Claims
- 1. A vehicle axle/suspension assembly, said assembly including:
a) at least one suspension beam mounted on a frame of said vehicle, said suspension beam comprising:
i) an axle mounting plate formed with a recess, said recess having a shape generally complementary to and surrounding about half of the periphery of an axle, said axle mounting plate having at least one edge defining the outermost limit of the recess, said recess being a smaller size or an equal size to said surrounded axle periphery prior to mounting said axle on said axle mounting plate, and upon mounting the axle on the axle mounting plate, an interface between said surrounded axle periphery and said axle mounting plate is free of clearance; and ii) at least one opening formed in said axle mounting plate, said opening being circumferentially offset from said edge defining the outermost limit of the recess, the opening further having a weld disposed therein for welding the axle mounting plate to the axle.
- 2. The vehicle axle/suspension assembly of claim 1, in which said interface between said surrounded axle periphery and said axle mounting plate is in compressive contact.
- 3. The vehicle axle/suspension assembly of claim 2, in which the cross-sectional shape of said axle adjacent to said suspension beam is deformed such that it has a different shape.
- 4. The vehicle axle/suspension assembly of claim 1, in which said axle mounting plate is free of additional parts and structure for mounting said axle.
- 5. The vehicle axle/suspension assembly of claim 1, in which said weld disposed in said axle mounting plate opening is disposed about a periphery of said opening and is continuous.
- 6. The vehicle axle/suspension assembly of claim 5, in which a pair of openings is formed in said axle mounting plate; and in which each of said openings is circumferentially offset from a vertical axis plane of said axle.
- 7. The vehicle axle/suspension assembly of claim 6, in which said suspension beam is a top mount beam; and in which each of said axle mounting plate openings is located adjacent to a respective one of an upper front and an upper rear quadrant of said axle.
- 8. The vehicle axle/suspension assembly of claim 7, in which said suspension beam is a rigid beam; in which a first cutout is formed in said axle mounting plate for accessing said upper front axle quadrant opening for welding the axle mounting plate to said axle; in which a first end of the beam is pivotally attached to said vehicle frame and a second end of said beam is attached to an air spring; in which an end plate is attached to said beam second end for supporting an air spring which extends between said end plate and the vehicle frame; and in which a second cutout is formed in the end plate for accessing said upper rear axle quadrant opening for welding said axle mounting plate to the axle.
- 9. The vehicle axle/suspension assembly of claim 8, in which a generally U-shaped rib is attached to and depends from said end plate and said axle mounting plate for supporting the end plate.
- 10. The vehicle axle/suspension assembly of claim 8, in which said rigid suspension beam includes an inverted U-shaped top channel; in which said top channel includes a pair of spaced-apart sidewalls and a top wall; in which an inverted U-shaped insert having a generally complementary size and shape to the top channel is disposed within said top channel adjacent to said axle mounting plate recess; in which said insert includes a pair of spaced-apart sidewalls and a top wall; and in which each of said insert sidewalls is attached to a respective one of said top channel sidewalls and said axle mounting plate with a single weld.
- 11. The vehicle axle/suspension assembly of claim 10, in which said axle mounting plate extends outboardly and inboardly beyond said top channel sidewalls adjacent to said axle mounting plate recess to provide a force bearing surface for force fitting said axle into the mounting plate recess.
- 12. The vehicle axle/suspension assembly of claim 7, in which said suspension beam is a spring beam; in which said axle mounting plate includes a front end and a rear end; in which the axle mounting plate is attached to and depends from a shock absorber mounting bracket adjacent to said spring beam; in which a first cutout is formed in said axle mounting plate front end for accessing said upper front axle quadrant opening for welding said axle mounting plate to said axle; in which a second cutout is formed in the axle mounting plate rear end for accessing said upper rear axle quadrant opening for welding the axle mounting plate to the axle; in which a first end of said beam is pivotally attached to said vehicle frame and a second end of said beam is attached to an air spring; and in which said air spring extends between said beam second end and the vehicle frame.
- 13. The vehicle axle/suspension assembly of claim 12, in which said axle mounting plate includes a pair of transversely spaced-apart, front to rear extending gussets.
- 14. The vehicle axle/suspension assembly of claim 6, in which said suspension beam is a bottom mount beam; and in which each of said axle mounting plate openings is located adjacent to a respective one of a lower front and a lower rear quadrant of said axle.
- 15. The vehicle axle/suspension assembly of claim 14, in which said suspension beam is a rigid beam; in which a first cutout is formed in said beam for accessing said lower front axle quadrant opening for welding the axle mounting plate to said axle; in which a first end of the beam is pivotally attached to said vehicle frame and a second end of said beam is attached to an air spring; in which said air spring extends between said beam second end and the vehicle frame; and in which a second cutout is formed in the beam rearwardly of said first cutout for accessing said lower rear axle quadrant opening for welding said axle mounting plate to the axle.
- 16. The vehicle axle/suspension assembly of claim 15, in which the rigid suspension beam includes a U-shaped bottom channel; and in which said bottom channel includes a pair of spaced-apart sidewalls and a bottom wall.
- 17. The vehicle axle/suspension assembly of claim 16, in which said axle mounting plate extends outboardly and inboardly beyond said bottom channel sidewalls adjacent to said axle mounting plate recess to provide a force bearing surface for force fitting said axle into the mounting plate recess.
- 18. The vehicle axle/suspension assembly of claim 14, in which said suspension beam is a spring beam; in which said axle mounting plate includes a front end and a rear end; in which the axle mounting plate is attached adjacent to and extends upwardly from said beam; in which a first cutout is formed in said axle mounting plate front end for accessing said lower front axle quadrant opening for welding said axle mounting plate to said axle; in which a second cutout is formed in said axle mounting plate rear end for accessing said lower rear axle quadrant opening for welding the axle mounting plate to the axle; in which a first end of the beam is pivotally attached to the vehicle frame and a second end of said beam is attached to an air spring; and in which said air spring extends between said beam second end and the vehicle frame.
- 19. The vehicle axle/suspension assembly of claim 18, in which the axle mounting plate includes a pair of transversely spaced-apart, front to rear extending gussets.
- 20. The vehicle axle/suspension assembly of claim 1, in which said axle is mounted in a pair of spaced-apart suspension beams.
- 21. A method of assembling a vehicle axle/suspension system, said method including the steps of:
a) preassembling at least one suspension beam including an axle mounting plate formed with a recess, said recess having a shape generally complementary to generally half of the periphery of an axle for surrounding said axle half periphery, said axle mounting plate having at least one edge defining the outermost limit of the recess, said recess being a smaller size or an equal size to the axle half periphery; b) force fitting said axle half periphery into the recess by applying pressure to the axle mounting plate so that an interface between said surrounded axle periphery and said axle mounting plate is free of clearance; c) disposing a weld in at least one opening formed in said axle mounting plate, said opening being circumferentially offset from said edge defining the outermost limit of the recess; and d) mounting said beam on a frame of said vehicle.
- 22. The method of assembling a vehicle axle/suspension system of claim 21, in which said interface between said surrounded axle periphery and said axle mounting plate is in compressive contact.
- 23. The method of assembling a vehicle axle/suspension assembly of claim 22, in which the cross-sectional shape of said axle adjacent to said suspension beam is deformed such that it has a different shape.
- 24. The method of assembling a vehicle top mount axle/suspension system of claim 21, in which said axle is mounted directly on said axle mounting plate without the use of additional parts and structure.
- 25. The method of assembling a vehicle axle/suspension system of claim 21, in which said weld disposed in said axle mounting plate opening is disposed about a periphery of said opening and is continuous.
- 26. The method of assembling a vehicle axle/suspension system of claim 25, in which a pair of openings is formed in said axle mounting plate; and in which each of said openings is circumferentially offset from a vertical axis plane of said axle.
- 27. The method of assembling a vehicle axle/suspension system of claim 26, in which said suspension beam is a top mount beam; and in which each of said axle mounting plate openings is located adjacent to a respective one of an upper front and an upper rear quadrant of said axle.
- 28. The method of assembling a vehicle axle/suspension system of claim 27, in which said suspension beam is a rigid beam; in which a first cutout is formed in said axle mounting plate for accessing said upper front axle quadrant opening for welding the axle mounting plate to said axle; in which a first end of the beam is pivotally attached to said vehicle frame and a second end of said beam is attached to an air spring; in which an end plate is attached to said beam second end for supporting an air spring which extends between said end plate and the vehicle frame; and in which a second cutout is formed in said end plate for accessing said upper rear axle quadrant opening for welding said axle mounting plate to the axle.
- 29. The method of assembling a vehicle axle/suspension system of claim 28, in which a generally U-shaped rib is attached to and depends from said end plate and said axle mounting plate for supporting the end plate.
- 30. The method of assembling a vehicle axle/suspension system of claim 28, in which said rigid suspension beam includes an inverted U-shaped top channel; in which said top channel includes a pair of spaced-apart sidewalls and a top wall; in which an inverted U-shaped insert having a generally complementary size and shape to the top channel is disposed within said top channel adjacent to said axle mounting plate recess; in which said insert includes a pair of spaced-apart sidewalls and a top wall; and in which each of said insert sidewalls is attached to a respective one of said beam top channel sidewalls and said axle mounting plate with a single weld.
- 31. The method of assembling a vehicle axle/suspension assembly of claim 30, in which said axle mounting plate is formed with flanges which extend outboardly and inboardly beyond said top channel sidewalls adjacent to said axle mounting plate recess; and in which a press applies a force to said axle mounting plate flanges sufficient to fit said axle into the mounting plate recess.
- 32. The vehicle axle/suspension assembly of claim 27, in which said suspension beam is a spring beam; in which said axle mounting plate includes a front end and a rear end; in which the axle mounting plate is attached to and depends from a shock absorber mounting bracket adjacent to said spring beam; in which a first cutout is formed in said axle mounting plate front end for accessing said upper front axle quadrant opening for welding said axle mounting plate to said axle; in which a second cutout is formed in the axle mounting plate rear end for accessing said upper rear axle quadrant opening for welding the axle mounting plate to the axle; in which a first end of said beam is pivotally attached to said vehicle frame and a second end of said beam is attached to an air spring; and in which said air spring extends between said beam second end and the vehicle frame.
- 33. The vehicle axle/suspension assembly of claim 32, in which said axle mounting plate includes a pair of transversely spaced-apart, front to rear extending gussets.
- 34. The method of assembling a vehicle axle/suspension assembly of claim 26, in which said suspension beam is a bottom mount beam; and in which each of said axle mounting plate openings is located adjacent to a respective one of a lower front and a lower rear quadrant of said axle.
- 35. The method of assembling a vehicle axle/suspension assembly of claim 34, in which said suspension beam is a rigid beam; in which a first cutout is formed in said beam for accessing said lower front axle quadrant opening for welding the axle mounting plate to said axle; in which a first end of the beam is pivotally attached to said vehicle frame and a second end of said beam is attached to an air spring; in which said air spring extends between said beam second end and the vehicle frame; and in which a second cutout is formed in the beam rearwardly of said first cutout for accessing said lower rear axle quadrant opening for welding said axle mounting plate to the axle.
- 36. The method of assembling a vehicle axle/suspension system of claim 35, in which the rigid suspension beam includes a U-shaped bottom channel; and in which said bottom channel includes a pair of spaced-apart sidewalls and a bottom wall.
- 37. The method of assembling a vehicle axle/suspension assembly of claim 36, in which said axle mounting plate is formed with flanges which extend outboardly and inboardly beyond said bottom channel sidewalls adjacent to said axle mounting plate recess; and in which a press applies a force to said axle mounting plate flanges sufficient to fit said axle into the mounting plate recess.
- 38. The vehicle axle/suspension assembly of claim 34, in which said suspension beam is a spring beam; in which said axle mounting plate includes a front end and a rear end; in which the axle mounting plate is attached adjacent to and extends upwardly from said beam; in which a first cutout is formed in said axle mounting plate front end for accessing said lower front axle quadrant opening for welding said axle mounting plate to said axle; in which a second cutout is formed in said axle mounting plate rear end for accessing said lower rear axle quadrant opening for welding the axle mounting plate to the axle; in which a first end of the beam is pivotally attached to the vehicle frame and a second end of said beam is attached to an air spring; and in which said air spring extends between said beam second end and the vehicle frame.
- 39. The vehicle axle/suspension assembly of claim 38, in which the axle mounting plate includes a pair of transversely spaced-apart, front to rear extending gussets.
- 40. The method of assembling a vehicle axle/suspension assembly of claim 21, in which said axle is mounted in a pair of spaced-apart suspension beams.
- 41. A vehicle axle/suspension assembly, said assembly including:
a) at least one top mount rigid suspension beam mounted on a frame of said vehicle, said suspension beam comprising:
i) an axle mounting plate formed with a recess, said recess having a shape generally complementary to and surrounding about half of the periphery of an axle, said axle mounting plate having at least one edge defining the outermost limit of the recess, said recess being a smaller size or an equal size to said surrounded axle periphery prior to mounting said axle on said axle mounting plate, and upon mounting the axle on the axle mounting plate, an interface between the surrounded axle periphery and said axle mounting plate is free of clearance; ii) at least a pair of openings formed in the axle mounting plate, said openings each being circumferentially offset from said edge defining the outermost limit of the recess and from a vertical axis plane of said axle, and further each of the openings being located adjacent to a respective one of an upper front and an upper rear quadrant of the axle, said axle mounting plate further being formed with a first cutout for accessing said upper front axle quadrant opening for welding the axle mounting plate to said axle; and iii) a first end of said beam being pivotally attached to said vehicle frame and a second end of said beam being attached to an air spring, and an end plate being attached to said beam second end for supporting said air spring which extends between said end plate and the vehicle frame, the end plate being formed with a second cutout for accessing said upper rear axle quadrant opening for welding said axle mounting plate to the axle, whereby each of said front and rear axle quadrant openings has a continuous weld disposed about the periphery of the opening.
- 42. The vehicle axle/suspension assembly of claim 41, in which a generally U-shaped rib is attached to and depends from said end plate and said axle mounting plate for supporting the end plate.
- 43. The vehicle axle/suspension assembly of claim 41, in which said rigid suspension beam includes an inverted U-shaped top channel; in which said top channel includes a pair of spaced-apart sidewalls and a top wall; in which an inverted U-shaped insert having a generally complementary size and shape to the top channel is disposed within said top channel adjacent to said axle mounting plate recess; in which said insert includes a pair of spaced-apart sidewalls and a top wall; and in which each of said insert sidewalls is attached to a respective one of said top channel sidewalls and said axle mounting plate with a single weld.
- 44. The vehicle axle/suspension assembly of claim 43, in which said axle mounting plate extends outboardly and inboardly beyond said top channel sidewalls adjacent to said axle mounting plate recess to provide a force bearing surface for force fitting said axle into the mounting plate recess.
- 45. A vehicle axle/suspension assembly, said assembly including:
a) at least one bottom mount rigid suspension beam mounted on a frame of said vehicle, said suspension beam comprising:
i) an axle mounting plate formed with a recess, said recess having a shape generally complementary to and surrounding about half of the periphery of an axle, said axle mounting plate having at least one edge defining the outermost limit of the recess, said recess being a smaller size or an equal size to said surrounded axle periphery prior to mounting said axle on said axle mounting plate, and upon mounting the axle on the axle mounting plate, an interface between the surrounded axle periphery and said axle mounting plate is free of clearance; ii) at least a pair of openings formed in the axle mounting plate, said openings each being circumferentially offset from said edge defining the outermost limit of the recess and from a vertical axis plane of said axle, and further each of the openings being located adjacent to a respective one of a lower front and a lower rear quadrant of the axle, said axle mounting plate further being formed with a first cutout for accessing said lower front axle quadrant opening for welding the axle mounting plate to said axle; and iii) a first end of said beam being pivotally attached to said vehicle frame and a second end of said beam being attached to an air spring, said air spring extending between said beam second end and the vehicle frame, said beam being formed with a second cutout rearwardly of said first cutout for accessing said lower rear axle quadrant opening for welding said axle mounting plate to the axle, whereby each of said front and rear axle quadrant openings has a continuous weld disposed about the periphery of the opening.
- 46. The vehicle axle/suspension assembly of claim 45, in which the rigid suspension beam includes a U-shaped bottom channel; and in which said bottom channel includes a pair of spaced-apart sidewalls and a bottom wall.
- 47. The vehicle axle/suspension assembly of claim 46, in which said axle mounting plate extends outboardly and inboardly beyond said bottom channel sidewalls adjacent to said axle mounting plate recess to provide a force bearing surface for force fitting said axle into the mounting plate recess.
- 48. A method of assembling a vehicle axle/suspension system, said method including the steps of:
a) preassembling at least one suspension beam including an axle mounting plate formed with a recess, said recess having a shape generally complementary to generally half of the periphery of an axle for surrounding said axle half periphery, said axle mounting plate having at least one edge defining the outermost limit of the recess, said recess being a smaller size or an equal size to the axle half periphery; b) force fitting said axle half periphery into the recess by applying pressure to the axle mounting plate so that an interface between said surrounded axle periphery and said axle mounting plate is free of clearance; c) at least a pair of openings formed in the axle mounting plate, said openings each being circumferentially offset from said edge defining the outermost limit of the recess and from a vertical axis plane of said axle, and further each of the openings being located adjacent to a respective one of an upper front and an upper rear quadrant of the axle, said axle mounting plate further being formed with a first cutout for accessing said upper front axle quadrant opening for welding the axle mounting plate to said axle; d) a first end of said beam being pivotally attached to said vehicle frame and a second end of said beam being attached to an air spring, and an end plate being attached to said beam second end for supporting said air spring which extends between said end plate and the vehicle frame, the end plate being formed with a second cutout for accessing said upper rear axle quadrant opening for welding said axle mounting plate to the axle, whereby each of said front and rear axle quadrant openings has a continuous weld disposed about the periphery of the opening; and e) mounting said beam on a frame of said vehicle.
- 49. The method of assembling a vehicle axle/suspension system of claim 48, in which a generally U-shaped rib is attached to and depends from said end plate and said axle mounting plate for supporting the end plate.
- 50. The method of assembling a vehicle axle/suspension system of claim 48, in which said rigid suspension beam includes an inverted U-shaped top channel; in which said top channel includes a pair of spaced-apart sidewalls and a top wall; in which an inverted U-shaped insert having a generally complementary size and shape to the top channel is disposed within said top channel adjacent to said axle mounting plate recess; in which said insert includes a pair of spaced-apart sidewalls and a top wall; and in which each of said insert sidewalls is attached to a respective one of said beam top channel sidewalls and said axle mounting plate with a single weld.
- 51. The method of assembling a vehicle axle/suspension assembly of claim 50, in which said axle mounting plate is formed with flanges which extend outboardly and inboardly beyond said top channel sidewalls adjacent to said axle mounting plate recess; and in which a press applies a force to said axle mounting plate flanges sufficient to fit said axle into the mounting plate recess.
- 52. A method of assembling a vehicle axle/suspension system, said method including the steps of:
a) preassembling at least one suspension beam including an axle mounting plate formed with a recess, said recess having a shape generally complementary to generally half of the periphery of an axle for surrounding said axle half periphery, said axle mounting plate having at least one edge defining the outermost limit of the recess, said recess being a smaller size or an equal size to the axle half periphery; b) force fitting said axle half periphery into the recess by applying pressure to the axle mounting plate so that an interface between said surrounded axle periphery and said axle mounting plate is free of clearance; c) at least a pair of openings formed in the axle mounting plate, said openings each being circumferentially offset from said edge defining the outermost limit of the recess and from a vertical axis plane of said axle, and further each of the openings being located adjacent to a respective one of a lower front and a lower rear quadrant of the axle, said beam further being formed with a first cutout for accessing said lower front axle quadrant opening for welding the axle mounting plate to said axle; d) a first end of said beam being pivotally attached to said vehicle frame and a second end of said beam being attached to an air spring, said air spring extending between said beam second end and the vehicle frame, said beam being formed with a second cutout rearwardly of said first cutout for accessing said lower rear axle quadrant opening for welding the axle mounting plate to the axle, whereby each of said front and rear axle quadrant openings has a continuous weld disposed about the periphery of the opening; and e) mounting said beam on a frame of said vehicle.
- 53. The method of assembling a vehicle axle/suspension system of claim 52, in which the rigid suspension beam includes a U-shaped bottom channel; and in which said bottom channel includes a pair of spaced-apart sidewalls and a bottom wall.
- 54. The method of assembling a vehicle axle/suspension assembly of claim 53, in which said axle mounting plate is formed with flanges which extend outboardly and inboardly beyond said bottom channel sidewalls adjacent to said axle mounting plate recess; and in which a press applies a force to said axle mounting plate flanges sufficient to fit said axle into the mounting plate recess.
CROSS-REFERENCE
[0001] This is a Continuation-In-Part of application Ser. No. 09/110,735, filed Jul. 02, 1998.
Continuation in Parts (1)
|
Number |
Date |
Country |
Parent |
09110735 |
Jul 1998 |
US |
Child |
09737672 |
Dec 2000 |
US |