Abstract: A sacrificial metal coating to resist corrosion is deposited onto a vehicle component during a shot peening operation. Since the deposition occurs during the shot peening operation, a separate coating step is not necessary. Preferably, the component is a vehicle suspension component.

Abstract: A method for enhancing the physical characteristics of a localized area of a suspension component by adding material to the points of high stress without a significant increase in weight or diameter of the suspension component. The material is in the form of a sleeve added to the exterior surface of the suspension component, a core added to the interior surface of a tubular suspension component, winding filaments, or powered material.

Abstract: A method of forming a stabilizer bar is provided that includes the steps of roll forming sheet metal coil into a continuous tube. Next, a first portion of the continuous tube is flattened. The first portion of the continuous tube is sheared to define a first end. Next, a second portion of the continuous tube is flattened. The continuous tube is sheared at the second portion to define a final unit length with a second end opposite the first end. That is, the length is sheared from the rest of the continuous tube. The final length is the length is needed to form a single stabilizer bar. Finally, the final unit length is deformed into the desired stabilizer bar shape.

Abstract: A suspension for a heavy duty vehicle is provided that includes a frame. A lower linkage is supported by the frame at a first pivotal connection. A drive axle assembly is supported by a lower linkage at a second pivotal connection. The drive axle assembly includes an input shaft defining a pinion angle. An upper linkage interconnects the drive axle assembly and the frame at third and fourth pivotal connections, respectively. The upper linkage includes an adjustment member, such as a turnbuckle, for modifying the length of the upper linkage to obtain a predetermined pinion angle. In this manner, the pinion angle may be adjusted upon assembly of the suspension system. Furthermore, by permitting the drive axle assembly to pivotally move relative to the linkages, the pinion angle may be maintained during suspension movement.

Abstract: A suspension assembly is provided for use in stabilizing a vehicle during turning maneuvers. The suspension assembly includes a frame and the stabilizer bar secured to the frame by a bracket. A bushing having a hole along an axis receives the stabilizer bar. The bushing has a first portion disposed between the bracket and the stabilizer bar with the stabilizer bar supported by the first portion in a slip-fit relationship. A second portion extends from the first portion along the axis with a tether portion connecting the first and second portions. A notch is arranged adjacent to the tether portion and separates the first and second portions. Preferably, the notch and tether portion provide a frangible connection between the first and second portions. A clamp is supported on the second portion to secure the second portion to the stabilizer bar thereby preventing relative rotation between the second portion and the stabilizer bar.

Abstract: An expandable insert secures a linkage bolt to the ends of a stabilizer bar. The insert comprises a cylindrical body portion, a cap, and an aperture. The insert is placed in the end of a stabilizer bar. As the linking bolt is torqued within the aperture of the insert, the threads of the linking bolt penetrate the insert. The torquing expands the insert outwardly towards the interior surface of the stabilizer bar, anchoring the insert inside the stabilizer bar and securing the linkage bolt to the end of the stabilizer bar.

Abstract: An improved suspension system includes a plurality of slider pins which are biased radially outwardly into engagement with openings in the suspension rails of the suspension system and the mating openings in the slider rail. The slider pins are provided with spring clamp structure and a wedged surface. The wedged surface forces the spring clamp radially outwardly into engagement with the openings in the suspension rails to secure the slider pins. Upon withdrawal of the slider pins, the spring clamp is biased radially inwardly to facilitate removal.

Abstract: A method of varying the bend radius while forming a stabilizer bar is achieved by varying the radius of the forming tool over which the stabilizer bar is bent. The bend radius of the stabilizer bar is varied by changing the position and/or shape of the forming tool in relation to the stabilizer bar. The stabilizer bar is formed by bending the bar over the forming tool to create a bend of desired radius. In the disclosed embodiments, the forming tool is bent chain, a conical tool, and an eccentric shape with several distinct radii.

Abstract: An autofrettage process employed on the inner surface of a tubular stabilizer bar. Road shock and other vibrations subject the stabilizer bar to tensile stresses. Tensile stresses cause fractures and decrease the fatigue life of the bar. In employing an autofrettage process, a pressurized fluid is introduced into the interior space of a sealed stabilizer bar, slightly increasing the inner diameter of the stabilizer bar. As the inner surface of the stabilizer bar is deformed, residual compressive stress forces are created which counteract and oppose the tensile stress forces. The residual compressive stress forces prevent the tensile stresses from fracturing the inner surface of the bar, increasing fatigue life. A shot peening process can be employed on the exterior surface of the bar to create residual compressive stress forces which counteract exterior tensile forces.

Abstract: An autofrettage process employed on the inner surface of a tubular stabilizer bar. Road shock and other vibrations subject the stabilizer bar to tensile stresses. Tensile stresses cause fractures and decrease the fatigue life of the bar. In employing an autofrettage process, a pressurized fluid is introduced into the interior space of a sealed stabilizer bar, slightly increasing the inner diameter of the stabilizer bar. As the inner surface of the stabilizer bar is deformed, residual compressive stress forces are created which counteract and oppose the tensile stress forces. The residual compressive stress forces prevent the tensile stresses from fracturing the inner surface of the bar, increasing fatigue life. A shot peening process can be employed on the exterior surface of the bar to create residual compressive stress forces which counteract exterior tensile forces.

Abstract: A method of enhancing the bending process of a stabilizer bar by locally pre-heating the stabilizer bar immediately prior to formation. By pre-heating the stabilizer bar, the stress in the stabilizer bar is relieved at the bending areas. This allows larger bars to be formed which would otherwise be outside of machine parameters. In the disclosed embodiments, the stabilizer bar is locally heated by induction coils or resistance heating at the bend areas.

Abstract: A vehicle system component is provided with an electrical charge to resist corrosion. Preferably, the electrical charge is generated by movement of components adjacent to the suspension component. Friction surfaces may be placed in contact with each other such that and heat is generated upon movement of the vehicle system components. The heat is transferred into electrical energy. In another embodiment, an electrical coil receives a magnetic member which moves within the coil to generate the current. The charge may be stored in a capacitor and periodically dispatched onto said component. The invention thus provides a low cost and simplistic way of resisting corrosion to vehicle components, and in particular to vehicle suspension components.

Abstract: A stabilizer bar is provided having a varying cross-section along the length of the bar. In particular, the stabilizer bar includes a first cross-sectional area and a second cross-sectional area that is different than the first cross-sectional area. A first surface at least partially defines the second cross-sectional area. The first surface has a non-circular shape with primary and secondary load bearing directions bearing different maximum loads in each of the directions. The shape of the second cross-sectional area may be arranged so that the primary load bearing direction is generally aligned with the highest load. Similarly, the shape of the second cross-sectional area may be arranged in a manner to bear the highest torsional load. The stabilizer bar may be solid or hollow. Preferred shapes may include egg-shaped or elliptical shaped surfaces. Alternatively, the stabilizer bar may have a generally uniform cross-sectional area along its length with the non-circular shape described above.