Abstract: A temperature indicator is mounted within a wheel hub to generate a warning signal when a wheel end component overheats. The temperature indicator comprises a thermal battery that is activated only when the wheel end component exceed a predetermined temperature. Once activated the battery powers an RF transmitter to generate a wireless warning signal that is transmitted to a remote receiver to display a warning.

Abstract: A drive axle assembly for a low floor vehicle utilizes a single input gear assembly to drive a pair of laterally spaced wheel ends. The input gear assembly is positioned next to one of the wheel ends so that the vehicle floor can be lowered to facilitate passenger access to the vehicle. Each wheel end includes a gear reduction assembly with a ring gear rotatably mounted within a gear housing. A drive gear is operatively coupled to the input gear assembly and is in meshing engagement with the ring gear. The gear reduction assembly also includes an output or driven gear, which is larger than the drive gear, to provide the desired gear reduction. The driven gear is also in meshing engagement with the ring gear. A pair of idler gears is rotatably mounted within the gear housing and are in meshing engagement with both the drive and driven gear. The idler gears and drive gear do not have a common centerline.

Abstract: An independent suspension module includes a plurality of control members that are positioned to allow the suspension module to be used on low profile vehicles such as low floor buses. The suspension module includes a plurality of control members that couple a support member to the vehicle structure so that the suspension module is appropriately supported relative to the vehicle. The control members include a first end supported near a vertical portion of the lower surface of the vehicle. A second end of at least some of the control members are supported on the support member of the suspension module such that the second ends are positioned between the inboard and outboard sides of the wheels.

Abstract: A vehicle trailer includes large side panels that are attached to a trailer superstructure. A method and apparatus for making the panels includes forming composite panels that are lightweight and economical to manufacture. In one embodiment, the superstructure has grooves for receiving the composite panels. The composite panels preferably fit together via a tongue and groove configuration. Alternatively, the superstructure has support beams that have threaded receiving holes. Each composite panel then includes threaded inserts aligned with the receiving holes and that attach to the receiving holes. In both embodiments, each composite panel preferably includes at least an outer colored layer, a sheet of polymeric material attached to the colored layer and an inner layer attached to the polymeric material. Other layers can be added depending upon the use of the vehicle. For instance, a layer of insulating foam can be added if the vehicle is to be refrigerated.

Abstract: A method of welding an axle housing surface to a blank surface includes generated heat in one of the two components. Heat is generated from at least one of these surfaces at their interface sufficient to weld them together. The surfaces are then applied together.

Abstract: A vehicle suspension assembly includes a shock absorber that provides variable damping dependent on the load conditions of the vehicle. A central rod of the shock absorber includes a central bore that is fluidly coupled with air pressure within air springs of the suspension assembly. As the vehicle load increases and the pressure within the air springs increases, a damping adjustment assembly within the shock absorber increases the stiffness or damping of the shock absorber. In one example, a plunger moves within the central bore in the rod between a first position where less damping is provided and a second position where increased damping is achieved. A unique adapter member facilitates using a rod of appropriate size to achieve the desired air pressure conditions within the rod, while at the same time supporting conventional piston and disc valve components and providing enough material strength to withstand the tensile loads experienced under full extension.

Abstract: A vehicle wheel end assembly includes a sleeve member that allows air to be vented from the wheel end while significantly reducing venting of lubricating fluid. The wheel end includes a hub that is driven by a gear assembly. Lubricating fluid is stored within the hub to lubricate the gear assembly. Air pressure that builds up within the wheel end during vehicle operation is vented from the wheel end assembly via a vent path. A sleeve is installed within the wheel end to block the lubricating fluid from entering the vent path.

Abstract: A trailer suspension slider is provided that includes a suspension bogey. A trailer is supported on the suspension bogey and is longitudinally movable between a plurality of position relative to the suspension bogey. The trailer includes a stop bar to prevent the bogey from sliding out from underneath the trailer during braking if the pins are disengaged. A locking pin mechanism is movable between a locked position in which the locking mechanism couples the suspension bogey and the trailer in one of the plurality of positions and an unlocked position in which the trailer can move relative to the suspension bogey. The suspension bogey may collide violently with the stop bar when braking from a relatively low speed when the pins are unlocked. To this end, an energy absorption device is supported on either the trailer or the suspension bogey. The energy absorption device collapses in response to the stop bar engaging either the energy absorption device or the suspension bogey.

Abstract: A carrier assembly for a drive axle includes an pinion and ring gear input that is operably coupled to a differential assembly. The differential assembly includes first and second case halves that attach to each other at an interface to define a case split line and a differential gear assembly supported by the first and second case halves with the gear assembly being operably coupled to drive a pair of laterally spaced wheels. The ring gear, first case half, and second case half are all connected together via a single bolted joint with the case split line being located behind the ring gear. The differential housing is supported on a pair of tapered roller bearings having a diverging apex configuration to reduce cup rotation. The pinion gear is solely supported by a pair of tapered roller bearings positioned on opposite sides of the ring gear. A two-piece pinion cage supports both pinion bearings and facilitates the setting of preload with the use of external shims.

Abstract: An axle assembly is provided that includes a tubular member having an outer wall and an interior cavity. The other wall includes a first interlocking feature. An axle component mounting member, such as a bearing shoulder sleeve and/or a brake flange, is arranged on a portion of the outer wall. The mounting member includes a second interlocking feature coacting with the first interlocking feature to affix the mounting member and tubular member to one anther. The axle assembly may be formed by arranging the axle mounting member into a die assembly. A tubular member may be arranged in the die assembly within an opening in the mounting member. A hydroforming process may be employed to pressurize a cavity within the tubular member. A portion of the tubular member is deformed into engagement with the mounting member to affix the mounting member to the tubular member.

Abstract: A vehicle brake assembly includes a disc that rotates about a lateral axis. A caliper is mounted to a non-rotating vehicle structure and supports a pair of brake pads that are positioned on opposing sides of the disc. An air chamber provides an actuation force for the brake assembly. A first actuator applies a force in a first direction parallel to the lateral axis to bring the brake pads into engagement with the disc during a braking operation. The air chamber includes a second actuator that applies a force in a second direction transverse to the lateral axis in response to a vehicle input. An adapter is operably coupled to the first and second actuators to translate the force applied in the first direction to the force applied in the second direction. The adapter includes a housing that is mounted to the caliper and a lever that pivots relative to the housing. The lever has one end connected to the first actuator and another end connected to the second actuator.

Abstract: An offset axle assembly includes a two-piece gear case. A first section of the gear case includes a drive gear assembly and the second section includes a driven gear attached to a shaft supported within the second section of the gear case. Attached to the end of the shaft is a hub. The hub is attached to the shaft by way of a plurality of mating splines. The hub is secured to the end of the shaft by a single nut. The hub may be removed from the shaft by removal of the single nut. One of the drive gear or driven gear assemblies is a planetary gear system. The planetary gear system includes a ring gear driven by a helical gear such that distance between axles is determined by the diameters of the helical and ring gear.

Abstract: A vehicle chassis having a hollow structural member is provided with an opening at an end. A cavity extends from the opening and is defined by interior walls. The hollow structural member may be an axle or a portion of a frame. A bulkhead is arranged in the cavity transverse to the interior walls and spaced from the opening. The bulkhead substantially extends between and connects the interior walls, preferably at a right angle. The chassis component, such as an air spring or a member clamped to the hollow structural member with a U-bolt, is supported exteriorly on the hollow structural member. The chassis component generates a force and the bulkhead provides a counterforce to maintain the structural integrity of the hollow structural member. In this manner, the hollow structural member is relatively thin to save weight and cost and is better able to withstand bending and torsional forces without the use of specialized brackets.

Abstract: An universal joint dissipates shock and reduces torsional vibration to the elements of the universal joint. An elastomeric material, such as a polyurethane, is introduced between the bores of the yokes of the joint and the respective adjacent bearing cups that are mounted on the shafts of the cross bar.

Abstract: A heavy-duty vehicle suspension assembly is provided that includes an axle assembly having opposing suspension arm mounting faces. A pair of modular suspension arm assemblies are secured to the axle assembly with the suspension arm assemblies extending outwardly from the axle assembly in opposite directions from one another. Each suspension arm assembly includes a first arm portion having a first end secured to the mounting face and extending to a second end. A second arm portion is secured to the second end and has a spring seat with a spring supported on each of the spring seats of the suspension arm assemblies for damping forces transmitted through the axle assembly. The first and second arm portions include mounting surfaces that overlap one another in a plurality of positions to permit the arm portions to be secured to one another in a plurality of configurations that accommodate numerous spring heights and pinion angles. The first and second arm portions may be constructed as separate castings.

Abstract: An axle end plug employs a magnet which attracts ferrous metallic debris from a cavity in a trailer axle wheel end. The axle end plug includes a vent hole which is substantially aligned with an aperture in the magnet. The vent hole vents the cavity in the trailer axle wheel end to the interior of the axle, rather than to the atmosphere. The arrangement prevents external contaminants such as dirt and water from entering the cavity. The magnet attracts ferrous debris which accumulates in the cavity from component wear or from manufacturing debris which remains in the axle interior. The magnet attracts and removes these particles from the trailer axle wheel end, minimizing the wearing of components.

Abstract: A brake shoe assembly includes the first and second sections defining a lining surface and a mounting tab. The mounting tab extends perpendicular from the lining surface and includes a series of notches allowing the formation of the lining surface into an arcuate shape. The mounting tabs are secured together such that subsequent manufacturing operations to correct distortion are not required. A brake lining is secured to the lining surface.

Abstract: A sensor system includes a housing that houses a thermally sensitive sensor, a transmitter portion and a power source. Preferably, the sensor device is encapsulated to protect the components from the environment. When the temperature in a component mounting the sensor system exceeds a preselected threshold, the thermostat sensor closes and the transmitter portion is energized by the power source to transmit a signal to a receiver unit.

Abstract: A suspension system provides a pair of walking beams mounted parallel to a longitudinal main frame of a vehicle subframe. The walking beams support tandem axles. The walking beams are mounted to lower outboard brackets extending from each axle. A spherical joint extending from each longitudinal end of each walking beam engages the lower outboard brackets. Each walking beam is constrained against fore-aft movement through a pair of watts linkages. The watts linkages are separated by a lateral torsion tube. Each walking beam is connected to its respective watts linkages through a revolute joint and pivot relative to the torque tube. A pair of tie-rods are attached between each watts linkages and a fixed support. The tie rods include spherical joints at each end. Each axle is further restrained by a V-rod attached to an upper bracket extending from each axle.

Abstract: A system for setting vehicle operator preferences is provided. The system includes a vehicle control module for controlling a vehicle component such as an HVAC unit. A data link is connected to the vehicle control module and may be an infrared signal receiver, a radio frequency signal receiver, a vehicle communications bus, or any other suitable data link. A portable handheld computing device includes a program having vehicle preferences stored in a memory. Preferably, the vehicle preferences may be input by the operator into the portable handheld computing device. The portable handheld computing device may be a Handspring® device, a Palmpilot® device, or any other suitable portable computing device. The portable handheld computing device sends the vehicle preferences to the vehicle control module through the data link to control the vehicle component. The vehicle preferences are sent by IR, RF, or any other suitable means. The system may be used to control an HVA system, for example.