U.S. patent application number 11/000810 was filed with the patent office on 2006-06-01 for suspension system having high strength arm to axle connection.
Invention is credited to Thomas N. Chalin.
Application Number | 20060113741 11/000810 |
Document ID | / |
Family ID | 36565948 |
Filed Date | 2006-06-01 |
United States Patent
Application |
20060113741 |
Kind Code |
A1 |
Chalin; Thomas N. |
June 1, 2006 |
Suspension system having high strength arm to axle connection
Abstract
A suspension system having a high strength arm to axle
connection. In a described example, a suspension system includes a
laterally extending axle and an arm assembly welded to the axle.
The arm assembly includes a longitudinally extending arm body
having top and bottom surfaces, an axle connector welded to the
axle and an end of the arm body, and a plate extending
longitudinally over and welded to the arm body top surface, wrapped
rearwardly about and welded to the axle connector, and extending
longitudinally over and welded to the arm body bottom surface. In a
method of constructing a suspension system, the method includes the
steps of welding an axle connector to an axle; welding a plate to
the axle connector, the plate being wrapped rearwardly about the
axle connector; and welding an arm body to the axle connector and
to the plate, the arm body having top and bottom surfaces, and the
plate being welded to each of the top and bottom surfaces.
Inventors: |
Chalin; Thomas N.;
(Fairview, TX) |
Correspondence
Address: |
SMITH SERVICES, P.C.
660 NORTH CENTRAL EXPRESSWAY
SUITE 230
PLANO
TX
75074
US
|
Family ID: |
36565948 |
Appl. No.: |
11/000810 |
Filed: |
December 1, 2004 |
Current U.S.
Class: |
280/124.116 |
Current CPC
Class: |
B60G 2204/4306 20130101;
B60G 2206/8201 20130101; B60G 2206/11 20130101; B60G 9/003
20130101; B60G 2204/1482 20130101; B60G 2200/31 20130101 |
Class at
Publication: |
280/124.116 |
International
Class: |
B60G 9/02 20060101
B60G009/02 |
Claims
1. A suspension system, comprising: a laterally extending axle; and
an arm assembly welded to the axle, the arm assembly including: a
longitudinally extending arm body having first and second surfaces,
an axle connector welded to the axle and a first end of the arm
body, and a first plate extending longitudinally over and welded to
the arm body first surface, wrapped rearwardly about and welded to
the axle connector, and extending longitudinally over and welded to
the arm body second surface.
2. The system of claim 1, wherein the axle connector is welded to
the axle at a position proximate a horizontal axis of the axle
approximately midway between upper and lower extents of the
axle.
3. The system of claim 2, wherein the axle connector includes an
opening at the position proximate the horizontal axis, wherein the
axle connector is welded to the axle about the opening, and wherein
the first plate overlies the opening when the first plate is welded
to the axle connector.
4. The system of claim 2, wherein the axle connector includes at
least one seam extending completely laterally across the axle
connector, and wherein the axle connector is welded along the seam
proximate the horizontal axis of the axle.
5. The system of claim 4, wherein the first plate overlies the seam
when the first plate is welded to the axle connector.
6. The system of claim 2, wherein the axle connector includes at
least two seams extending completely laterally across the axle
connector dividing the axle connector into at least two sections,
and wherein the axle connector is welded along each of the seams
proximate the horizontal axis of the axle.
7. The system of claim 1, wherein a pivot connection sleeve is
welded to a second end of the arm body opposite the first end.
8. The system of claim 7, wherein a lever arm is welded to the
sleeve.
9. The system of claim 8, wherein an axle lift actuator is
connected between the lever arm and a hanger bracket.
10. The system of claim 7, wherein the first plate is welded to the
sleeve.
11. The system of claim 1, wherein the arm body has a generally
U-shaped cross-sectional shape with at least two generally
vertically extending legs and a base extending between the legs,
and wherein the first plate is welded to the at least two legs and
to the base.
12. The system of claim 1, wherein the arm body has a box
cross-sectional shape and includes at least two generally vertical
legs, and a second plate joined to the legs, the first plate
overlapping the second plate.
13. The system of claim 1, wherein the arm body has a generally
I-shaped cross-sectional shape with upper and lower generally
horizontally extending flanges, and wherein the first plate is
welded to the flanges.
14. A method of constructing a suspension system, the method
comprising the steps of: welding an axle connector to an axle;
welding a plate to the axle connector, the plate being wrapped
rearwardly about the axle connector; and welding an arm body to the
axle connector and to the plate, the arm body having first and
second surfaces, and the plate being welded to each of the first
and second surfaces.
15. The method of claim 14, wherein the plate welding step is
performed after the axle connector welding step.
16. The method of claim 14, wherein the arm body welding step is
performed after the plate welding step.
17. The method of claim 16, wherein the plate welding step is
performed after the axle connector welding step.
18. The method of claim 14, wherein the axle connector welding step
further comprises welding the axle connector to the axle at a
position proximate a horizontal axis of the axle approximately
midway between upper and lower extents of the axle.
19. The method of claim 18, wherein the axle connector includes an
opening at the position proximate the horizontal axis, wherein the
axle connector welding step further comprises welding the axle
connector to the axle about the opening, and wherein the plate
welding step further comprises welding the plate with the plate
overlying the opening.
20. The method of claim 18, wherein the axle connector includes at
least one seam extending completely laterally across the axle
connector, and wherein the axle connector welding step further
comprises welding along the seam proximate the horizontal axis of
the axle.
21. The method of claim 20, wherein the plate welding step further
comprises welding the plate with the plate overlying the seam.
22. The method of claim 18, wherein the axle connector includes at
least two seams extending completely laterally across the axle
connector dividing the axle connector into at least two sections,
and wherein the axle connector welding step further comprises
welding along each of the seams proximate the horizontal axis of
the axle.
23. The method of claim 14, further comprising the step of welding
a pivot connection sleeve to the arm body.
24. The method of claim 23, further comprising the step of welding
a lever arm to the sleeve.
25. The method of claim 24, further comprising the step of
connecting an axle lift actuator between the lever arm and a hanger
bracket.
26. The method of claim 23, further comprising the step of welding
the plate to the sleeve.
27. The method of claim 14, wherein the arm body has a generally
U-shaped cross-sectional shape with at least two generally
vertically extending legs and a base extending between the legs,
and wherein the plate welding step further comprises welding the
plate to the legs and to the base.
28. The method of claim 14, wherein the arm body has a box
cross-sectional shape and includes at least two generally vertical
legs, and a base joined to the legs, and wherein the plate welding
step further comprises welding the plate to the legs and to the
base.
29. The method of claim 14, wherein the arm body has a generally
I-shaped cross-sectional shape with upper and lower generally
horizontally extending flanges, and wherein the plate welding step
further comprises welding the plate to the flanges.
Description
BACKGROUND
[0001] The present invention relates generally to vehicle
suspension systems and, in an embodiment described herein, more
particularly provides a suspension system having a high strength
arm to axle connection.
[0002] In the vehicle suspension system art, it is increasingly
important to reduce the weight and cost of manufacturing of a
suspension system, while maintaining load carrying capacity and
increasing functionality. To this end, many configurations of
suspension systems and methods of manufacturing suspension systems
have been developed. However, improvements are made in at least one
of the goals of reducing weight and cost, or maintaining load
carrying capacity and increasing functionality, but not both.
[0003] Therefore, it may be seen that improvements exist in the art
of vehicle suspension systems, but are not completely
satisfactory.
SUMMARY
[0004] In carrying out the principles of the present invention, in
accordance with one of multiple examples described below, a
suspension system is provided which accomplishes all of the
objectives discussed above.
[0005] In one aspect of the invention, a suspension system is
provided which includes a laterally extending axle and an arm
assembly welded to the axle. The arm assembly includes a
longitudinally extending arm body having top and bottom surfaces,
an axle connector welded to the axle and an end of the arm body,
and a plate extending longitudinally over and welded to the arm
body top surface, wrapped rearwardly about and welded to the axle
connector, and extending longitudinally over and welded to the arm
body bottom surface.
[0006] In another aspect of the invention, a method of constructing
a suspension system is provided. The method includes the steps of
welding an axle connector to an axle; welding a plate to the axle
connector, the plate being wrapped rearwardly about the axle
connector; and welding an arm body to the axle connector and to the
plate, the arm body having top and bottom surfaces, and the plate
being welded to each of the top and bottom surfaces.
[0007] These and other features, advantages, benefits and objects
of the present invention will become apparent to one of ordinary
skill in the art upon careful consideration of the detailed
description of representative embodiments of the invention
hereinbelow and the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a schematic side elevational view of a suspension
system embodying principles of the present invention;
[0009] FIG. 2 is an enlarged scale isometric view of an arm
assembly used in the suspension system of FIG. 1;
[0010] FIG. 3 is a rear view of the arm assembly;
[0011] FIG. 4 is a top plan view of the arm assembly;
[0012] FIG. 5 is an isometric view of an axle connector used in the
arm assembly;
[0013] FIG. 6 is a side view of the arm assembly;
[0014] FIG. 7 is a schematic cross-sectional view of the arm
assembly, taken along line 7-7 of FIG. 6; and
[0015] FIG. 8 is a schematic cross-sectional view of an alternate
construction of the arm assembly.
DETAILED DESCRIPTION
[0016] Representatively illustrated in FIG. 1 is a suspension
system 10 which embodies principles of the present invention. In
the following description of the suspension system 10 and other
apparatus and methods described herein, directional terms, such as
"above", "below", "upper", "lower", etc., are used for convenience
in referring to the accompanying drawings. Additionally, it is to
be understood that the various embodiments of the present invention
described herein may be utilized in various orientations, such as
inclined, inverted, horizontal, vertical, etc., and in various
configurations, without departing from the principles of the
present invention. The embodiments are described merely as examples
of useful applications of the principles of the invention, which is
not limited to any specific details of these embodiments.
[0017] As depicted in FIG. 1, a hanger bracket 12 is attached to a
vehicle frame rail 14. An arm assembly 16 is pivotably connected to
the hanger bracket 12 at a pivot connection 18. An axle 20 is
attached at an end of the arm assembly 16 opposite the pivot
connection 18.
[0018] An air spring 22 is connected between the frame rail 14 and
the arm assembly 16, for example, using a mounting plate 24
attached to the frame rail and another mounting plate 26 attached
to a rear end of the arm assembly. The air spring 22 functions to
suspend the frame rail 14 above the arm assembly 16 with some
compliance for traversing bumps and dips in a road surface. A
rubber spring could be used as well as the air spring 22.
[0019] A lever arm 28 is attached to a forward end of the arm
assembly 16. An axle lift actuator 30 is connected between the
lever arm 28 and the hanger bracket 12. The actuator 30 functions
to lift the axle 20 relative to the road surface when the actuator
30 is expanded by applying air pressure to the actuator 30 and
exhausting air pressure from the actuator 22.
[0020] Certain elements are not shown in FIG. 1 for illustrative
clarity. For example, wheels, tires, brake components, shock
absorbers, steering mechanisms, etc. are not shown, but a person
skilled in the art will appreciate how these elements would be used
in the suspension system 10. Only one suspension system 10 is
depicted in FIG. 1, but it should be understood that typically
another suspension system would be attached to another frame rail
laterally spaced apart from the frame rail 14 shown in FIG. 1.
[0021] The suspension system 10 illustrated in FIG. 1 is of the
type known to those skilled in the art as a lift axle air ride
trailing arm suspension system. However, it should be understood
that it is not necessary for a suspension system constructed using
the principles of the invention to be a lift axle suspension
system, an air ride suspension system, or a trailing arm suspension
system. The suspension system 10 can also be steerable or
non-steerable.
[0022] Only one arm assembly 16 is depicted in FIG. 1. However, any
number of arm assemblies could be used. For example, two arm
assemblies 16 could be used in a suspension system.
[0023] If the suspension system 10 is a lift axle suspension system
as depicted in FIG. 1, the actuator 30 can be positioned other than
between the lever arm 28 and hanger bracket 12. For example, the
actuator 30 could be connected between the lever arm 28 and a
bracket separately attached to the frame rail 14, between the lever
arm 28 and another lever arm on another arm assembly, or in any
other position.
[0024] In this description, the term "longitudinal" is used to
indicate the direction parallel to the length of the frame rail 14,
that is, between the forward and rear ends of the vehicle. The term
"lateral" is used to indicate the direction orthogonal to the
longitudinal direction in a horizontal plane, that is, from side to
side of the vehicle.
[0025] Referring additionally now to FIG. 2, the arm assembly 16 is
depicted in more detail apart from the remainder of the suspension
system 10. In this view it may be seen that the arm assembly 16
includes a longitudinally extending arm body 32, a pivot connection
sleeve 34 attached at a forward end of the arm body, the lever arm
28 attached to the sleeve, an axle connector 36 attached at a rear
end of the arm body, and a plate 38 attached to the sleeve, axle
connector and arm body.
[0026] Preferably, each of the attachments described above is
accomplished by welding. In one method of constructing the arm
assembly 16, the axle connector 36 is welded to the axle 20, but
the arm assembly is not welded directly to the axle. The plate 38
is then wrapped rearwardly about the axle connector 36 and welded
to the axle connector. The arm body 32 is welded to the plate 38
and the axle connector 36. The sleeve 34 is also welded to the
plate 38 and to the arm body 32. The lever arm 28 is welded to the
sleeve 34 if the suspension system 10 is a lift axle suspension
system.
[0027] The sleeve 34 is configured to receive a resilient pivot
bushing (not shown) therein of the type well known to those skilled
in the art as being used in pivot connections, such as the pivot
connection 18. The axle connector 36 is configured to receive the
axle 20 therein.
[0028] Referring additionally now to FIG. 3, a rear view of the arm
assembly 16 is depicted with the axle 20 received in the axle
connector 36. In this view, the manner in which the plate 38 wraps
rearwardly about the axle connector 36 may be clearly seen.
[0029] Note that the plate 38 overlies a seam 40 of the axle
connector 36. As will be described in further detail below, the
plate 38 also overlies an opening 42 formed in the axle connector
36 at the rear seam 40.
[0030] Referring additionally now to FIG. 4, a top view of the arm
assembly 16 is depicted. In this view, the relative longitudinal
positionings of the sleeve 34, plate 38 and axle connector 36 may
be seen. As described above, the plate 38 is welded to both the
sleeve 34 and the axle connector 36.
[0031] Referring additionally now to FIG. 5, the axle connector 36
is illustrated apart from the remainder of the arm assembly 16. In
this view it may be seen that the axle connector 36 is divided into
two generally semicircular sections 48, 50 by the seams 40
extending laterally across the axle connector. The openings 42 are
formed at the seams 42, so that the seams also divide the openings
in half.
[0032] To attach the axle connector 36 to the axle 20, the sections
48, 50 are first positioned on the axle so that the seams 40 and
openings 42 are at positions approximately midway between upper and
lower extents 54, 56 of the axle, that is, the seams are located
approximately at a horizontal plane intersecting a longitudinal
axis 52 of the axle. This positioning is visible in FIG. 6.
[0033] When properly positioned, the axle connector 36 is biased
into intimate contact with the axle 20, for example, by clamping
the sections 48, 50 onto the outer surface of the axle. This
removes any voids between the axle connector 36 and the axle 20
prior to welding, thereby strengthening the welded connection.
[0034] Alternatively, the axle connector 36 could be constructed as
a single piece (i.e., having a continuous circumference), instead
of being divided into the separate sections 48, 50. In that case,
the axle connector 36 could be pressed onto the axle 20 (the axle
connector having an initial inner diameter less than an outer
diameter of the axle), such that voids between the axle connector
and axle are removed prior to welding. Methods other than
press-fitting could be used, such as by heating the axle connector
36 to expand it prior to positioning it on the axle 20 and/or
cooling the axle to contract it prior to positioning the axle
connector on the axle, etc.
[0035] In the illustrated embodiment, the axle connector 36 is
welded to the axle 20 along the seams 40 (which also welds the
sections 48, 50 to each other) and about the openings 42. Note
that, in other embodiments, the sections 48, 50 may be welded to
each other along the seams 40 without also welding to the axle 20,
so that the axle connector 36 is mainly, or completely, welded to
the axle at the openings 42. When the plate 38 is later welded to
the axle connector 36, it will overlie the rear seam 40 and opening
42, thereby further strengthening the welded connection.
[0036] Also visible in FIG. 6 is the manner in which the plate 38
is attached to both a top surface 44 of the arm body 32 and a
bottom surface 46 of the arm body. By welding the plate 38 to the
top and bottom surfaces 44, 46 of the arm body 32 at either side of
the rearward wrap of the plate about the axle connector 36, the
connection between the axle connector and the remainder of the arm
assembly 16 is strengthened, providing a relatively light weight
assembly which is both capable of carrying substantial loads and
economical to manufacture.
[0037] Note that various different sequences may be used to weld
the plate 38 and the arm body 32 to the axle connector 36. The
plate 38 could be welded to the axle connector 36 first, and then
the arm body 32 could be welded to the plate and the axle
connector. The arm body 32 could be welded to the axle connector 36
first, and then the plate 38 could be welded to the axle connector
and the arm body. The plate 38 could be welded to the arm body 32,
and then the plate and arm body could be welded to the axle
connector 36. Other sequences may be used in keeping with the
principles of the invention.
[0038] Referring additionally now to FIG. 7, a schematic
cross-sectional view of the arm assembly 16 is depicted. In this
view, it may be seen that the arm body 32 is a U-shaped channel
with two generally vertically extending legs 58 and a generally
horizontally extending base 60 connecting lower ends of the legs.
The bottom surface 46 of the arm body 32 is formed on the base 60,
and the top surface 44 of the arm body is formed on upper ends of
the legs 58.
[0039] Referring additionally now to FIG. 8, an alternate
configuration of the arm body 32 is depicted. In this
configuration, the arm body 32 is I-shaped with upper and lower
horizontally extending flanges 62, 64 and a vertical web 66
connecting the flanges. The bottom surface 46 of the arm body 32 is
formed on the lower flange 64, and the top surface 44 of the arm
body is formed on the upper flange 62.
[0040] Although U-shaped channel and I-shaped configurations of the
arm body 32 have been described, any shape may be used for the arm
body in keeping with the principles of the invention. For example,
the arm body 32 could be box-shaped, cylindrical, oval,
longitudinally curved, laterally curved, etc. A box cross-sectional
shape of the arm body 32 could have a rectangular, trapezoidal or
other closed rectilinear shape. The shapes described above could be
inverted, rotated or otherwise changed in orientation.
[0041] Furthermore, although the U-shaped channel depicted in FIG.
7 and the I-shaped configuration depicted in FIG. 8 are each shown
as being constructed of a single piece of material, they (or any
other configuration of the arm body 32) may in practice be
constructed of separate pieces, such as plates, joined to each
other by welding or other methods. For example, the arm body having
a box cross-sectional shape could include top and bottom plates
joined to at least two generally vertical legs, with one of the top
and bottom plates overlapping the other after wrapping rearwardly
about the axle connector 36. In that case, the top plate would
correspond to the top plate 38, the bottom plate would correspond
to the horizontal base 60, and the legs would correspond to the
legs 58 of the embodiment shown in FIG. 7, except that the top and
bottom plates and legs would be separately constructed and then
joined to each other.
[0042] Of course, a person skilled in the art would, upon a careful
consideration of the above description of representative
embodiments of the invention, readily appreciate that many
modifications, additions, substitutions, deletions, and other
changes may be made to these specific embodiments, and such changes
are within the scope of the principles of the present invention.
Accordingly, the foregoing detailed description is to be clearly
understood as being given by way of illustration and example only,
the spirit and scope of the present invention being limited solely
by the appended claims and their equivalents.
* * * * *