Abstract: An axle-to-beam connection for an axle/suspension system of a heavy-duty vehicle that includes an axle, a beam with an alignment assembly, and an axle mount assembly. The alignment assembly is integrally formed with or is rigidly attached to the beam. The axle mount assembly intimately contacts and captures the axle. The axle is rigidly secured to the axle mount assembly without line welds. The axle mount assembly is removably connected to the alignment assembly to secure the axle to the beam.

Abstract: An axle-to-beam connection for a suspension assembly of an axle/suspension system of a heavy-duty vehicle including an axle, a beam, and a top pad. The beam includes an alignment assembly for aligning the axle with the beam. The top pad includes an integrally-formed bump stop boss and is fixedly attached to the axle and removably attached to the alignment assembly of the beam.

Abstract: A brake system component axle mount for a vehicle axle/suspension system includes an axle having at least one depression formed therein. A sleeve is formed with at least one depression and disposed about the axle so that the axle depression and the sleeve depression matingly engage one another to form a mated pair of depressions. A brake mount assembly is rigidly attached to the sleeve. A method of forming the brake system component axle mount includes providing an axle and disposing a sleeve about the axle. At least one mated pair of depressions is simultaneously formed in the axle and the sleeve. A brake mount assembly is rigidly attached to the sleeve.

Abstract: An axle-to-beam connection for a suspension assembly of an axle/suspension system of a heavy-duty vehicle including an axle, a beam, and a top pad. The beam includes an alignment assembly for aligning the axle with the beam. The top pad includes an integrally-formed bump stop boss and is fixedly attached to the axle and removably attached to the alignment assembly of the beam.

Abstract: A steering centering/damping mechanism for a steerable heavy-duty vehicle axle/suspension system which includes a mechanically operated structure that provides a positive steering centering force to the axle/suspension system at a zero steer angle. The mechanically operated structure of the steering centering/damping mechanism also provides a positive steering centering force that increases in intensity as the steer angle of the axle/suspension system increases. In an embodiment of the steering centering/damping mechanism, the mechanically operated structure is a flat spring integrated into one or more steering assemblies of the axle/suspension system.

Abstract: An air spring with damping characteristics for a suspension assembly of a heavy-duty vehicle includes a bellows and a piston. The bellows includes a bellows chamber. The bellows is attached to a main member of the heavy-duty vehicle and to the piston. The piston includes an open bottom that is sealingly closed by a disc attached to the open bottom. The piston and the disc define a piston chamber. The piston is mounted on the suspension assembly of the heavy-duty vehicle. The bellows chamber and the piston chamber are in fluid communication with each other via at least one opening, wherein airflow between the bellows chamber and the piston chamber provides damping to the suspension assembly of the heavy-duty vehicle.

Abstract: A bushing assembly pivotally connects the beams of an auxiliary lift axle/suspension system to a hanger and to an axle seat. The bushing assembly includes a pair of bushings, a metal sleeve, a pin with a threaded end, a pair of washers, and a threaded nut. The pair of bushings are disposed into an opening formed near an end of the beam. Each one of the pair of bushings includes a cylindrical wall comprising an inner end, an outer end, a central opening extending from the inner end to the outer end, an exterior surface, an interior surface, and a flange. The interior surface of the bushings includes at least one groove formed therein for preventing lubricant from escaping the bushing assembly during operation of the lift axle/suspension system while a sealing feature prevents contaminants from migrating into the bushing assembly.

Abstract: A steering centering/damping mechanism for a steerable heavy-duty vehicle axle/suspension system which includes a mechanically operated structure that provides a positive steering centering force to the axle/suspension system at a zero steer angle. The mechanically operated structure of the steering centering/damping mechanism also provides a positive steering centering force that increases in intensity as the steer angle of the axle/suspension system increases. In an embodiment of the steering centering/damping mechanism, the mechanically operated structure is a flat spring integrated into one or more steering assemblies of the axle/suspension system.

Abstract: A suspension system can include an air spring, an air reservoir external to the air spring, and a flow control device which variably restricts flow of air between the air spring and the air reservoir. Flow between the air spring and the air reservoir may be permitted in response to compliance of the suspension system, and the air spring can have an internal air volume at least 2½ times as great may permit flow between the air spring and the air reservoir in response to a predetermined pressure differential level across the flow control device. Multiple air reservoirs can be internal to an axle, or other suspension system or vehicle component, and can be isolated from each other.

Abstract: An air spring with damping characteristics for a suspension assembly of a heavy-duty vehicle includes a bellows and a piston. The bellows includes a bellows chamber. The bellows is attached to a main member of the heavy-duty vehicle and to the piston. The piston includes an open bottom that is sealingly closed by a disc attached to the open bottom. The piston and the disc define a piston chamber. The piston is mounted on the suspension assembly of the heavy-duty vehicle. The bellows chamber and the piston chamber are in fluid communication with each other via at least one opening, wherein airflow between the bellows chamber and the piston chamber provides damping to the suspension assembly of the heavy-duty vehicle.

Abstract: A damping air spring and shock absorber combination for heavy-duty vehicle axle/suspension systems includes a damping air spring and a shock absorber both operatively attached to the axle/suspension system. The damping air spring primarily provides damping to the axle/suspension system over a first range of frequencies. The shock absorber primarily provides damping to the axle/suspension system over a second range of frequencies. The first range of frequencies is from about 0.0 Hz to about 6.0 Hz and the second range of frequencies is from about 0.0 Hz to about 13.0 Hz.

Abstract: An air spring with damping characteristics for a suspension assembly of a heavy-duty vehicle includes a bellows and a piston. The bellows includes a bellows chamber. The bellows is attached to a main member of the heavy-duty vehicle and to the piston. The piston includes an open bottom that is sealingly closed by a disc attached to the open bottom. The piston and the disc define a piston chamber. The piston is mounted on the suspension assembly of the heavy-duty vehicle. The bellows chamber and the piston chamber are in fluid communication with each other via at least one opening, wherein airflow between the bellows chamber and the piston chamber provides damping to the suspension assembly of the heavy-duty vehicle.

Abstract: A bushing assembly pivotally connects the beams of an auxiliary lift axle/suspension system to a hanger and to an axle seat. The bushing assembly includes a pair of bushings, a metal sleeve, a pin with a threaded end, a pair of washers, and a threaded nut. The pair of bushings are disposed into an opening formed near an end of the beam. Each one of the pair of bushings includes a cylindrical wall comprising an inner end, an outer end, a central opening extending from the inner end to the outer end, an exterior surface, an interior surface, and a flange. The interior surface of the bushings includes at least one groove formed therein for preventing lubricant from escaping the bushing assembly during operation of the lift axle/suspension system while a sealing feature prevents contaminants from migrating into the bushing assembly.

Abstract: An air spring with damping characteristics for a suspension assembly of a heavy-duty vehicle includes a bellows and a piston. The bellows includes a bellows chamber. The bellows is attached to a main member of the heavy-duty vehicle and to the piston. The piston includes an open bottom that is sealingly closed by a disc attached to the open bottom. The piston and the disc define a piston chamber. The piston is mounted on the suspension assembly of the heavy-duty vehicle. The bellows chamber and the piston chamber are in fluid communication with each other via at least one opening, wherein airflow between the bellows chamber and the piston chamber provides damping to the suspension assembly of the heavy-duty vehicle.

Abstract: A damping air spring and shock absorber combination for heavy-duty vehicle axle/suspension systems includes a damping air spring and a shock absorber both operatively attached to the axle/suspension system. The damping air spring primarily provides damping to the axle/suspension system over a first range of frequencies. The shock absorber primarily provides damping to the axle/suspension system over a second range of frequencies. The first range of frequencies is from about 0.0 Hz to about 6.0 Hz and the second range of frequencies is from about 0.0 Hz to about 13.0 Hz.

Abstract: An axle-to-beam or crossbrace-to-beam connection for a vehicle axle/suspension system includes an axle or crossbrace having at least one depression formed therein. A sleeve is formed with at least one depression and disposed about the axle or crossbrace so that the axle or crossbrace depression and the sleeve depression matingly engage one another to form a mated pair of depressions. A method of forming the axle-to-beam or crossbrace-to-beam connection includes providing an axle or crossbrace and disposing a sleeve about the axle or crossbrace. At least one mated pair of depressions is simultaneously formed in the axle or crossbrace and the sleeve. The sleeve is immovably mounted to a vehicle axle/suspension system.

Abstract: A piston for an air spring of a heavy-duty vehicle includes a sidewall and a central hub. The sidewall and the central hub are attached to a first bottom plate of the piston. A top plate is removeably attached to a top portion of the sidewall and a top portion of the central hub. A bottom portion of said central hub includes a second bottom plate that is recessed relative to the first bottom plate for attachment to a piston mounting pedestal that is in turn mounted to a beam of a suspension assembly of the heavy-duty vehicle.

Abstract: An axle-to-beam or crossbrace-to-beam connection for a vehicle axle/suspension system includes an axle or crossbrace having at least one depression formed therein. A sleeve is formed with at least one depression and disposed about the axle or crossbrace so that the axle or crossbrace depression and the sleeve depression matingly engage one another to form a mated pair of depressions. A method of forming the axle-to-beam or crossbrace-to-beam connection includes providing an axle or crossbrace and disposing a sleeve about the axle or crossbrace. At least one mated pair of depressions is simultaneously formed in the axle or crossbrace and the sleeve. The sleeve is immovably mounted to a vehicle axle/suspension system.

Abstract: A steering lock mechanism for a steerable axle/suspension system includes a pair of independent tie rods, each one connected to a respective one of a pair of pivoting ends of a steerable axle/suspension system and also connected to a steering bracket that is pivotally connected to the axle of the steerable axle/suspension system. A primary lock assembly, which includes an air spring, and a secondary lock assembly are operatively connected to the steering bracket and to the steerable axle/suspension system. When the air spring of the primary lock assembly is inflated with air or when the secondary lock assembly is activated, the steering bracket is prevented from pivoting and in turn the first and second tie rods are prevented from moving transversely, so that the steerable axle/suspension system is locked into a generally straight travel position during operation of the vehicle.

Abstract: An axle-to-beam or crossbrace-to-beam connection for a vehicle axle/suspension system includes an axle or crossbrace having at least one depression formed therein. A sleeve is formed with at least one depression and disposed about the axle or crossbrace so that the axle or crossbrace depression and the sleeve depression matingly engage one another to form a mated pair of depressions. A method of forming the axle-to-beam or crossbrace-to-beam connection includes providing an axle or crossbrace and disposing a sleeve about the axle or crossbrace. At least one mated pair of depressions is simultaneously formed in the axle or crossbrace and the sleeve. The sleeve is immovably mounted to a vehicle axle/suspension system.