This invention relates to spring members having bushing mounts, and more particularly to a spring members having bushing mounts with improved bushing retention characteristics.
Elongate spring members, such as leaf springs and spring beams, are often used in vehicle suspension systems designed to resiliently connect a vehicle's axle(s) to its frame. However such spring members can be used in many different situations and the present invention is applicable to any of these and is not intended to be limited to vehicle suspensions.
An example of an application for elongate spring members relates to air bag suspension systems, which are applied in great number to heavy truck fleets utilized in the transport industry. Air suspensions for large commercial trucks are used for on and off highway use, such as highway tractor and off road construction vehicles. In such systems, one end of a spring beam features a bushing mount, or eye, for pivotally attaching the spring beam to the frame. An air bag at the other end is supported between the spring beam and a frame element, while the axle is coupled to the spring beam between the two ends. The air bag's resiliency to compression serves to limit pivotal motion of the spring beam and attached axle towards the frame. Bushing mounts are commonly used in applications where it is desirable to pivotally mount a spring member at its end(s).
Typically, a bushing mount is of a rolled form with an open end and straight internal profile, thereby defining a cylindrical opening, or eye, for housing a bushing therein. Again using vehicle suspension as an example, a pivot pin passed through the bushing supports the spring beam for pivotal motion on the vehicle frame while the bushing prevents direct contact of the pin and spring beam to reduce wear caused by relative motion therebetween. The open ends of these standard rolled mounts tend to open further during deformation caused by excessive loading. This deformation changes the size and shape of the eye so that the bushing is no longer properly seated and firmly secured therein.
Regardless of the type of loading, deformation of the bushing mount 12 will cause the size and shape of a cylindrical opening 22 formed by the rolled end 14 to change. It is important to maintain consistency in this opening 22, as it houses a bushing 24 and a pin 26 by which the beam 10 is pivotally supported. Maintaining the size of the opening 22 is thus very important as retention of the bushing 24 therein is necessary to support the spring beam 10 and prevent failure of the suspension system.
As shown in
U.S. Pat. No. 5,366,238 of Stephens teaches a spring member produced from a one inch thick blank of spring steel and having an integral eye. The material is cut using plasma arc cutting techniques to produce an elongate spring member having a vertical depth greater than its horizontal width. The production of a spring member from such a relatively thin blank may place undesirable limits on the shape and dimensions of an achievable end product.
U.S. Pat. No. 3,671,030 of Marion teaches a leaf spring having an integral eye formed by creating two slits proximate one of its ends parallel to its length, then displacing an intermediate portion of the leaf between the slits and adjacent edge portions outside the slits in opposite directions to create opposed semi-cylindrical loops. In this arrangement, the spring material does not extend the full length of the eye thereabove and therebelow, which may limit the strength of the bushing mount.
As a result, there is a desire for spring members producible in various sizes and shapes having bushing mounts that offer improved bushing retention characteristics, thereby improving the safety and reliability levels of the suspension systems in which they are used.
According to a first aspect of the invention there is provided a combination of a suspension assembly and a frame, said combination comprising;
an elongate spring member having opposite first and second ends, said spring member being pivotally supported on the frame at said first end; and
a coupling supported on the elongate spring member and spaced from the first end thereof, said coupling thereby being supported on the frame by said spring member;
the elongate spring member comprising a forged mounting element at the first end thereof, said forged mounting element having a cylindrical inner surface defining a cylindrical opening extending transverse to said spring member, said spring member being pivotal about said opening;
the forged mounting element being integral with the elongate spring member and the inner surface of said forged mounting element being endless about the cylindrical opening.
The forged integral bushing mount forms an endless loop around the cylindrical opening extending the full width of the sprin. By eliminating the open end found in typical rolled bushing mounts, the integral mount better resists deformation under loading conditions. As a result, the forged mount can be made to have a thinner cross section than the typical rolled form, thereby decreasing the overall weight of the spring member.
A width of the elongate spring member may exceed a thickness thereof.
Side edges of the elongate spring member may each deviate from a planar path along a length thereof.
Preferably there is provided a bushing disposed in and extending along the cylindrical opening of the forged mounting element. In this case, there may be provided a pin supported on the frame and extending through the bushing in the cylindrical opening, the spring member being pivotal about said pin.
Preferably the coupling comprises an axle seat.
The spring member may comprise a spring beam.
There may be provided an air spring bag supported on the spring member and spaced from the first end thereof, said air spring bag being disposed between said spring member and the frame so as to resist pivotal motion of said spring member about the first end thereof toward said frame. In this case, preferably the coupling is disposed between the first end of the spring member and the air spring bag and the air spring bag is disposed at the second end of the spring member.
According to a second aspect of the invention, there is provided a combination of a suspension assembly and a frame, said combination comprising:
an elongate spring member having opposite first and second ends, said spring member being pivotally supported on the frame at said first end; and
a coupling supported on the elongate spring member and spaced from the first end thereof, said coupling thereby being supported on the frame by said spring member;
the elongate spring member comprising a mounting element at the first end thereof, said mounting element having an inner surface defining an opening extending transverse to said spring member, said spring member being pivotal about said opening; and
the inner surface of the mounting element comprising:
The ridges at the opposite ends of the cylindrical opening reduce the inner diameter of the mount on each side of the spring member. These ridges are thereby arranged to house a component having an outer diameter greater than the inner diameter of the ridges between them.
Preferably there is provided a bushing disposed in the opening of the mounting element and extending along the substantially cylindrical portion of the inner surface of said mounting element, said bushing being larger between the ridge portions of said inner surface than said opening at said ridge portions of said mounting element such that said ridges prevent said bushing from sliding out of said opening. In other words, there may be provided a bushing disposed in the opening of the mounting element, the bushing comprising a substantially cylindrical main portion disposed between the ridge portions of the inner surface of the mounting element, the main portion having an outer diameter larger than the opening of the mounting body at the ridge portions.
Securely housed between the ridges, a bushing without an external metal sleeve or bonding compound can be retained in the bushing mount. Without the stress exerted on the bushings by an interference fit between the outer sleeve and the inner surface of the mount, the bushing life is extended. Also, the high cost and environmental susceptibility associated with bonding compounds are avoided.
Preferably the bushing comprises tapered portions narrowing toward opposite ends thereof from an outer diameter larger than the opening of the mounting element at the ridge portions. Preferably the outer diameter narrows to a size smaller than the opening of the mounting element at the ridge portions.
Preferably the inner surface of the mounting element further comprises two transitional portions each extending, and gradually decreasing in diameter, from the cylindrical portion to a respective one of the ridge portions.
Preferably the ridge portions, extending away from the central portion and the transitional portions, are of constant diameter.
Preferably the tapered portions of the bushing and the transitional portions of the inner surface of the mounting element having generally equal slopes.
Preferably the main portion of the bushing is generally equal in length to the cylindrical portion of the inner surface of the mounting element.
Preferably the outer diameter of the main portion of the bushing does not exceed a diameter of the cylindrical portion of the inner surface of the mounting element,
Preferably the mounting element is integral with the elongate spring member and the inner surface of said mounting element being endless about the cylindrical opening.
Preferably each ridge portion extends fully about the opening.
According to a third aspect of the invention, there is provided a combination of a suspension assembly and a frame, said combination comprising:
an elongate spring member having opposite first and second ends, said spring member being pivotally supported on the frame at said first end; and
a coupling supported on the elongate spring member and spaced from the first end thereof, said coupling thereby being supported on the frame by said spring member;
the elongate spring member comprising a mounting element at the first end thereof, said mounting element having an inner surface defining an opening extending transverse to said spring member, said spring member being pivotal about said opening; and
the inner surface of the mounting element comprising:
the mounting element being integral with the elongate spring member and the inner surface of said mounting element being endless about the cylindrical opening.
According to a fourth aspect of the invention there is provided a spring element comprising:
an elongate member having opposite ends, at least one of said ends comprising a forged mounting element having a cylindrical inner surface defining a cylindrical opening extending transverse to said elongate member,
the forged mounting element being integral with the elongate spring beam and the inner surface of said forged mounting element being endless about the cylindrical opening.
According to a fifth aspect of the invention there is provided a spring element comprising:
an elongate member having opposite ends, at least one of said ends comprising a mounting element having an inner surface defining an opening extending transverse to said elongate member;
the inner surface of the mounting element comprising:
According to a sixth aspect of the invention there is provided a spring element comprising:
an elongate member having opposite ends, at least one of said ends comprising a mounting element having an inner surface defining an opening extending transverse to said elongate member;
the inner surface of the mounting element comprising:
the mounting element being integral with the elongate spring beam and the inner surface of said mounting element being endless about the cylindrical opening.
In the accompanying drawings, which illustrate exemplary embodiments of the present invention:
A transitional area 36 between the bushing mount 32 and the upper and lower surfaces 38 and 40 of the spring beam 30 features smooth curves between the generally flat surfaces of the beam and the round outer surface 42 of the mount. These curves, or lead in radii avoid the presence of sharp corners which can lead to premature failure of the beam 30, as sharp corners experience higher stress concentrations than rounded corners during loading.
Like those of typical spring beams, the bushing mounts 32 of the first embodiment can house externally sleeved or unsleeved bushings. As shown in
The first embodiment of the present invention improves the bushing retention characteristics of the bushing mount of a spring beam without modifying the type of bushing used or the way the bushing is secured in the cylindrical opening. By forging the end of the beam 30 to form the integral mount 32, the opening 34 is completely enclosed and therefore less prone to deformation. The continual loop structure of the mount 32 can be made to have a thinner cross section of material than the open loop of the prior art due to this improved resistance to deformation, thereby reducing the overall weight of the beam 30. The forged mount 32 deflects in a consistent manner regardless of the direction of loading. This equalized loading situation will extend the life of the bushing so that less frequent replacement is required.
The ridges, or lips, at the ends of the bushing mount of the second embodiment encapsulate the bushing to withstand lateral loads transmitted by a suspension system. Without the stress induced by an interference fit between the mount and an externally sleeved bushing, the life of the bushing is improved. Also, the use of costly, condition sensitive bonding compounds is avoided. It should be appreciated that reducing the number of components required in the suspension assembly also reduces the number of variables involved in its function and/or failure. In this case, a three part combination of a bushing, a spring beam and a retaining component therebetween (for example, a sleeve or bonding compound) has been reduced to a two part combination of a bushing and a spring beam. Bushings are installed into the ridged bushing mount 60 with the aid of a tapered installation sleeve or shallow funnel. Bushings are generally only removed after failure, in which case the bushings would be loose in the mount 60 and therefore easy to remove.
It should be appreciated that the ridges of the mounting element's inner surface need not extend fully about the opening to block withdrawal of the bushing, but that extending the ridges fully along the mounting element improves the strength with which the bushing is secured in place.
In each of the embodiments described above, the mounts provide improved bushing retention over typical spring beam bushing mounts. In each of the three detailed embodiments, the width of the eye is precisely maintained and is finished to achieve a full diameter land on the side where it interfaces with the attaching component. The opening, or bore, through the mount is precision sized to provide a smooth surface for flush engagement with the appropriate type of bushing. It should be appreciated that while described in the context of spring beams used in air suspension systems, the present invention can be applied to bushing mounts for various other applications. For example, leaf springs are commonly mounted with bushings inserted into eyes at their ends for use in suspension applications.
As illustrated by
Since various modifications can be made in my invention as herein above described, and many apparently widely different embodiments of same made within the spirit and scope of the claims without department from such spirit and scope, it is intended that all matter contained in the accompanying specification shall be interpreted as illustrative only and not in a limiting sense.
This application claims the benefit under 35 U.S.C.119(e) of U.S. provisional application Ser. No. 60/728,802, filed Oct. 21, 2005.
Number | Date | Country | |
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60728802 | Oct 2005 | US |