Abstract: A mold for gravity casting vehicle wheels having reusable thermally insulative linings attached to the interior of the gate and ball riser cavities. After filling the mold with molten metal, the gate cavity can be pressurized to assure that the mold cavity is completely filled. The ball riser cavity also can be pressurized subsequent to the gate cavity pressurization. The pressure on the gate and ball riser cavities forces molten metal from the cavities into the mold cavity as the metal cools and solidifies.

Abstract: An electronic brake controller for actuating electric wheel brakes of a towed vehicle which includes a zero adjusting circuit for a pendulum in an inertia sensor.

Abstract: A plated vehicle wheel having non-plated tire bead seats and a process for forming same. The process includes masking a portion of the tire bead seats before plating the wheel. The process also includes forming the tire bead seats with an oversized diameter. Following plating, the tire bead seats are machined to a final diameter. The process can further include thermally depositing a layer of a ceramic material over a portion of the tire bead seat surface. The plating does not adhere to the ceramic material.

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: An improved method for forming a vehicle wheel includes the steps of steps of: (a) providing a rim defining a rim axis and including a generally axially extending well portion and a pair of opposed ends, one of said ends including an inboard tire bead seat retaining flange and an inboard tire bead seat, and the other end including an outboard tire bead seat; (b) providing a generally circular disc blank formed from aluminum and defining a disc axis, the disc blank including an inner annular wheel mounting portion and an outer annular portion; (c) initially stamping the disc blank to produce a generally bowl shaped disc having a first axial distance defined between an inner surface of the outer annular portion and an inner surface of the inner annular wheel mounting portion; (d) subjecting the bowl shaped disc to an intermediate metal forming operation to produce a partially formed disc having a second axial distance defined between the inner surface of the outer annular portion and the inner surface of the in

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 for measuring the axial deviation of a vehicle wheel surface relative to a reference plane. The apparatus includes a base which supports the vehicle wheel. A post is mounted upon the base. The post has an axial bore formed therein. The bore has an end surface which is a known axial distance from the reference plane. The apparatus also has a housing adapted to contact a plurality of points located on a surface of the wheel, the plurality of points defining an annular surface on a portion of the wheel face. The apparatus further includes a gage mounted in the housing. The gage has a probe which is received by the post bore. The gage is operative to measure the deviation of the axial distance between the annular surface on the wheel face and the reference plane.

Abstract: A vehicle wheel including a wheel rim having a central axis and a plurality of generally parallel wheel discs extending across the wheel rim. The wheel discs are spaced axially apart and are generally perpendicular to the central axis. The wheel discs are permanently secured to the wheel rim.

Abstract: An automotive wheel having an outboard face presenting an asymmetric appearance and having a permanently fixed counterbalance weight near the outer periphery of the wheel to balance the wheel. The wheel disk has an asymmetric design which tends to statically and dynamically unbalance the wheel. A relatively light counterbalance weight is permanently fixed to the wheel during manufacture of the wheel. This counterbalance weight statically and dynamically balances the overall wheel.

Abstract: A multi-piece wheel mold defining a mold cavity having a wheel rim cavity and a wheel disc cavity includes a large mass of metal adjacent to the outboard end of the wheel rim cavity and a small mass of metal adjacent to the inboard end of the wheel rim cavity. The mold also includes tapered side segments having a portion adjacent to the inboard end of the wheel rim cavity which is formed from a metal having a first conductivity of heat transfer. The side segments further have a second portion adjacent to the outboard end of the wheel rim cavity which is formed from a second metal having a second conductivity of heat transfer which is greater than the conductivity of heat transfer of the first portion. Molten metal in the mold cavity initially begins to solidify in the outboard end of the wheel rim cavity.

Abstract: A method for fabricating a vehicle wheel having a wheel rim mechanically rolled onto a wheel disc. The wheel disc includes at least one continuous circumferential bead or groove. During the rolling operation a complementary groove or bead is formed in the wheel rim. The bead is received by the groove to mechanically secure to the wheel rim to the wheel disc. A resilient material including an adhesive is disposed between the wheel disc and the wheel rim. The adhesive bonds the wheel rim to the wheel disc while the resilient material forms air-tight seal therebetween.

Abstract: A plated vehicle wheel having non-plated tire bead seats and a process for forming same. The process includes masking a portion of the tire bead seats before plating the wheel. The process also includes forming the tire bead seats with an oversized diameter. Following plating, the tire bead seats are machined to a final diameter. The process can further include thermally depositing a layer of a ceramic material over a portion of the tire bead seat surface. The plating does not adhere to the ceramic material.

Abstract: An electronic brake controller for actuating electric wheel brakes of a towed vehicle in response to actuation of the brakes of an associated towing vehicle. The brake controller includes a sensor for producing a brake control signal which is representative of the desired braking of the towed vehicle. The controller also includes a microprocessor for responsive to the brake control signal for generating an output signal for actuating the electric wheel brakes of the towed vehicle.

Abstract: An electronic brake controller for actuating electric wheel brakes of a towed vehicle in response to braking of an associated towing vehicle. The controller includes a microprocessor responsive to the braking of the towing vehicle for generating an output signal for actuating the towed vehicle brakes in accordance with a brake response curve. The brake response curve can include a non-linear portion.

Abstract: An improved vehicle wheel welding station which minimizes the stoppages of the welding station to replace the contact tip and/or welding wire conduit includes an wheel support fixture for supporting a vehicle wheel and at least three welding torches supported relative to the wheel support fixture. Each of the welding torches is movable with respect to the fixture in a generally radial direction between a retracted non-working position and an extended working position. Each of the welding torches including a generally straight body defining an upper end portion and an opposite lower end portion. The upper end portion of each torch is operatively connected to a conduit assembly adapted to contain and feed a weld wire into the body, and the lower end portion is operatively connected to a nozzle assembly adapted to produce a weld along a selected arcuate portion of a wheel assembly.

Abstract: An improved vehicle wheel cover retention system and method for producing the same includes a vehicle wheel having a disc defining an outboard facing wheel surface and including an outboard tire bead seat retaining flange. The outboard bead seat retaining flange includes an outer peripheral end and an inner surface having a circumferential, radially outwardly facing groove formed therein. The vehicle wheel further includes a wheel cover which covers at least a portion of the outboard facing wheel surface and the entire portion of the outer peripheral end of the outboard bead seat retaining flange. The wheel cover includes an inner cover surface and an outer annular lip which extends into the groove when the wheel cover is installed on the disc.

Abstract: An improved wheel construction includes a disc and a rim secured together and which define a radially inwardly facing circumferential cavity in the wheel. In accordance with the present invention, a filler material is disposed in a substantial portion of the cavity to prevent road material or other debris from accumulating in the cavity and causing an out-of-balance wheel condition.

Abstract: An improved method is disclosed for producing a wheel rim for use in a vehicle wheel. The method includes the steps of: (a) providing a flat sheet of material; (b) forming the flat sheet into a hoop having a first predetermined axial length; (c) expanding the hoop to a predetermined inner hoop diameter; (d) flow spinning the hoop to produce a wheel rim preform having a second predetermined axial length greater than the first predetermined axial length, the wheel rim preform including opposed axial ends and a thinned axially extending intermediate portion located between the axial ends; (e) subsequent to step (d), flaring at least one axial end of the wheel rim preform; and (f) subsequent to step (e), subjecting the wheel rim preform to a series of roll forming operations to produce a finished wheel rim having at least one tire bead seat retaining flange, at least one tire bead seat surface, and a generally axially extending well.

Abstract: A layer of material is thermally sprayed onto a portion of the surface of a vehicle wheel rim drop well with an arc plasma spray gun. Before spraying, the drop well surface is prepared by removing any dirt, oil and oxides. The sprayed layer has a greater density than the metal forming the wheel rim and reduces the porosity of the drop well.