MXPA00009791A - Apparatus and method for joining vehicle frame components - Google Patents

Abstract

An apparatus and method for joining two or more vehicle components together to form a joint in a vehicle body and frame assembly 10 is disclosed. The frame assembly 10 can include a pair of longitudinally extending side rails 11, 12 having a plurality of transverse cross members 13-15 extending therebetween. At least one of the side rails 11, 12 includes a portion 21 that is deformed inwardly to define a mounting projection 24 that is sized to receive an end of one of the cross members 13-15 therein. The mounting projection 24 is preferably formed having a first relatively large diameter portion 24a that is somewhat larger in diameter than the outer diameter of the end of the cross member 13-15 and a second relatively small diameter portion 24b that is only slightly larger in diameter than the outer diameter of the end of the cross member 13-15. An internal magnetic pulse welding inductor assembly 25 is inserted within the cross member 13-15 to generate an intense electromagnetic fiel d. The presence of this electromagnetic field causes the end of the cross member 13-15 to expand outwardly into engagement with the first and second portions of the mounting projection 24a, b of the side rail at a high velocity. The high velocity impact of the end of the cross member 13-15 with the mounting projection 24a, b of the side rail 11, 12 causes some portions of the end of the cross member 13-15 and the mounting projection 24a, b of the side rail 11, 12 to weld or molecularly bond together, and causes other portions of the end of the cross member 13-15 and the mounting projection 24a, b of the side rail 11-12 to mechanically interlock or engage one anther to form a joint for the vehicle body and frame assembly 10.

Description

APPARATUS AND METHOD FOR JOINING COMPONENTS OF VEHICLE FRAMEWORK BACKGROUND OF THE INVENTION This invention relates in general to body and frame vehicle assemblies. In particular, this invention relates to an apparatus and method for forming joints between various components, such as between side rails and cross members in such body and frame vehicle assembly. Many land vehicles in normal use, such as automobiles, vans and trucks, include a body assembly and a frame that is supported on a plurality of ground clutch wheels by an elastic suspension system. The structures of the known body and frame assemblies can be divided into two general categories, namely, separate and unified. In a typical separate body and frame assembly the structural components of the body portion and the frame portion are separated and independent of each other. When assembled, the frame portion of the assembly is resiliently supported on the wheels of the vehicle by the suspension system and acts as a platform, on which the body portion of the assembly and other components of the vehicle can be mounted. Separate body and frame assemblies of this general type are found in most older vehicles, but remain in use today for many relatively large or specialized modern vehicles, such as large vans, sport utility vehicles and trucks. In a typical unified body and frame assembly, the structural components of the body portion and the frame portion are combined into an integral unit that is resiliently supported on the wheels of the vehicle by the suspension system. Unified body and frame assemblies of this general type are found in many relatively small modern vehicles such as automobiles and small vans. Each of these body and frame assemblies is comprised of a plurality of individual vehicle frame components that are secured together. In the past, virtually all of these vehicle frame components have been manufactured from a metallic material. Traditionally, steel has been the preferred material for manufacturing all vehicle frame components because of their relatively high strength, relatively low cost, and manufacturing reliability. The vehicle frame components manufactured from traditional metallic materials have been secured by conventional welding techniques. As is well known, conventional welding techniques involve the application of heat to localized areas of two metal members, which results in a crescence of the two metal members. This welding may or may not be carried out with the application of pressure, and may or may not include the use of a filler metal. Although conventional welding techniques have worked satisfactorily in the past, there are some drawbacks in the use of same for joining vehicle frame metal components together. First, as noted above, conventional welding techniques involve the application of heat to localized areas of the two metal frame members. This application of heat can cause undesirable distortions and introduce fragility in the metallic components. Second, while conventional welding techniques are well suited for joining components that are formed from similar metallic materials, it has been found that it is a little more difficult to adapt them for use in joining components formed from dissimilar metallic materials. Third, conventional welding techniques are not easily adapted to join components that have different thickness gauges. Since the production of vehicle frames is commonly a high volume and low margin process, it would be desirable to provide an improved apparatus and method for permanently joining two or more metallic vehicle frame components that avoid the drawbacks of conventional welding techniques.

BRIEF DESCRIPTION OF THE INVENTION The present invention relates to an improved apparatus and method for joining two or more components of a vehicle therebetween, to form a joint in a body and vehicle frame assembly. The frame assembly may include a pair of longitudinally extending side rails, which have a plurality of transverse cross member members extending therebetween. At least one of the side rails includes a portion that is deformed inwardly to define a mounting projection, which is dimensioned to receive an end of one of the cross member therein. The mounting projection is preferably formed having a first portion of relatively large diameter that is slightly larger in diameter than the outer diameter of the end of the cross member, and a second portion of relatively small diameter that is only slightly larger in diameter than the diameter outer end of the crossbar. An internal magnetic pulse welding inductor assembly is inserted into the crossbar to generate an intense electromagnetic field. The presence of this electromagnetic field causes the end of the cross member to expand outwardly to mesh with the first and second portions of the side rail mounting projection at a high speed. The high-speed impact of the end of the crossbar with the mounting projection of the side rail causes some portions of the end of the crossbar and the mounting projection of the side rail to be soldered or molecularly bonded together, and causes other end portions of The rail and the side rail assembly projection are mechanically interlocked or meshed with one another to form a jig for the body and vehicle frame assembly.

Various objects and advantages of this invention will become apparent to those skilled in the art from the following detailed description of the preferred embodiments, when read in light of the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a schematic perspective view of a body and vehicle frame assembly manufactured in accordance with the apparatus and method of this invention. Figure 2 is a sectional elevation view of a first modality of unites? joint between one of the side rails and one of the crosspieces illustrated in Figure 1, before being joined together by an internal magnetic pulse welding inductor according to this invention. Figure 3 is a sectional elevation view of the first embodiment of the joint illustrated in Figure 2, showing the side rail and the cross member after being joined together by the internal magnetic pulse welding inductor. Figure 4 is a sectional elevation view of a second embodiment of a joint between one of the side rails and one of the crossbars illustrated in Figure 1, before being joined together by an internal magnetic pulse welding inductor in accordance with this invention. Figure 5 is a sectional elevation view of the second embodiment of the joint illustrated in Figure 4, showing the side rail and the cross member after they have been partially joined together by means of an internal magnetic pulse welding inductor. Figure 6 is a sectional elevation view of a second embodiment of the joint illustrated in Figure 5, showing the side rail and the cross member after having been completely joined together by means of an internal magnetic pulse welding inductor. Figure 7 is a sectional elevation view of the second embodiment of the joint illustrated in Figure 4, before being joined together by an internal modified magnetic pulse welding inductor in accordance with this invention. Figure 8 is a sectional elevation view of the second embodiment of the joint illustrated in Figure 7 showing the side rail and the cross member after being joined together by means of the modified internal magnetic pulse welding inductor. Figure 9 is a sectional elevation view of a third embodiment of a joint between one of the side rails and one of the crossbars illustrated in Figure 1, before being joined together by an internal magnetic pulse welding inductor according to this invention. Figure 10 is a sectional elevation view of the third embodiment of the joint illustrated in Figure 9, showing the side rail and the cross member after they have been partially joined together by the internal magnetic pulse welding inductor. Figure 11 is a sectional elevation view of the third embodiment of the joint illustrated in Figure 10, showing the side rail and the cross member after having been completely joined together by the internal magnetic pulse welding inductor.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring now to the drawings, a body and vehicle frame assembly, generally indicated as 10, is illustrated schematically in FIG. ~~ "" .--- «- < • - - < "----" has been manufactured in accordance with the apparatus and method of this invention The illustrated body and vehicle frame assembly 10 is a ladder frame assembly.However, it will be appreciated that the apparatus and method of this invention can be used in the manufacture of any type of vehicle body and frame assembly, such as the unified body and frame assemblies where the structural components of the body portion and the frame portion are combined within an integral unit. The illustrated ladder frame assembly 10 includes a pair of longitudinally extending side rails 11 and 12, having a plurality of transverse crosspieces 13, 14, and 15 extending therebetween.The side rails 11 and 12 extend longitudinally. along the length of the assembly 10, and are generally parallel to each other.Each of the side rails 11 and 12 illustrated is formed of a single member. or unit that extends along the total length of the assembly 10. However, it will be appreciated that the side rails 11 and 12 may extend for only a portion of the length of the frame assembly 10. Alternatively, each or both of the rails Side 11 and 12 can be formed by two or more sections • A &b; & de of individual side rails that are welded or secured together in any manner to form the side rails 11 and 12. The illustrated side rails 11 and 12 are formed by open channel structural members having a generally transverse shape In the form of C. However, the side rails 11 and 12 can be formed in any desired transverse shape. In addition, as will be apparent below, the side rails 11 and 12 may be formed by closed channel structural members having any desired transverse shape. The side rails 11 and 12 can be formed of any desired material or group of materials. The crosspieces 13, 14, and 15 extend generally perpendicular to the side rails 11 and 12. The crosspieces 13, 14, and 15 are spaced apart from one another along the length of the assembly 10. The ends of the crosspieces 13 , 14, and 15 are secured to side rails 11 and 12 in respective joints, whose structures will be described and illustrated in detail later. When secured to the side rails 11 and 12, the cross members 13, 14, and 15 provide the desired stiffness to the assembly 10. Although three crosspieces 13, 14, and 15 are shown in Figure 1, it will be appreciated that a larger number can be provided. or less of such crossings. The crosspieces 13, 14, and 15 illustrated are formed by closed channel structural members, which generally have a circular transverse shape. However, the crosspieces 13, 14, and 15 can be formed having any desired transverse shape and can, if desired, be of open channel structural members. The crosspieces 13, 14, and 15 may also be formed of any desired material or group of materials. Referring now to Figure 2, a first embodiment of a joint between one of the side rails 11 and one of the cross members 13 illustrated in Figure 1 is illustrated, before being joined together. As shown therein, the side rail 11 includes a central network 21 having upper and lower flanges 22 and 23 extending therefrom. A portion of the net 21 is deformed inwardly to provide an opening defining a mounting projection of the cross member, generally indicated 24. As will be explained in more detail below, the mounting projection 24 is sized to receive one end of the crossbar 13 in it to form a joint between the side rail 11 and the crossbar 13. In the illustrated embodiment, the mounting projection 24 is generally of cylindrical configuration, corresponding to the generally cylindrical configuration of the end of the cross piece 13. However, it will be appreciated that the mounting projection 24 and the end of the cross piece 13 can have any desired configuration. The mounting projection 24 is preferably formed of a first portion of relatively large diameter 24a, and of a second portion of relatively small diameter 24b. The relatively large diameter portion 24a of the mounting projection 24 is somewhat larger in diameter than the outer diameter of the end of the crossmember 13, thus providing a relatively large annular gap therebetween as shown in Figure 2. The portion of diameter 24b The relatively small portion of the mounting projection 24 is only slightly larger in diameter than the outer diameter of the end of the cross member 13, thus providing a relatively small annular gap therebetween as shown in Figure 2. An internal brazing welding assembly is provided. magnetic pulse, generally indicated as 25, for connecting the end of the cross member 13 to the mounting projection 24 of the side rail 11. The magnetic pulse welding inductor assembly 25 is TiáaétÉá¿ ** * ^ * ^ * ^^ -. ^ L ^ - ^^ ^^ - ^^^^^^ * ^^ ^^^^ * ^ * j * ^^^^^^^^^ ^ £ you ^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^ generally conventional in the art and includes an electromagnetic coil 26 which is carried on the end of a movable support 27. the coil 26 comprises a coil of an electrical conductor 5 has lead wires 26a and 26b that extend therefrom through a switch (not shown) to a electric power source (not shown). In a manner that is known in the art, when the switch is closed an electrical circuit is formed closed through the lead wires 26a and 26b between the electric power source and the coil 26. As a result, the electric current flows through the coil 26, causing an intense electromagnetic field to be generated around it. The presence of this electromagnetic field causes the end of the cross member 13 to expand outward at a high speed until it meshes with the mounting projection 24 of the side rail 11. This high speed gear causes some portions of the end of the cross member 13 and of the mounting projection 24 are welded or molecularly bonded together, while other end portions of the cross member 13 and the mounting projection 24 are mechanically entangled with each other or interlocked between each other. yes, as shown in Figure 3. Specifically, d & Because of the relatively large size of the annular gap between the first end portion of the cross member 13 and the relatively large diameter portion 24a of the mounting projection 24, the generation of the electromagnetic field causes the first end portion of the crossbar 13 to be Accelerate through a relatively large distance to reach a relatively high speed. Since it has the ability to achieve this relatively high velocity, the outer surface of the first portion of the end of strut 13 is welded or bind molecularly with the inner surface of the portion of relatively large projection assembly 24 24th diameter. However, because of the relatively small annular gap between the second end portion of the crossbar 13 and the relatively small diameter portion 24b of the mounting projection 24, the generation of the electromagnetic field causes the second end portion of the crossbar 13 accelerate through a relatively small distance, to reach a relatively low speed. Since it does not have the ability to reach a relatively high speed, the outer surface of the second end portion of the cross member 13 will be mechanically engaged and interlock with the inner surface of the relatively small diameter portion 24b of the mounting projection 24. , but it will not be welded or molecularly bound with it. Thus, the first end portions of the cross member 13 and the mounting projection 24 are welded or molecularly joined together, while the second end portions of the cross member 13 and the mounting projection 24 are mechanically interlocked or meshed with each other. As mentioned above, the illustrated assembly projection 24 is generally cylindrical in shape, generally corresponding to the cylindrical shape of the end of the cross piece 13. However, the mounting projection 24 and the end of the cross piece 13 can have any desired shape. For example, it may be desirable in some instances to form the mounting projection 24 and the end of the cross member 13 having non-circular transverse shapes. These non-circular transverse forms would provide a capacity to a? A? To S8 reei * jst¡ei-aí ,. a - = joint, so as to resist the rotary movement of the cross member 13 relative to the side rail 11 under the influence of torsional stresses that may be encountered during use.

Referring now to Figure 4, a second embodiment of a joint between a modified structure for one of the side rails 11 'and one of the crosspieces 13 illustrated in Figure 1 is illustrated before being joined together. As shown therein, the modified side rail 11 'is a closed channel structural member including first and second networks 31 and 32 having upper and lower flanges 33 and 34 extending therebetween. A portion of the first network 31 is deformed inwardly to provide an opening defining a first cross-member mounting projection, generally indicated as 35, which is sized to receive a first end portion of the cross member 13 therein. Similarly, a portion of the second network 32 is deformed inwardly to provide an opening defining a second cross-member mounting projection, indicated generally as 36, which is sized to receive a second end portion of the cross member 13 therein. In the illustrated embodiment, the mounting projections 35 and 36 are generally cylindrical in shape generally corresponding to the cylindrical shape of the end of the cross member 13. However, it will be appreciated that the first and second mounting projections 35 and 36 and the end of the cross member 13 can have any desired shape. The first mounting projection 35 is preferably formed having a first portion of relatively large diameter 35a, and a second portion of relatively small diameter 35b. Similarly, the second mounting projection 36 is preferably formed having a first portion of relatively large diameter 36a and a second portion of relatively small diameter 36b. The relatively large diameter portions 35a and 35b of the mounting projections 35 and 36 are somewhat larger in diameter than the outer diameter of the corresponding portions of the cross member 13, thus providing relatively large annular spacings therebetween as shown in Figure 4 The relatively small diameter portions 35b and 36b of the mounting projections 35 and 36 are only slightly larger in diameter than the outer diameter of the end of the cross member 13, thus providing relatively small annular spacings between them, as shown in the Figure 4. To form the gasket, the magnetic pulse welding inductor assembly 25 is initially inserted into the end of the crossbar 13, such that ^ riM ^^ tetfub is located within the first mounting projection 35 of the side rail 11 '. Then, the coil 26 is connected to the electric power source to generate the intense electromagnetic field. In the same way, as described above, the generation of the electromagnetic field by the coil 26 causes a first portion of the end of the crossbar 13 and the mounting projection 35 to be welded or molecularly joined together, while the second portion of the The end of the crossbar 13 and the first mounting projection 35 are mechanically entangled or interlocked, as shown in FIG. Figure 5. Specifically, given the relatively large annular gap between the first end portion of the cross member 13 and the relatively large diameter portion 35a of the first mounting projection 35, the generation of the electromagnetic field causes the first end portion. of crossbar 13 is accelerated through a relatively large distance to reach a relatively high speed. Since it is capable of reaching this relatively high speed, the outer surface of the first end portion of the cross member 13 will be soldered or molecularly bonded to the inner surface of the relatively large diameter portion 35a of the mounting projection 35. However , given the relatively small annular gap between the second end portion of the crossbar 13 and the relatively small diameter portion 35b of the first mounting projection 35, the generation of the electromagnetic field causes the second end portion of the crossbar 13 to be accelerated to through a relatively small distance to reach a relatively low speed. Since it does not have the ability to reach a relatively high speed, the outer surface of the second end portion of the cross member 13 will mesh and mechanically interlock with the inner surface of the relatively small diameter portion 35b of the first mounting projection 35. , but it will not be soldered or molecularly linked with it. Thus, the first end portion of the cross member 13 and the first mounting projection 35 are welded or molecularly bonded together, while the second end portion of the cross member 13 and the first mounting projection 35 are mechanically interlocked or meshed with each other . If desired, expansion of the crossbar 13 additionally (or alternatively) will result in the creation of a cambered portion 13a. The cambered portion 13a is formed immediately adjacent and abuts the inner end of the relatively small diameter portion 35b of the first mounting projection 35. Thus, the cambered portion 13a of the cross member 13 is contiguous and mechanically interlaced or meshed side rail 11 to prevent axial removal of it. Then, the magnetic pulse welding inductor assembly 25 is now moved within the end of the cross member 13 so that it is located within the second mounting portion 36 of the side rail 11 '. Then, the coil 26 is connected to the electric power source to generate the intense electromagnetic field. In the same way as described above, the generation of the electromagnetic field by means of the coil 26 causes a third portion of the crossbar 13 and the second mounting projection 36 to be welded or molecularly joined together, while a fourth portion of the crossbar 13 and the second mounting projection 36 are mechanically interlocked or meshed with each other, as shown in Figure 6. Specifically, since the relatively large annular gap between the first end portion of the cross member 13 and the diameter portion Relatively large 36a of the second mounting projection 36, the generation of the electromagnetic field causes the third end portion of the crossbar 13 to be accelerated over a relatively large distance to reach a relatively high speed. Since it is capable of reaching this relatively high speed, the outer surface of the third end portion of the cross member 13 will be welded or molecularly bonded to the inner surface of the relatively large diameter portion 36a of the second mounting projection 36. However, since the relatively small annular spacing between the second portion of the end of the crossbar 13 and the relatively small diameter portion 36b of the second mounting projection 36, the generation of the electromagnetic field causes the fourth portion of the end of the crossbar 13 to be accelerated over a relatively small distance to reach a relatively low speed. Since it is unable to reach a relatively high speed, the outer surface of the fourth portion of the end of the cross member 13 will mesh and interlock mechanically with the inner surface of the diameter portion 36b of the second mounting projection 36, but will not weld or will bind molecularly with it. Thus, the third portion of the cross member 13 and the second mounting projection 36 are welded or molecularly joined together, while the fourth portion of the cross member 13 and the second mounting projection 36 are mechanically interlocked or interlocked with each other. Similarly, the expansion of the crossbar 13 may additionally (or alternatively) result in the creation of a second cambered portion 13b. The second cambered portion 13b is formed immediately adjacent and abuts the inner end of the relatively small diameter portion 36b of the second mounting projection 36. Thus, the cambered portion 13a of the crossbar 13 is mechanically interlocked or interlocked or meshed side rail 11 to prevent axial removal of it. Figure 7 is a sectional elevation view of the second embodiment of the gasket illustrated in Figures 4, 5, and 6 before being joined together by an internal modified magnetic pulse welding inductor, generally indicated as 25 ', of according to this invention. The modified magnetic pulse welding inductor assembly 25 'is identical to the magnetic pulse welding inductor assembly 25 described above, except that it includes an enlarged serpentine 26' which is large enough to simultaneously cause the end of the cross member 13 to be connected to both the first and the second mounting projections 35 and 36 of the side rail 11 'in the manner described above. The expansion of the crossbar 13 additionally (or alternatively) results in the creation of a single bulged portion 13c. The cambered portion 13c is formed between and abuts the inner ends of the relatively small diameter portions 35b and 36b of the first and second mounting projections 35 and 36 respectively. Thus, the cambered portion 13c of the cross member 13 is contiguous and mechanically interlocked or meshes with the side rail 11 'to prevent axial removal thereof. Referring now to Figure 9, there is illustrated a third embodiment of a joint between an additional modified structure for one of the side rails 11"and one of the crosspieces 13 illustrated in Figure 1 before being joined together. As shown therein, the modified side rail 11"is a closed channel structural member that includes first and second networks 41 and 42 having upper and lower flanges 43 and 44 extending therebetween. A portion of the first network 41 is deformed outward to provide an opening defining a first cross member mounting projection 45 that is dimensioned to receive a first end portion of the cross member 13 therein. Similarly, a portion of the second network 32 is deformed outward to provide an opening defining a second mounting projection 46 of cross member that is sized to receive a second portion of the end of the crossbar 13 therein. In the illustrated mode, the mounting projections 45 and 46 are generally cylindrical in shape, generally corresponding to the cylindrical shape of the end of the cross member 13. However, it will be appreciated that the first and second mounting projections 45 and 46 and the end of the crossbar 13 can have any desired shape. The first and second mounting projections 45 and 46 are preferably somewhat larger in diameter than the outer diameter of the corresponding portions of the end of the cross member 13, thus providing relatively larger annular spacings therebetween, as shown in Figure 9. To form the joint, the magnetic pulse welding inductor assembly 25 is initially inserted into the end of the cross member 13 so that it is positioned within the first mounting projection 45 of the side rail 11". After the ^^^^^^ coil 26 is connected to the electric power source to generate the intense electromagnetic field. In the same manner as described above the generation of the electromagnetic field by the coil 26 causes the first portion of the cross member 13 and the first mounting projection 45 to be welded or molecularly bonded together, while the second portion of the cross member 13 is intertwined mechanically or mesh with the network 41, as shown in Figure 10. Specifically, since the relatively large annular gap between the first end portion of the cross member 13 and the first mounting projection 45 of relatively long diameter, the generation of the electromagnetic field causes the first portion The end of the cross member 13 is accelerated through a relatively large distance to reach a relatively high speed. Since it is capable of reaching this relatively high speed, the outer surface of the first end portion of the crossbar 13 will be welded or molecularly bonded to the inner surface of the first mounting projection 45. However, a second end portion of the crossbar 13 is expanded inside the side rail 11"to form a portion "-" - > «••• > «• ''. . . . . . ....Item. ^ .--, ^ - »--- ^ ..... . , f] j1j ^ j_L _ ^ _ j »I warped 13d. Thus, the first portion of the crossbar 13 and the first mounting projection 45 are welded or molecularly bonded together, while the cambered portion 13d of the crossbar 13 is mechanically interlaced and interlocked or meshed with the network 41. Then, the assembly The magnetic pulse welding inductor 25 is further moved within the end of the cross member 13 so that it is located within the second mounting portion 46 of the side rail 11". Then, the coil 26 is connected to the electric power source to generate an intense electromagnetic field. In the same manner as described above, the generation of the electromagnetic field by the coil 26 causes the third portion 'of the crossbar 13 and the second mounting projection 46 to be welded or molecularly joined together, while a fourth portion of the crossbar 13 is mechanically entangled or meshed with the net 42 as shown in Fig. 11. Specifically, since the relatively large annular gap between the first end portion of the cross member 13 and the second relatively long mounting projection 46, the The generation of the electromagnetic field causes the third portion of the end of the crossbar 13 to accelerate through a relatively large distance to reach a relatively high speed. Since it has the ability to reach this relatively high speed, the outer surface of the third end portion of the cross member 13 will be welded or molecularly bonded to the inner surface of the second mounting projection. However, a second portion of the end of the cross member 13 is expanded into the interior of the side rail 11"to form a second cambered portion 13e. Thus, the third portion of the crossbar 13 and the first mounting projection 46 are welded or molecularly joined together, while the second cambered portion 13e of the crossbar 13 is mechanically interlaced and meshed or meshed with the network 42. According to the conditions of the patent statutes, the principle and mode of operation of this invention have been explained and illustrated in their preferred embodiment. However, it should be understood that this invention can be practiced in a manner different from that specifically explained and illustrated without departing from its spirit or scope.

Claims (19)

1. RE IVINDICATIONS 1. A method for forming a joint between first and second components, comprising the steps of: (a) providing a first component having an opening; (b) providing a second component within the opening of the first component; and (c) generating an electromagnetic field within the second component, causing it to expand outwardly until it joins the first component at a rate such as to be welded thereto.
2. 2. The method according to claim 1, wherein step (a) is carried out by providing a first vehicle frame component, and wherein stage (b) is carried out by providing a second vehicle frame component.
3. 3. The method according to claim 2, wherein step (a) is carried out by providing a side rail for a vehicle frame assembly, and wherein stage (b) is brought to '' "•" - ** "• - - * * * fe - mf ------ da - ^ - ^ - É-MilÉ-iiiÉ- ^ d-cabo providing a crossbar for a frame assembly vehicle.
4. 4. The method according to claim 1, wherein step (a) is carried out by providing a mounting projection extending from the opening of the first component, and wherein step (b) is carried out by providing the second component inside the assembly projection of the first component.
5. 5. The method according to claim 4, wherein step (a) is further carried out by providing a mounting projection with a relatively large diameter first portion and a relatively small diameter portion.
6. 6. The method according to Claim 5, wherein step (c) is carried out causing a first portion of the second component to expand outwardly until it is joined to the first portion of relatively large diameter of the mounting projection of the first component at such a speed that it is welded to it, and causing a second portion of the second component to be --i-i-- < -É - li? ' .-Y*. i.? s. * --- «? ..-« *. expand outwardly until it joins the second relatively small diameter portion of the mounting projection of the first component at such a speed that it is mechanically interlocked therewith.
7. 7. The method according to Claim 5, wherein step (c) is carried out causing a portion of the second component to be bent so that it rests on the mounting portion of the first component.
8. 8. The method of compliance in Claim 1, wherein step (a) is carried out by providing a first component having first and second openings, providing the second component within the first and second openings of the first component, and generating the field electromagnetic within the second component, causing it to expand outwardly until it joins the first component at such a speed that it is welded thereto.
9. 9. The method according to Claim 8, wherein step (a) is carried out ..? C ?. t- providing a first mounting projection extending from the first opening of the first component, and providing a second mounting projection extending from the second opening of the first component, and wherein step (b) is carried out providing the second component within the first and second assembly projections of the first component.
10. 10. The method of compliance with Claim 9, wherein step (a) is further carried out by providing the first mounting projection with a first portion of relatively large diameter and a second portion of relatively small diameter, and providing the second mounting projection with a first portion of relatively large diameter and a second portion of relatively small diameter.
11. 11. The method according to claim 10, wherein step (c) is carried out (c) (1) causing a first portion of the second component to expand outwardly until it is joined to the first portion of relatively large diameter of the first assembly projection of the first ^ ^ ^^ ajte M. component at such a speed that it is welded to it, (c) (2) causing a second portion of the second component to expand outwardly until it joins the second relatively small diameter portion of the first mounting projection of the first component to a speed such that it is mechanically interlocked therewith, (c) (3) causing a third portion of the second component to expand outwardly until it joins the first relatively large diameter portion of the second mounting projection of the first component at a speed such that it is welded thereto, and (c) (4) causing a fourth portion of the second component to expand outwardly until it joins the second portion of relatively small diameter of the second mounting projection of the first component at a speed that interlaces mechanically with it.
12. 12. The method according to claim 11, wherein step (c) is carried out causing a portion of the second component to be bent so that it rests on the first mounting portion of the first component. , ~ «.l. *« ?? < tí * í? lj A «* ........ -to,-. .... * *, *. ... ^ i ... and,.,
13. 13. The method according to claim 12, wherein step (c) is carried out causing a portion of the second component to be bent so that it rests on the second mounting projection of the second component.
14. 14. The method according to claim 11 wherein steps (c) (1) and (c) (2) are carried out before steps (c) (3) and (c) (4).
15. 15. The method according to Claim 11 wherein steps (c) (1) and (c) (2) are carried out simultaneously with steps (c) (3) and (c) (4).
16. 16. The method according to claim 4, wherein step (a) is carried out by providing a mounting projection extending inwardly from the opening of the first component.
17. 17. The method according to claim 4 wherein step (a) is carried out by providing a mounting projection that is Y. . . * MUttah extends outward from the opening of the first component
18. 18. The method according to Claim 1 wherein step (c) is carried out causing a portion of the second component to expand outwardly until it is joined to a first portion of the first component at such a speed that it is welded thereto, and causing a second portion of the second component to expand outwardly until it is joined with a second portion of the first component at such a speed that it is mechanically entangled therewith.
19. 19. An apparatus for forming a joint between the first and second components, comprising: means for providing a first component having an opening; means for providing a second component within the opening of the first component; and means for generating an electromagnetic field within the second component, causing it to expand outwardly until it joins the first component at such a rate that it is welded thereto. SUMMARY OF THE INVENTION The present invention describes an apparatus and method for joining two or more vehicle components together to form a joint in a body and vehicle frame assembly. The frame assembly may include a pair of longitudinally extending side rails, which have a plurality of transverse cross members extending therebetween. At least one of the side rails includes a portion that is deformed inward to define a mounting projection that is dimensioned to receive one end of one of the cross members therein. The mounting projection is preferably formed having a first portion of relatively large diameter that is somewhat larger in diameter than the outer diameter of the end of the cross member, and a second portion of relatively small diameter that is only slightly greater than the outer diameter of the end of the crossbar. An internal magnetic pulse welding inductor assembly is inserted into the crossbar to generate an intense electromagnetic field. The presence of this electromagnetic field causes the end of the cross member to expand outwardly until it joins the first and second portions of the side rail mounting projection at a high speed. The high-speed impact of the end of the crossbar with the side rail mounting projection causes some portions of the cross member end and the side rail mounting projection to be welded or molecularly bonded together, and causes other portions of the end of the cross member and the mounting projection of the sidearm to mechanically interlock or join together to form a joint for the body and frame assembly of the vehicle. ?? . l, t • «i. > , i., - í -., '. ,., ..,. »,.,,? -, .- ..». .. ... - -. ^. > «A ^ -í-,,. . - > * - .. to. .i..m * s¡¡. ^^ ...