Abstract: A clamp assembly of a vehicle leaf spring suspension is disclosed. The clamp assembly has an axle bracket secured to a vehicle axle and a top cap secured to the axle bracket by mechanical fasteners to define an axle seat. The axle bracket and top cap may include interlocking keys and keyways to cooperate with the mechanical fasteners in transmitting the load from the vehicle axle. A spring seat of the leaf spring is received within the axle seat and is tapered. The tapered spring seat, when combined with a deformable liner in the axle seat, effectively eliminates the inactive portion of the leaf spring to increase the effective length of the spring and minimize the spring rate.

Abstract: An axle/suspension system for a heavy-duty vehicle, in which the vehicle includes a frame that extends in a longitudinal direction relative to the vehicle. The axle/suspension system is attached to the vehicle frame via at least one hanger and includes at least one beam, which includes a first end and a second end. The first end of the beam is connected to the hanger, and the second end of the beam immovably captures an axle, which extends in a transverse direction relative to the vehicle. The beam is formed of a composite material and has a substantially constant cross section in the transverse direction to provide sufficient strength to control roll forces encountered by the vehicle during operation.

Abstract: A hubcap for a wheel end assembly of a heavy-duty vehicle seals an outboard end of the wheel end assembly. The wheel end assembly includes a wheel hub formed with a cavity that contains lubricant, and the hubcap positively engages and mounts on the outboard end of the wheel hub to prevent the escape of lubricant and the ingress of contaminants. The integrally-formed hubcap includes a generally cylindrical sidewall and an outboard wall that extends generally perpendicular to the sidewall. A lip extends inboardly from and a shoulder extends radially outwardly from an inboard end of the sidewall, and the lip and shoulder cooperate to positively mechanically engage the outboard end of the wheel hub. An O-ring is disposed between the lip and the wheel hub to provide a seal. The hubcap also is adapted to accommodate components of a tire inflation system and other auxiliary components.

Abstract: A non-torque reactive air suspension exhibiting excellent roll stability characteristics is shown to include frame hangers mounted to frame rails extending longitudinally on opposite sides of a vehicle. Longitudinally extending beams are connected to the frame hangers at one end and extend parallel to the frame rails. At their other ends, the beams are joined by a crossbrace extending laterally across the vehicle centerline. In a central portion thereof, the beams have an axle pivot bore to which an axle clamp assembly is connected, the axle clamp assembly clamping a drive axle housing for the vehicle. The axle pivot bore is generally aligned with the drive axle. A control rod assembly is connected to suspension or frame components. Together with the beams, the control rod assembly forms a parallelogram configuration wherein the beams form the lower linkages of that configuration and the control rods included within the control rod assembly form the upper linkages of that configuration.

Abstract: A leading or trailing arm vehicle suspension system comprised of a fabricated vehicle axle and a fully integrated beam casting providing bending stiffness to control axle windup and longitudinal stiffness to control axle position is disclosed. The beam casting is attached to the vehicle axle with a thru-bolt connection. The beam casting includes rack and pinion mounting attachment holes and also includes other built-in features providing efficient transfer of loads into the vehicle axle.

Abstract: A vehicle tire inflation system includes an air supply that is connected to a vehicle tire by a pneumatic conduit. A pump that is independent of and pneumatically parallel to the vehicle air supply includes an inlet and an outlet. The pump inlet receives air from atmosphere, the pump compresses the air, and the pump outlet is fluidly connected to the pneumatic conduit. When the air pressure in the pneumatic conduit drops below a predetermined level, compressed air from the pump is introduced into the pneumatic conduit, thus increasing the air pressure in the conduit to increase the air pressure that is available to the tire. A reservoir tank, which is also independent of the vehicle air supply, may be in fluid communication with the pump outlet and the pneumatic conduit.

Abstract: An elastomeric spring suspension is described for supporting a longitudinally extending vehicle frame rail above first and second axles forming a tandem axle configuration. The suspension includes a frame hanger assembly mounted to the vehicle frame rail. The frame hanger assembly has two full spring modules, each of which includes two shear springs, a progressive spring rate load cushion having a pyramidal shape with a flattened top surface and a spring mount for mounting the springs. A saddle assembly is connected to the spring mount, and an equalizing beam is connected to the saddle assembly and further connected to the axles. The spring rate for the suspension increases almost linearly as a function of sprung load, resembling a pneumatic suspension. Accordingly, the suspension exhibits excellent ride quality, without sacrificing roll stability.

Abstract: A frame for a heavy-duty vehicle includes a pail of spaced-apart, parallel, elongated, and longitudinally-extending main members. At least a pair of transverse cross members extend between and are attached to the main members, and each one of at least a pair of hangers is attached to and depends from a respective one of the main members and/or the cross members. A component is disposed between each one of the hangers and its respective main member, or alternatively is incorporated into the hangers, for absorbing the energy that is created by an extreme event during vehicle operation, to reduce the possibility of damage to the main members and/or the cross members caused by movement of at least one of the hangers during the extreme event.

Abstract: A temperature warning system for a heavy-duty vehicle, having at least one axle formed with an inner diameter. The axle includes a pair of spindle ends, and a wheel end assembly rotatably mounted on each spindle end. A thermal switch is disposed in the inner diameter of at least one of the axle spindle ends. The switch is electrically connected to a control module to form a closed electrical circuit, and the control module is electrically connected to an indicator device. When the temperature of the switch reaches a predetermined minimum temperature, such as from undesirable increased temperature in the axle spindle end and/or the wheel end assembly, the switch opens, breaking the closed electrical circuit, and causing the control module to activate the indicator device. The indicator device is viewable by the vehicle operator during its operation, thus warning the operator of the undesirable high temperature condition.

Abstract: A height control valve for an air spring of an air-ride axle/suspension system of a heavy-duty vehicle includes a body. The valve body is pneumatically connected to an air reservoir of the vehicles an ail spring, and to atmosphere A control arm actuates the valve to direct air from the reservoir into the air spring, when air is to be added to the air spring When air is to be exhausted from the air spring, the valve, actuated by the control arm, directs air from the air spring to atmosphere The valve includes a throttle assembly that can regulate the rate of pneumatic flow from the air spring to atmosphere when the vehicle is loaded and the air spring is in an extended condition. A throttle assembly can also be used to regulate the rate of pneumatic flow from the air reservoir to the air spring.

Abstract: A temperature warning system for a vehicle includes a thermal plug disposed on the wheel end assembly of the vehicle. The thermal plug is in fluid communication with an air supply and with a flow sensor. The flow sensor is operatively connected to a warning light or indicator. Excessive heat in the axle spindle end and/or the wheel end assembly causes a fusible material in the thermal plug to melt allowing air to flow from the air supply through the thermal plug thus activating the flow sensor. The flow sensor in turn activates the warning light or indicator alerting the driver of the vehicle of a problem condition at the wheel end assembly and/or axle spindle.

Abstract: A rotary union is integrated into the interior of a heavy-duty vehicle hub cap. The hub cap includes a cylindrical sidewall, and an outboard wall that is integrally formed with an outboard end of the sidewall, and which extends generally perpendicular to the sidewall. The hub cap also includes a radially-extending flange that is formed on an inboard end of the sidewall, which receives fasteners to mount the hub cap on a wheel hub. The sidewall and the outboard wall form an interior compartment in the hub cap, and a rotary union is mounted to the hub cap in the interior compartment. The rotary union is mounted on the inboard surface of the outboard wall of the hub cap and is in general axial alignment with an axial centerline of a wheel end assembly, providing fluid communication from a tire inflation system to the tires of the vehicle.

Abstract: A frame for a heavy-duty vehicle includes a pair of spaced-apart and longitudinally-extending main members. At least two cross members extend between and are attached to the main members. Each one of at least a pair of hangers is attached to and depends from a respective one of the main members for suspending an axle/suspension system from the frame. A force distribution assembly is attached to the main members and the hangers and includes a component that deforms or shears in an extreme event. The force distribution assembly extends perpendicularly between the main members and interrupts the transmission of forces encountered by the axle/suspension system that move through each one of the hangers to its respective main member, and redirects at least a portion of such forces across said force distribution assembly and into the other one of the main members.

Abstract: An axle spindle nut assembly secures a wheel end assembly on an axle spindle. The wheel end assembly includes outboard and inboard outboard bearings that are immovably mounted on the axle spindle, and a wheel hub which is rotatably mounting on the bearings. The spindle nut assembly includes a nut that threads onto an outboard end of the axle spindle, and is tightened against the outboard bearing to a selected torque level. The nut includes an outboard surface that is formed with a plurality of features. A washer is formed with a tab that engages a keyway of the axle spindle outboardly of the nut, and with a plurality of mating features that mechanically engage the features formed in the outboard surface of the nut to prevent substantial rotation of the nut after the nut has been tightened to the selected torque level.

Abstract: An elastomeric spring suspension is described for supporting a longitudinally extending vehicle frame rail above first and second axles forming a tandem axle configuration. The suspension includes a frame hanger assembly mounted to the vehicle frame rail. The frame hanger assembly has two full spring modules, each of which includes two shear springs, a progressive spring rate load cushion having a pyramidal shape with a flattened top surface and a spring mount for mounting the springs. A saddle assembly is connected to the spring mount, and an equalizing beam is connected to the saddle assembly and further connected to the axles. The spring rate for the suspension increases almost linearly as a function of sprung load, resembling a pneumatic suspension. Accordingly, the suspension exhibits excellent ride quality, without sacrificing roll stability.