InnoSys Tensioning Process Presented to: Ford Motor Co 29Feb08 Patented and Patents pending

Reduces Cost ► Eliminates self adjust mechanisms ► Reduces standard processing time and cost by combining pre-stretch and adjustment in one process

Reduces Warranty Cost ► Accurate & repeatable tensioning process eliminates tension related warranty

Simplifies Plant Processing ► Pre-stretch and adjustment are combined into one operation. ► Operator installs the tool onto the adjuster nut and is then free to perform other operations while the system is tensioned

InnoSys Tensioning System Process Explanation

Typical Tension Controlled Process

Flat part of curve where the slack is being removed Transition area where the brakes are starting to drag Steep part of curve, brakes are fully engaged and building clamp load

Typical Tension Controlled Process Flat part of curve where the slack is being removed Transition area where the brakes are starting to drag Here is the ideal tension for a properly adjusted park brake. The slack is removed and the brakes do not drag

Typical Tension Controlled Process

Normal Measurement Variation

Typical Tension Controlled Process Normal Measurement Variation Results in large travel variation

InnoSys Tensioning Process The Innosys method targets high loads in the steep part of the travel – tension curve. Tensioning in the steep part of the curve reduces travel variation and effectively pre- stretches the cable system. Ideally this target should set to the normal max operating force. Measurement variation

InnoSys Tensioning Process The InnoSys process holds the nut away from the equalizer transfering the cable force to a load cell that is located directly inline with the cable. This results in very accurate tension measurements which translates into low travel variation

InnoSys Self Tensioning Process

InnoSys End Effector Operation

InnoSys End Effector Operation Tool Released

Locking balls are in released position so the nut can be installed or removed from the tool

InnoSys End Effector Operation Tool Released Locking balls in the released position

InnoSys End Effector Operation Tool Cocked Once the shaft is pushed back far enough the release ring pushes the locking balls inward and locks the piston in the retracted position When the shaft is pushed back float sleeve will push the locking balls inward and lock the nut in the nose of the tool holding the nut away from the equalizer

InnoSys End Effector Operation Direct Inline Tension Measurement Load Internal load cell gives a direct and accurate measurement of the cable force Once locked in position the nut is held away from the equalizer which transfers the cable tension through the inputshaft back to the load cell. This direct inline measurement results in very accurate cable tension measurements. Inputshaft Load Cell

InnoSys End Effector Measurement Accuracy % Error Between Internal Load Cell and Actual Cable Force This graph demonstrates the ability of the Innosys tool to measure the cable force with exceptional accuracy

InnoSys Tensioning System Sequence of Operations 1.Operator loads nut into nose of tool and cocks tool locking the nut in the tool which holds the nut away from the equalizer. 2.Operator installs anti-rotation device onto threaded rod 3.Operator presses start trigger and is then free to perform other tasks 4.PLC commands nut runner to run fast forward until the run fast target is achieved. 5.PLC then commands nut runner to run slow until target tension is achieved 6.PLC watches force in load cell and restarts nut runner if system relaxes 7.PLC continues to retension system until tension stabilizes 8.Once the cable force stabilizes the PLC commands the nut runner to back off a specified distance. 9.Operator releases tool by pulling release ring.

InnoSys Tension Controlled Process Summary ► Action 1 – End effecter is placed on the nut ► Action 2 – Operator cocks the end effecter. In doing so the nut is securely captured and positioned away from the equalizer. This allows the ► Action 3 – Operator presses start trigger and the nut is run up the threaded rod until the target tension is achieved. Setting the target tension to a force that is close to the max system operating tension accurately measured directly in line with the cable axis because the nut is held away from the equalizer and the tool’s internal load cell is located in line with the cable axis. ► Action 3 – Once pre-stretch tension is achieved and stable, a specific amount of tension is removed from the cable system through a combination of running reverse revolutions and returning the nut to the equalizer. The operator un-cocks the tool to release the nut and return it to the equalizer. Process is now complete.

InnoSys Self Tensioning Process

InnoSys Tensioning System Plant Capability Data Setting target force to the max normal operating force reduces variation

InnoSys Self Tensioning Process ► Plants Currently in Production  Shreveport - October 2003  Flint - November 2003  Doraville - June 2004  Wilmington - September 2005  LDT – August 2006 ► Plants Being Tooled for Production  Cami – Spring 2008  Spring Hill – Spring 2008  7 GMT900 Truck Plants – Spring 2009