Abstract: At least one bimetal tab is disposed in a groove between a wheel disc formed from a first metal and a wheel rim formed from a second metal which is different from the first metal. The bimetal tab is formed by roll bonding a layer of the first metal to a layer of the second metal. The first metal layer of the bimetal tab is adjacent to the wheel disc while the second metal layer of the tab is adjacent to the wheel disc. A spot weld which extends through the bimetal tab secures the wheel disc to the wheel rim.

Abstract: An electronic controller for actuating electric wheel brakes on a towed vehicle which includes a device for sensing the electric current flowing to the towed vehicle wheel brakes. The device is operative to interrupt the flow of electric current if the current flow becomes excessive. The controller also retains gain settings if the supply of power to the controller is interrupted and has a visual display for indicating results of self-diagnostic testing.

Abstract: A partial wheel rim is press fit onto a cylindrical collar which extends axially from an inboard surface of a fall face wheel disc. The rim includes a circumferential bead which is received by a corresponding circumferential groove formed in the wheel disc collar to retain the wheel rim upon the wheel disc.

Abstract: The present invention relates to a modular brake rotor having friction rings secured to a core. The core includes a hat section having a hat wall, and a plurality of circumferentially spaced apart support ribs. A pair of friction rings having inner surfaces are secured to the support rib inboard and outboard mounting surfaces. The support ribs extend into recesses formed in the inner surfaces of the friction rings to secure the friction rings to the support ribs. The ribs may include protrusions formed using dowels which extend through the support ribs and project out of the inboard and outboard mounting surfaces and into the recesses. Alternatively, the protrusions may be formed integrally with the support ribs.

Abstract: A zinc alloy melt-out core comprises from 0.75% to 3% Cu, from 0% to 0.3% Ni, from 0% to 0.5% Al, and balance Zn. The zinc alloy melt-out core is used in pressure casting processes for producing an aluminum article having a hollow. The zinc alloy core has a shape-imparting outer surface. In the pressure casting process, the zinc alloy core preserves a space corresponding to the hollow. The zinc alloy core has improved hot strength and thus maintains its integrity during the pressure casting process, inhibiting seepage of the core material into the aluminum cast article. Preferred zinc alloy melt-out cores further comprise an outer coating of insulating material selected from the group consisting of mica, graphite, ceramics and combinations thereof.

Abstract: An improved vehicle wheel cover retention system and method for producing the same wherein the wheel includes a disc defining an outboard facing wheel surface and including an outboard tire bead seat retaining flange. The flange includes an outer surface having a circumferential, radially inwardly facing groove formed therein. The groove is defined by a generally axially extending first surface and a second surface angled relative to the first surface. The wheel further includes a wheel cover covering at least a portion of the outboard facing wheel surface. The cover includes an outer annular lip which extends into the groove and is positioned adjacent the first surface. The groove and the lip have a configuration which enables the lip to spring outwardly into the groove when the cover is pressed on the disc.

Abstract: An apparatus and method for reclaiming metal chips formed while machining metal castings to their finished shape. The apparatus includes a stationary charging tube extending in a generally perpendicular direction from the charge well of a reverbratory furnace. The lower end of the charging tube is attached to a box-shaped structure which has an open bottom. The sides of the structure extend into a pool of molten metal contained in the charge well. A variable rate feeder provides a continuous supply of metal chips to the charging tube at a rate which is essentially the same as the rate at which the chips are being produced. The chips form a column within the charging tube which extends through the box-shaped structure and into the pool of molten metal. As the chips at the bottom of the column are melted, additional chips are added to the top, forcing the bottom of the column of chips into the pool of molten metal.

Abstract: A two piece wheel having a partial wheel rim mechanically attached to a full face wheel disc by at least one locking pin. The locking pin extends through an aperture formed in a collar extending from an inboard surface of the wheel disc and a corresponding aperture formed through the wheel rim end and is secured by a weld. A resilient material is disposed between the wheel disc and rim end to form an air-tight seal therebetween.

Abstract: A two piece vehicle wheel having a wheel rim secured to a wheel disc by a locking member which is received by complementary grooves formed in the wheel rim and the wheel disc. A layer of resilient material forms a seal between the wheel rim and the wheel disc. The sealing material can included an adhesive.

Abstract: A fixture for holding a brake drum or other similarly shaped workpiece for machining. The fixture includes a body having a body cavity and a clamping assembly disposed therein. The clamping assembly includes a positioning plate having a plurality of positioning posts secured thereto. The positioning posts are received within fastener apertures formed in the brake drum mounting face for locating the drum within the fixture so that the drum axis is coaxially aligned with the fixture axis for proper machining. The clamping assembly further includes a clamping plate and clamping flange for clamping the mounting face of the brake drum during machining to simulate the compressive forces applied to the drum as it is mounted to a vehicle during operation. The fixture further includes first and second pluralities of chucking assemblies for gripping the body of the brake drum along respective first and second spaced apart planes thereby reducing distortions caused by the cutting tool during machining.

Abstract: An electrical short circuit protection device for an electric trailer brake controller includes a fuse connected between the controller and the trailer brakes and an acoustic piezoelectric transducer connected across the fuse. Upon a short circuit fault developing in the trailer brakes, the fuse opens and the transducer generates an audio warning signal.

Abstract: A tire pump mounted upon a wheel includes a reciprocating piston driven by one of a pendulum assembly or flywheel.

Abstract: Improved gray iron compositions comprise at least about 90 weight % iron, at least about 3.40 weight % carbon, from about 1 to 2.5 weight % silicon, from about 0.4 to 1.0 weight % manganese, and from about 0.02 to 0.07 weight % tin. Preferably, the gray iron compositions of the invention also include from about 0.2 to about 0.5 weight % chromium, and may further preferably include from about 0.25 to 0.75% molybdenum and/or from about 0.3 to 1.0% copper, and may optionally also include small amounts (less than about 1%) of such elements as titanium or vanadium, as examples. The gray iron compositions which may advantageously be used in the manufacture of vehicle brake components, especially the braking surfaces of vehicle brake drums or brake rotors.

Abstract: A composite brake drum for a motor vehicle or the like is comprised of a cast metal drum section, a stamped steel drum back, and a cast metal mounting face. The drum section and mounting face are preferably formed of cast iron. The composite drum of the invention provides a reduction in weight and in the amount of machining required as compared with a full cast brake drum. At the same time, the composite brake drum of the invention permits an increase in the thickness of the mounting face as compared with conventional composite brake drums, allowing motor vehicle manufacturers to use the same hubs and keep the vehicle track the same regardless of whether a particular vehicle includes a disc/drum or a disc/disc brake system.

Abstract: The invention is directed to a rotor having a vented hat section and a method of forming the same. Such a rotor includes a hat section having a central mounting face and a cylindrical shoulder or hat wall extending axially from the mounting face to an annular peripheral section having friction surfaces disposed on opposite sides. A plurality of spaced apart vents are defined in the wall of the hat section. The vented rotor is formed by first casting a rotor to the desired configuration including at least the hat section. The initial casting is formed in such a manner that one or more depressions are provided in the radially inner surface of the wall of the hat section. These depressions do not extend through the wall of the hat section. Then, material is removed in one or more machining steps from the radially outer surface of the wall of the hat section proximate the depressions.

Abstract: A brake rotor includes a radially inner hub or hat section having a central mounting face for mounting the rotor on an associated drive member, with an outer friction portion extending from the cylindrical hat wall. The outer friction portion includes a pair of opposite, flat annular friction rings adapted to interface with associated friction members. The outer friction portion of the rotor further includes a core extending radially outwardly from the cylindrical hat wall of the hat section. A layer of a sound dampening material is secured between the pair of outer friction ring sections and the core. The rotor of the invention transmits less noise than conventional rotors.

Abstract: The invention is directed to a method of forming a vented rotor for caliper disc brakes and the like. Such a vented rotor includes an outer friction portion having one or more ring sections with opposed friction surfaces adapted to interface with associated friction members. The vented rotor is formed by first casting a rotor to the desired configuration including at least the ring section. This initial casting is formed in such a manner that one or more depressions are provided a surface of the ring section. Then, material is removed in one or more machining steps from portions of the friction surface opposite the friction surface having the depressions, to the point that the depressions extend completely through the ring section to form the vents.

Abstract: A composite rotor for caliper disc brakes and the like includes an outer friction portion having two ring sections, with a plurality of supports extending therebetween to fixedly interconnect the ring sections in a mutually parallel, spaced apart relationship defining a cavity therebetween. The ring sections have opposite friction surfaces which interface with associated friction members. The rotor also includes an inner hub portion having a central mounting section which mounts the same on a drive member, and a peripheral section cast into the cavity of the outer friction portion to integrally interconnect the inner hub and outer friction portions of the rotor with primarily mechanical bonds formed at an unfused interface.

Abstract: An apparatus for checking leakage of a test gas through a wheel. The apparatus comprises wheel recognition apparatus for generating a first signal indicative of selected parameters of a wheel, a test cell for applying a differential pressure of a test gas through a selected portion of the wheel, and detecting apparatus for determining a leak rate of the test gas through the selected portion of the wheel. The detecting apparatus generates a second signal indicative of the leak rate. The apparatus of the invention also includes a microprocessor operatively connected to the recognition apparatus for receiving and processing the first signal to determine the model of the wheel from among a group of preselected model wheels. The apparatus is also operatively connected to the test cell for controlling operation of the detecting apparatus according to the model of the wheel, and operatively connected to the detecting apparatus for receiving and processing the second signal to generate a record of the leak rate.