Abstract: A multi-mode trailer suspension system for use on a highway and a railroad is provided. The suspension system has a frame and a sub-frame pivotally connected to the frame. At least one lower suspension arm is pivotally connected to one of either the frame or the sub-frame. The lower suspension arm supports an axle assembly. At least one suspension spring is arranged between the sub-frame and the lower suspension arm to provide damping. At least one bi-directional actuator interconnects the frame and the sub-frame for moving the sub-frame relative to the frame to a plurality of positions, namely a highway position, a rail position, and a transition position. Accordingly, the bi-directional actuator is used to raise and lower the trailer without using the suspension springs.

Abstract: A system for determining the amount of material in a brake lining includes a frictional brake surface and a brake lining having a sensor for producing an output signal indicating the temperature of the sensor. A brake actuation system actuates the brake lining against the frictional brake surface and, thereafter, releases the brake lining from the frictional brake surface. A timer measures a time period beginning when the brake lining is released from the frictional brake surface and ending when the sensor output signal reaches a return point indicative of the brake lining having cooled. A controller compares the measured time period to electronically stored predetermined values to determine the thickness of the brake lining. The invention further includes a method for determining the amount of brake lining material based upon this structure.

Abstract: A vehicle tire inflation system includes an axle assembly with an axle housing having an air supply conduit. Air is provided to the air supply conduit from an air tank mounted on the vehicle. The axle includes least one wheel hub rotatably supported on the axle housing by bearings. A hub cap is mounted at one end of the wheel hub and has an inlet and an outlet interconnected by a passageway. Air flows from the air supply conduit to the inlet, through the passageway, and out the outlet. At least one pneumatic tire is mounted for rotation with the wheel hub and has a tire inlet. A hose connects the hub cap to the tire to route air from the hub cap outlet to the tire inlet.

Abstract: A vehicle hub includes a generally cylindrical axially extending body forming an inboard bearing seat, an outboard bearing seat and lubricant cavity therebetween. The hub is preferably cast as an integral component from a ductile iron. A plurality of integral open ribs connects the body to a radially extending flange. The ribs form an open area between the body and the ribs. The open structure of ribs providing increased cooling for the bearings and lubricant while decreasing weight without sacrificing hub strength and rigidity. The lubricant cavity is of a reduced diameter which reduces the volume of lubricating medium required to fill the cavity and minimizes the centrifuge effect acting upon the medium. The beneficial effects of the improved hub providing increased bearing cooling, lighter weight, a smaller lubricant cavity and increased strength.

Abstract: An improved press fit joint is particularly useful for iron parts. An outer part receives an inner part which is press fit into a bore in the outer part. The outer part has a hole, and the inner part has a dimple which is aligned with the hole when the inner part is forced into the outer part. The dimple has a dimension which is greater than the dimension of the hole. A puddle weld is formed within the hole and in the dimple. The puddle weld thus provides a secondary retention holding the inner part within the outer part.

Abstract: A system for indicating the amount of material in a brake lining includes a frictional brake surface and a brake lining having a sensor for detecting when the temperature of the brake lining exceeds a predetermined temperature. A brake actuation system actuates the brake lining against the frictional brake surface. A controller counts the number of temperature detections and the number of brake actuations during a predetermined period and produces a first signal when a ratio of the number of temperature detections to the number of brake actuations is equal to or greater than a first predetermined value. In a preferred embodiment of this invention, the controller produces a second signal when the ratio of the number of temperature detections to the number of brake actuations is equal to or greater than a second predetermined value and less than the first predetermined value. The invention further includes a method for determining wear based upon this structure.

Abstract: A brake shoe assembly includes a brake lining and a brake lining wear sensor. The brake lining has a predetermined thickness which gradually wears away as the brake shoe assembly is used to brake a vehicle. The brake lining wear sensor has a pair of spaced electrical conductors and an electrical resistance located across the pair of spaced conductors for indicating the thickness of the brake lining. The brake lining wear sensor is positioned to wear away concurrently with the brake lining, thereby continuously changing the electrical resistance across the pair of spaced conductors. In this manner, the electrical resistance across the pair of spaced conductors is used to determine the thickness of the brake lining. The brake lining wear sensor can be assembled in alternative embodiments as disclosed.

Abstract: The method of this invention for assembling vehicle brake shoes includes the use of linear friction welding. Two generally planar web members having arcuate edges are precisely aligned. Each of the web members preferably includes a series of projections along an outer arcuate edge. A table member that has a curvature corresponding to the outward arcuate edge of the web members is placed in contact with the projections along the outer arcuate edge of the web members. The webs and the table are moved relative to each other, under load, to cause an increase in temperature within the metal material of the webs and the table. After the temperature is sufficiently increased, but before the material reaches its melting temperature, the relative motion is stopped and the web members are precisely aligned with the table member. Then the load is increased and the table is forced against the web members. The projections are then deformed, a flash results, and the web members are fixedly joined to the table member.

Abstract: A bushing boot for a cam braking system is disclosed that snaps in place over a bushing assembly. The bushing assembly supports a camshaft in the cam braking system. The bushing boot is preferably generally cylindrical having a first end, a second end and an internal bore extending along a longitudinal axis. In a preferred embodiment, the boot also has an internal circumferential groove within the bore at its first end and an external circumferential groove at its second end. The bushing assembly includes a washer at an end adjacent the boot. The internal groove of the boot snaps in place over the outside diameter of the bushing assembly washer, thereby providing an axial locating feature. The internal bore of the boot receives the camshaft. Further, the external groove on the boot receives a tie strap to connect the boot to the camshaft. In the preferred embodiment, the boot rotates with the camshaft. In an alternative embodiment, the boot does not have an external circumferential groove.

Abstract: A brake shoe assembly includes a brake lining and a housing. The brake lining has a predetermined thickness which gradually wears away and increases in temperature during a vehicle braking application. The housing is positioned to wear away and increase in temperature concurrently with the brake lining. An electrical wear loop circuit is encapsulated in the housing for directing power from a power source to a remote indicator in response to a wear opening in the loop circuit. A thermally sensitive switching element is encapsulated in the housing and connected in electrical series with the wear loop circuit for directing power from the power source to the remote indicator in response to the temperature of the housing exceeding a predetermined temperature threshold.

Abstract: An axle alignment system includes a transmitter, reflectors, and an indicator area. The transmitter transmits signals, preferably laser beams, to each reflector. Signals received by the reflectors attached to the end of the axles are reflected at a predetermined angle and direction to be viewed on an indicator area. The indicator area receives the redirected signals from each reflector and provides a visual illustration of the relationship between the suspension axle and another suspension part such as the suspension subframe siderails. Accordingly, the angularity of the axles relative to the siderails may be adjusted such that each of the reflected signals are displayed simultaneously on a reference marker. Once the reflected signals are aligned with respect to the reference marker, the axles are assured to be in accurate alignment.

Abstract: A vibration sensor includes a housing having an opening, and a movable trigger retained within the housing by a resilient member. The moveable trigger includes a projection of a dimension to fit at least partially through the opening. The resilient member retains the movable trigger within the housing until overcome by a predetermined acceleration. Whereas the moveable trigger is maintained within the housing the vibration sensor is minimally affected by radial acceleration while providing a calibrated resistance which must be overcome by an acceleration of predetermined severity along the measured direction. When the sensor experiences a predetermined acceleration, the trigger slides within the housing until the projection encounters the opening. The projection then “pops” through the opening such that the projection encounters a switch which awakes and activates a transmitter to send a signal to a warning device.

Abstract: A method and system for providing variable load control and isolation in a vehicle suspension includes a variably flexible suspension element coupled between the frame of the vehicle and the wheel. The variably flexible suspension element comprises an electrically responsive material disposed therein that varies stiffness in response to electrical control signals applied thereto. The electrical control signals are generated by an electronic control unit and are representative of road conditions traveled by the vehicle as sensed by at least one sensor.

Abstract: A tubular axle having a spindle and a bearing shoulder is formed directly into heat-treated tubing. The method generally includes a heating operation, and a two stage forming operation. The first operation is to induction heat a steel tubular axle blank to a temperature less than 1500 degrees Fahrenheit. The next operation includes forcing a preform die assembly onto the tubular blank to reduce a length of the blank to a second diameter while forming an intermediate section having a first and second ramped section. The final operation includes forcing an upset die assembly onto the end of the blank to form a gathered material section formed intermediate the first ramped section and the second ramped section. The second diameter provides a pre-machined diameter for the final axle spindle and the gathered material section provides a pre-machined area for the final integral bearing shoulder.

Abstract: An axle assembly includes an axle, a tire having a predetermined air inflation pressure rotatably supported on the axle, and a tire inflation system for detecting an actual tire inflation pressure less than the predetermined air inflation pressure, replenishing the tire with air, and producing an inflation signal. An inventive electronic recorder receives the inflation signal, increments a count register, and transmits count register data to an output device. In a first embodiment of this invention, the electronic recorder is mounted at an easily accessible location on a vehicle which includes the axle assembly. In a second embodiment of this invention, the tire is mounted to a wheel assembly and the axle assembly further includes an electronic hub odometer for detecting a revolution of the wheel assembly and producing an odometer signal.

Abstract: A method and system for determining the performance characteristics of at least one selected vehicle component utilizes a plurality of variables and takes into account the interrelationship of those vehicles. Specifically, a detected temperature, load and road grade condition are utilized to determine a rate of change in a performance characteristic of a selected component relative to time. The rate of change information is provided to a vehicle operator on a real-time basis and stored in memory for later use by a service technician. Determining a performance characteristic based on a plurality of variables and storing information regarding that characteristic over time provides additional useful information to a service technician enabling the technician to more quickly and effectively diagnose potential problems with the vehicle components.

Abstract: A system actively monitors the fatigue of gears used in a vehicle drive axle assembly. The system includes a sensor system for detecting a speed of rotation and a torque. The speed of rotation and the torque are indicative of the speed of rotation and the torque on the gears. A microprocessor communicates with the sensor system to gather the speed of rotation and torque information. The microprocessor utilizes the information to actively determine gear fatigue. The microprocessor compares the gear fatigue with a pre-selected threshold gear wear value. If the pre-selected threshold value has been exceeded, the microprocessor provides an output, which preferably notifies the driver of the excessive gear fatigue.

Abstract: A drive line vibration sensor includes an emitter, a receiver, and a controller. The emitter and receiver are mounted in a differential manner such that drive line vibrations cause the emitter to vibrate at a different frequency than the receiver. In operation the emitter transmits a signal to the receiver such that the differential movement of the transmitter relative to the receiver produces a variation in the signal received by the receiver which is identifiable by the controller. In another embodiment, the emitter pulses the signal such that the frequency of the vibration can be determined. A recording device is preferably in communication with the controller to record the variation in the signal to provide an inexpensive diagnostic and maintenance system which can record the overall operation of a drive line under actual operational conditions.

Abstract: A roll-over detector for vehicles includes a first accelerometer mounted on a first axle of the vehicle, a second accelerometer mounted on a second axle of the vehicle, and a third accelerometer mounted on a third axle of the vehicle. A controller compares data received from the first and second accelerometers and actuates a safety device to prevent a roll-over condition if the differences between the data exceed a predetermined value. The controller utilizes data from the third accelerometer to account for the effect of road conditions on the variations between the data from the first and second accelerometers.

Abstract: An axle assembly for supporting wheels is provided that has a spindle defining an axis of rotation with a threaded end portion. A hub assembly is supported by the spindle and is adapted to support the wheels. A bearing assembly is arranged adjacent to the threaded end portion and is interposed between the spindle and the hub assembly for permitting low friction rotation of the hub assembly relative to the spindle about the axis. An end nut is secured to the threaded end portion of the spindle for retaining the bearing assembly and the hub assembly on the spindle. A washer is interposed between said bearing assembly and the end nut wherein the washer secures the end nut to the spindle for preventing rotation of the end nut about the axis.