detection signal from the interference sensor.

Seal based object detection for vehicle door assist system

A mounting assembly for a vehicle side door motor includes an upper hinge element configured for receiving a side door motor drive shaft and a motor mounting bracket configured to receive the side door motor drive shaft and to allow a radial adjustment of the drive shaft for alignment of an axis of the motor with a side door hinge axis. The upper hinge element may define a clevis including a lower clevis portion having a motor drive shaft mounting aperture dimensioned to allow the radial adjustment feature. The motor mounting bracket includes one or more mounting apertures dimensioned to allow a vehicle fore/aft adjustment and in/out adjustment of the side door motor element. The motor mounting assembly is further configured to allow a vehicle up/down adjustment of the side door motor.

Mounting and aligning a vehicle side door motor within the current bill of process

A sub-frame assembly supports a pair of wheels on a vehicle. The base may be an extrusion having a matrix of panels extending in a vertical direction. The sub-frame assembly has control arm brackets disposed on opposing ends of the base and attachment towers extending above the brackets providing attachment points to connect portions of an independent suspension to the vehicle and support a pair of wheels. The base, control brackets and attachment towers may be individual modular pieces. Left and right hand control brackets and attachment towers may be provided by respective unitary support pieces attached to opposing ends of the base. The unitary support pieces may be extrusions having panels extending in a transverse direction, nonaxial to the base. The base, control arm brackets and attachment towers, alternatively, may be provided by a single unitary extrusion having a matrix of panels extending in a transverse direction.

Extruded metal sub-frame for a vehicle

Power Management for vehicle door system

A motor vehicle sub-frame is provided. That motor vehicle sub-frame includes a front cross member, a rear cross member and first and second side rails connected to the front and rear cross members at each side of the sub-frame. The side rails both include a first component having a first extrusion axis and a second component having a second extrusion axis. The first and second components are joined together so that the two components effectively form an at least partially closed or boxed construction providing enhanced bending and torsion resistances while minimizing component weight.

Extruded multi-component motor vehicle sub-frame

A method of closing a vehicle door includes the steps of providing a door pivotally coupled to a vehicle body, transmitting a door closing signal to a controller, identifying a current position of the door using a position sensor, closing the door using a power assist device powered from a hinge axis of the door, monitoring the door position during closing, releasing a catch of a latch mechanism when a latch striker of the vehicle body is partially received in the latch mechanism, and latching the door to the vehicle body.

Automotive door power assist

A vehicle door controller is disclosed. The vehicle door controller is in communication with an actuator configured to control a door and is further in communication with a temperature sensing device. The controller is configured to receive a temperature signal from the temperature sensing device. Based on the temperature signal, the controller is configured to identify an actuator condition. In response to the actuator condition, the controller is configured to control the actuator to move the door to a resting position.

Temperature control for powered vehicle doors

A vehicle includes a door rotatably coupled to a vehicle body, wherein a power assist device is coupled between the door and the vehicle body on a hinge assembly. An audio sensor is disposed on the vehicle and is operably coupled to a controller. The controller is configured to receive voice command data from the audio sensor via a signal, identify a control command correlating to the voice command data, and output a signal to the power assist device to move the door according to parameters defined within the control command.

Active door operation based on voice commands

A bi-directional element drive system includes a motor having a drive shaft, a cable anchor and a cable connector. The cable connector is carried on the drive shaft and has two ends connected to the cable anchor. In addition the drive system includes a support and a driven element. The driven element is displaced between a first position and a second position relative to the support by the motor.

Growing community of inventors

Allen Park, MI, United States of America

Gerald J Heath