The invention relates generally to vehicle axle systems. Specifically, the present invention relates to torsion axle systems having anti-sway and load-equalizing features.
Various configurations of torsion axle mechanisms with compressible inserts, typically rubber, are known in the field of axle design. Torsion axles are mechanisms that reduce the sway in vehicles typically encountered when making turns in a vehicle carrying a heavy load or an unevenly distributed load.
Shafts 106a and 106b are rotationally linked to spindle arms 108a and 108b, respectively. Spindle arms 108a and 108b are attached to spindle 116a and spindle 116b, respectively. Rubber inserts 104a and 104b function as suspension absorbing members, shown more clearly in
The axle mechanism described above does not have anti-sway capability, primarily because the left and right sides of the torsion axle and the inserts are not configured in a manner that allow them to communicate forces between the left and right sides of the torsion axle. Reducing sway in a vehicle can be achieved by transferring force between separated left and right shafts of a torsion axle.
Furthermore, existing load-equalizing mechanisms between a front torsion axle and rear torsion axle have complex structures. Load-equalization is desirable in multi-stage axle mechanisms where distribution of loads between axles becomes unbalanced. It would be desirable to have a mechanism that has both anti-sway capabilities and load-equalizing features that is relatively simple in structure and design.
Apparatus and methods relating to anti-sway features of a torsion axle system are described. In one aspect of the present invention, a system includes an axle assembly with two opposed ends, each end having a spindle arm, and an anti-sway mechanism disposed at a location between the two opposed ends of the axle assembly. In one embodiment the anti-sway mechanism includes an axle tube middle segment with inserts, and spindle arm shaft ends extending into the axle tube middle segment and inserts
In another aspect of the present invention an anti-sway mechanism includes an axle tube segment which houses two shafts, each shaft secured in place by inserts, typically rubber, wherein a rotational force applied to one shaft is transmitted to another shaft by the axle tube segment and the inserts. In one embodiment, the anti-sway mechanism is unattached to a vehicle frame thereby allowing the tube segment to react to a rotational force and transmit a portion of the rotational force to an opposing shaft. In another embodiment, the anti-sway mechanism includes a first set of inserts press-fitted between the axle tube segment and one of the shafts and a second set of inserts press-fitted between the axle tube segment and the other shaft, such that rotation of one shaft causes rotation of the other shaft.
In another aspect of the present invention, an axle system for a vehicle includes two end axle tube segments and a middle axle tube segment, each having inserts. One end axle tube segment contains a first portion of a first spindle shaft attached to a first spindle arm. Another end axle tube segment contains a first portion of a second spindle shaft attached to a second spindle arm. The middle axle tube segment contains a second portion of the first spindle shaft and a second portion of the second spindle shaft, wherein the middle axle tube segment is separate from the two end axle tube segments.
In another aspect of the present invention, a method of adjusting anti-sway capability of an axle is described. A length of a first set of inserts in a middle segment of an axle tube is adjusted to be shorter or longer. A length of a second set of inserts in the middle segment of the axle tube may also be adjusted to be shorter or longer. In one embodiment, the length of a third set of inserts in at least one of two end segments of the axle tube is adjusted. In yet another embodiment, one or more of the compressibility, density, resilience and material of the inserts are adjusted to achieve the desired anti-sway capability of the torsion axle.
In another aspect of the present invention, an anti-sway mechanism of an axle system is described. The anti-sway mechanism includes an end portion of a spindle shaft extending into a center axle tube and pressure-absorbing inserts positioned between an outer surface of the end portion of the spindle shaft and an inner surface of the center axle tube. An outside portion of the spindle arm shaft is connected to a spindle arm such that when pressure is applied to the spindle arm, the pressure is transferred through the end portion of the spindle shaft to the pressure-absorbing inserts in the center axle tube.
In another aspect of the present invention, an anti-sway mechanism is described. The anti-sway mechanism has a spindle shaft having an outer surface contained in an axle tube segment having an inner surface and a first set of inserts housed between the inner surface of the axle tube segment and the outer surface of the spindle shaft. The anti-sway mechanism also includes another spindle shaft having an outer surface contained in the axle tube segment and another set of inserts housed between the inner surface of the axle tube segment and the outer surface of the spindle shaft, wherein the axle tube segment can rotate such that a portion of a force causing rotation of one spindle shaft is transferred to the other spindle shaft. This transfer occurs through the axle tube segment and the sets of inserts.
A torsion axle system having anti-sway capabilities is described in the various figures. The system utilizes a segmented axle tube for housing extended spindle shafts and pressure-absorbing inserts, collectively providing anti-sway capability for a vehicle.
Spindle arm shaft 408 is attached to spindle arm 412 and spindle arm shaft 410 is attached to spindle arm 414, such that rotational movement of a spindle arm causes rotational movement of the spindle arm shaft. Spindle arms 412 and 414 are linked to spindles 416 and 418, respectively. In a preferred embodiment, a set of inserts 420 and 422 are press-fitted into axle tube end segments 402 and 404. In a preferred embodiment, a set of inserts includes four inserts. In other embodiments, there may be fewer or more inserts in axle tube end segments 402 and 404. For example, there can be three or two inserts in an axle tube depending on the cross-sectional shape of the tube and the spindle arm shaft. Inserts 420 and 422 are typically shorter in length than the length of axle tube segments 402 and 404. However, in another embodiment, they may be the same length as axle tube segments 402 and 404. Also shown are inserts 602 and 604 in middle axle tube segment 406, discussed below with reference to
Spindle arm shafts 408 and 410 extend into axle tube middle segment 406.
However, middle tube segment 406 and inserts 602 and 604 enable an interaction or communication between opposed spindle arm shafts 408 and 410. The two shafts are reactive to each other in that when a rotational force is applied to one shaft, this force is communicated to the other shaft through rubber inserts 602 and 604 and the rotational movement of middle tube segment 406. The rotational force applied to one shaft results in the transmission of forces received by the other shaft through the rotational movement of axle tube middle segment 406. The rotational movement of a spindle arm shaft causes middle segment 406 to rotate. The rotation of middle segment 406 transmits rotational forces to the other spindle arm shaft via inserts 602 and 604. The rotational movement of middle segment 406 is possible because segment 406 is not mounted to the vehicle frame or any other object and is free to rotate in either direction (unlike end axle tube segments 402 and 404). As described below, this interaction or communication is predictable and can be calibrated to produce effective anti-sway capability.
In other preferred embodiments, materials other than rubber, such as springs, can be used for transmitting forces through axle tube middle segment 406 and in end tube segments 402 and 404. If springs are used, an outer end of a spring is fixedly attached to a component, such as a spindle arm, and the inner end of the spring comes in contact with and rotates middle segment 406 when forces are exerted on the spindle. By rotating segment 406, forces are transmitted to a second spring on the other side of axle tube 400. In this embodiment, two springs, one at each end of the axle tube, fit around a circular axle tube.
In a preferred embodiment, the degree of anti-sway capability of a given torsion axle can be adjusted in numerous ways. One is by changing the length of inserts 602 and 604 in axle tube middle segment 406.
One way of calibrating the anti-sway capability of a torsion axle is by adjusting length /2 of middle segment rubber inserts 602 and 604. If stronger anti-sway functionality is desired; length /2 can be made longer. If less anti-sway functionality is desired, length /2 can be made shorter. In another embodiment, length /2 can be held constant while changing the material used for the inserts. In other embodiments, the length and material of the inserts can be modified. Similarly, the anti-sway capability of the torsion axle can be calibrated by adjusting length /1 of end segment rubber inserts 420 and 422.
In another embodiment, anti-sway capability of the torsion axle can be calibrated by adjusting length /3, the length of the tube end segments and the length of inserts 420 and 422. That is, by adjusting the location of the disjoints in the axle tube, the anti-sway capability of the axle can be tuned. As with the anti-sway feature of middle segment 406, changing the type of material of inserts 420 and 422 can also adjust the anti-sway capability of the axle. In other preferred embodiments, the length and material of the spindle shafts and various dimensions of the components described above can be adjusted to calibrate the anti-sway capability of the torsion axle. In other preferred embodiments, the durometer of the inserts can be changed. Changing the durometer includes adjusting the resilience, compressibility, and density of the insert material to calibrate the anti-sway capability of the torsion axle. In another embodiment in which springs are used to absorb pressure, the tension and torsional properties of the springs can be adjusted to calibrate the anti-sway capability of the torsion axle.
A multi-axle vehicle having anti-sway features of the present invention can operate in conjunction with a multi-axle equalizing mechanism. A multi-axle equalizing mechanism allows a vehicle load to be balanced between two torsion axles that have the same load rating. An axle load rating is a recommended working load (e.g., 2000 lbs, 3500 lbs.) for a particular axle. This load recommendation is generally based on weights an axle can carry. It is normally desirable that each axle carry similar load amounts. If a particular axle temporarily experiences a heavier load, for example when the vehicle hits a bump, it is desirable to contemporaneously equalize the temporary unevenness of load between two axles. In another scenario, the differential in axle load may be continual (e.g., a moving van carrying a heavier load on one end of the van) in which case multi-axle equalizing should be constant.
Multi-axle load equalizing can be achieved by having one or more links, also referred to as struts, between axles.
In a preferred embodiment, anchor bracket 906 on front axle spindle arm 902 is between the torsion shaft and the spindle and anchor bracket 908 is adjacent to the torsion shaft opposite the spindle. The distance between anchor bracket 906 and torsion shaft may be the same as or different from the distance between anchor bracket 908 and the torsion shaft on the rear spindle arm. In another embodiment, the anchor brackets may be separate from spindle arms 904 and 902.
The embodiments of the present invention recited herein are intended to be merely exemplary and those skilled in the art will be able to make numerous modifications to them without departing from the spirit of the present invention. For example, the cross-sectional shape of the inserts can have shapes other than circular. In another example, springs, rather than inserts, can be used to absorb pressure from a load. In another example, the anti-sway mechanism can be closer to one side of the axle tube rather than being generally in the center. All such modifications are intended to be within the scope of the present invention as defined by the claims.