Abstract: An axle mount for a brake system component of an axle/suspension system includes a weld disposed on and between the axle of the axle/suspension system and a brake system component. The weld secures the brake system component to the axle of the axle/suspension system to form a bracket-to-axle connection. The connection includes a peened portion that is formed by working the surface of the connection by mechanical means. The peened portion of the connection exhibits residual compressive stresses that increase the durability of the brake bracket-to-axle connection and also the durability of the axle itself.

Abstract: A directional damper for heavy-duty vehicle axle/suspension systems includes damping means disposed at least between the vehicle and a suspension assembly of the vehicle. The damping means provides directional damping to the suspension assembly with respect to a selected datum, such as the beam or the main member of the vehicle.

Abstract: A directional damper for heavy-duty vehicle axle/suspension systems includes damping means disposed at least between the vehicle and a suspension assembly of the vehicle. The damping means provides directional damping to the suspension assembly with respect to a selected datum, such as the beam or the main member of the vehicle.

Abstract: An axle/suspension system for heavy-duty vehicles having a frame and at least one suspension assembly operatively connected to the frame, the axle/suspension system including a mechanical stop having a plurality of links and a first end and a second end, the second end rigidly attached to the suspension assembly and the first end rigidly attached to the vehicle frame, wherein the first end and the second end control a distance between the first end and the second end, and control the plurality of links to attain a movement tolerance range of said mechanical stop from about 0.0 inches to about 2.0 inches.

Abstract: A shock mount support assembly for a shock absorber of a suspension assembly of an axle/suspension system includes a shock support bracket formed with an opening. A fastener is disposed through the opening in the shock support bracket and an eyelet of the lower end of the shock absorber to loose-fit the shock support bracket to the shock absorber, and to the suspension assembly beam in a transverse direction. The shock support bracket includes at least one transversely elongated or oversized opening that aligns with an opening formed in the beam. A fastener is disposed through the pair of aligned openings in order to loose-fit attach the shock support bracket to the beam. During assembly, the eyelet fastener is tightened first drawing the shock support bracket transversely outboardly. The fastener disposed through the shock support bracket-to-beam attachment is tightened, rigidly attaching the shock support bracket to the suspension assembly.

Abstract: An axle mount for a brake system component of an axle/suspension system includes a weld disposed on and between the axle of the axle/suspension system and a brake system component. The weld secures the brake system component to the axle of the axle/suspension system to form a bracket-to-axle connection. The connection includes a peened portion that is formed by working the surface of the connection by mechanical means. The peened portion of the connection exhibits residual compressive stresses that increase the durability of the brake bracket-to-axle connection and also the durability of the axle itself.

Abstract: An air-ride beam-type axle/suspension system for a heavy-duty vehicle with a gross axle weight rating of greater than 23,000 lbs./axle includes a pair of transversely spaced beams. Each one of the beams includes inboard and outboard sidewalls. A large diameter axle extends between and is rigidly connected to the beams via a pair of axle-to-beam connections. Each one of the axle-to-beam connections includes a sleeve having an increased thickness rigidly connected to the axle and the beam. Each sleeve is formed with at least a front and a rear window located between the beam sidewalls. The inboard and/or outboard edges of the sleeve windows are spaced relatively far from the beam sidewalls. The sleeve windows are asymmetrically angled with respect to the horizontal centerline of the axle at design ride height. The axle/suspension system reduces weight while maintaining desired stiffness and durability of the axle/suspension system.

Abstract: An axle-to-beam connection for axle/suspension systems includes a pair of U-bolt brackets that extend generally to or beyond a selected centerline of the axle. The U-bolt brackets are located a distance from one another so that the distance between the U-bolt brackets is equivalent to or preferably less than the outside diameter of the axle resulting in a slight deformation of the axle and a compressive preload between the axle and the U-bolt brackets when the axle is seated between the U-bolt brackets. A weld is placed between the U-bolt brackets and the axle at or beyond the horizontal centerline of the axle within the residual compressive stress field on the axle created by the interference fit of the axle into the U-boll brackets. Means for securing connection of the axle to the beam includes a U-boll or other similar means to provide additional locating support to the axle.

Abstract: A shock mount support assembly for a shock absorber of a suspension assembly of an axle/suspension system includes a shock support bracket formed with an opening. A fastener is disposed through the opening in the shock support bracket and an eyelet of the lower end of the shock absorber to loose-fit the shock support bracket to the shock absorber, and to the suspension assembly beam in a transverse direction. The shock support bracket includes at least one transversely elongated or oversized opening that aligns with an opening formed in the beam. A fastener is disposed through the pair of aligned openings in order to loose-fit attach the shock support bracket to the beam. During assembly, the eyelet fastener is tightened first drawing the shock support bracket transversely outboardly. The fastener disposed through the shock support bracket-to-beam attachment is tightened, rigidly attaching the shock support bracket to the suspension assembly.

Abstract: A brake system component axle mount for a vehicle axle/suspension system includes an axle having at least one depression formed therein. A sleeve is formed with at least one depression and disposed about the axle so that the axle depression and the sleeve depression matingly engage one another to form a mated pair of depressions. A brake mount assembly is rigidly attached to the sleeve. A method of forming the brake system component axle mount includes providing an axle and disposing a sleeve about the axle. At least one mated pair of depressions is simultaneously formed in the axle and the sleeve. A brake mount assembly is rigidly attached to the sleeve.

Abstract: An air-ride beam-type axle/suspension system for a heavy-duty vehicle with a gross axle weight rating of greater than 23,000 lbs./axle includes a pair of transversely spaced beams. Each one of the beams includes inboard and outboard sidewalls. A large diameter axle extends between and is rigidly connected to the beams via a pair of axle-to-beam connections. Each one of the axle-to-beam connections includes a sleeve having an increased thickness rigidly connected to the axle and the beam. Each sleeve is formed with at least a front and a rear window located between the beam sidewalls. The inboard and/or outboard edges of the sleeve windows are spaced relatively far from the beam sidewalls. The sleeve windows are asymmetrically angled with respect to the horizontal centerline of the axle at design ride height. The axle/suspension system reduces weight while maintaining desired stiffness and durability of the axle/suspension system.

Abstract: An axle-to-beam connection for axle/suspension systems includes a pair of U-bolt brackets that extend generally to or beyond a selected centerline of the axle. The U-bolt brackets are located a distance from one another so that the distance between the U-bolt brackets is equivalent to or preferably less than the outside diameter of the axle resulting in a slight deformation of the axle and a compressive preload between the axle and the U-bolt brackets when the axle is seated between the U-bolt brackets. A weld is placed between the U-bolt brackets and the axle at or beyond the horizontal centerline of the axle within the residual compressive stress field on the axle created by the interference fit of the axle into the U-boll brackets. Means for securing connection of the axle to the beam includes a U-boll or other similar means to provide additional locating support to the axle.

Abstract: A cold-formed, raised-center axle for a heavy-duty vehicle includes a central tube having a pair of ends, a pair of spindles attached to the central tube ends, and a wall thickness of from about 0.500 to about 0.625 inches. A hump is formed in the center portion of the tube and includes compressive residual stresses in its bottom portion when the axle is in an in-service position. A method for forming the raised-center axle includes the steps of providing a substantially straight axle, inserting the axle into a press, over-forming a hump in the axle in the direction such that camber is induced in the axle, and forming the axle in a second direction, thereby substantially removing the camber and replacing a detrimental residual stress state in the humped portion of the axle with a beneficial residual stress state.

Abstract: A lift-type axle/suspension system of a heavy-duty vehicle includes ride air springs for providing vehicle load support when the system is lowered, and one or more lift air springs for selectively raising the system when such additional load support is unnecessary or when greater vehicle maneuverability is desired. An apparatus integrates and simultaneously controls the operating systems for the lift and ride air springs. The control apparatus includes a plurality of conduits and valves which enable pressurized air from the lift air springs to be rapidly provided to the ride air springs when the system is being lowered. The additional air supplements the normal source of air from the vehicle compressed air source to ensure sufficient and timely air for smooth and efficient operation of the ride air springs without excessive buckling or folding, thus maintaining adequate overall vehicle air pressure needed for operating other vehicle components.

Abstract: A lift-type axle/suspension system of a heavy-duty vehicle includes ride air springs for providing vehicle load support when the system is lowered, and one or more lift air springs for selectively raising the system when such additional load support is unnecessary or when greater vehicle maneuverability is desired. An apparatus integrates and simultaneously controls the operating systems for the lift and ride air springs. The control apparatus includes a plurality of conduits and valves which enable pressurized air from the lift air springs to be rapidly provided to the ride air springs when the system is being lowered. The additional air supplements the normal source of air from the vehicle compressed air source to ensure sufficient and timely air for smooth and efficient operation of the ride air springs without excessive buckling or folding, thus maintaining adequate overall vehicle air pressure needed for operating other vehicle components.