Abstract: An assembly method is provided for a vehicle having an axle assembly. The assembly method comprises fastening a drum brake assembly having a brake spider to a brake flange of an axle assembly and routing electrical lines through the brake spider and the brake flange of the axle assembly. The assembly method further comprises coupling an electric drive motor to an axle of the axle assembly, attaching the electrical lines to the electric drive motor and coupling a wheel hub to the axle assembly. The assembly method further comprises disposing the drum brake assembly inside a chamber of a brake drum portion, the brake drum portion located coaxial to the axle and disposing the electric drive motor inside a chamber of a brake adapter portion, the brake adapter portion located coaxial to the axle.

Abstract: A method of manufacturing a camshaft for a drum brake includes designing a tubular camshaft and thereafter forming the camshaft as a unitary body through, for example, an additive manufacturing process. The camshaft is designed with a first end portion configured for coupling to a brake actuator, a second end portion defining a cam configured to engage cam followers coupled to first and second brake shoes, rotation of the cam causing the first and second brake shoes to move between positions of engagement and disengagement with an associated braking surface, and an intermediate portion disposed between the first and second end portions. A wall thickness of at least one of the end portions and the intermediate portion is configured to achieve at least one of a predetermined torsional stiffness in the camshaft and vibration damping in the camshaft at a selected frequency.

Abstract: A brake shoe for a drum brake includes a unitary body defining a brake table and one or more webs supporting the brake table. Each web has first and second ends. The first end is configured for pivotally coupling to an associated brake spider of the drum brake and the second end is configured to respond to a force applied by an actuator that causes the brake shoe to move between positions of engagement and disengagement with an associated braking surface. The unitary body further defines one or more supports extending between the two webs and/or between one of the webs and the brake table. In some embodiments, the supports comprise vibration dampers configured to deflect from an unloaded position to a loaded position in the presence of a load and to return to the unloaded position in the absence of the load.

Abstract: A drum brake assembly for use with a wheel end electric drive motor arrangement can generate brake dust, which may accumulate on the electric motor and cause heat retention problems that are detrimental to motor performance and longevity. These issues are addressed by providing an assembly including a support attachable to a vehicle axle element, brake shoes pivotally mountable on the support, and a wheel spindle interconnected with one end of the axle element. A wheel hub is rotatable around the spindle, and an electric motor unit is disposed between an end of the axle element and the spindle to produce rotation of the hub relative to the axle element. A brake drum is securable to the hub for rotation with the hub relative to the spindle by way of the electric motor unit. The brake drum includes a circumferential perimeter wall overlying the brake shoes, and a fan rotor is interconnected with that wall for rotation together with the drum and the wheel hub relative to the spindle.

Abstract: The rotor of an electric motor unit has a web portion partially enclosing the remainder of the unit and terminating in a circumferentially extending rim. The brake drum defines an engagement surface for drum brake linings, and has an outboard end defining a flange securable to the wheel hub. The brake drum also includes an open inboard end, partly covered over by a dust guard, and a circumferential wall extending between the outboard and inboard ends and surrounding the engagement surface. By way of keys and slots or recesses, a reinforcing ring interlocks the circumferentially extending rim of the web portion and the circumferential brake drum wall. The reinforcing ring is secured to the circumferentially extending rim and to the wall of the brake drum at a location disposed axially between the rim of the web portion and the brake drum lining engagement surface.

Abstract: A one piece drum brake spider construction eliminates welds and distortion, at least relative to a typically fabricated spider, and should improve brake performance. The spider includes a main body plate having opposed flat sides, an outer perimeter, and an inner perimeter configured to receive an axle tube. Vibration control structure is preferably formed on at least one of the opposed flat sides of the main body plate, and the brake drum spider additionally includes weight minimizing features. At least the main body plate may be produced by any of a casting technique, a stamping technique, a machining technique, and an additive manufacturing technique. The invention also concerns a process of producing such a brake drum spider.

Abstract: An integrated brake spider and mounting bracket arrangement for a drum brake includes a brake spider with a spider mounting section, having openings through which fasteners may pass to secure the brake spider to an axle flange of a vehicle. The spider is also provided with a base section having an attachment surface for a bracket, and the bracket is secured by way of a metal fabrication process to the attachment surface of the base section and to actuator support structure adapted to support an actuator for the drum brake.

Abstract: A bracket for a brake assembly and a brake actuator includes a unitary body including a tube configured to receive a camshaft of the brake assembly and an actuator mounting arm disposed proximate a first end of the tube and configured to receive the brake actuator. In some embodiments, the tube includes one or more helical ribs formed on a radially inner surface. The bracket further includes either a brake spider or a brake spider mounting flange disposed proximate a second end of the tube. In either embodiment, material may be omitted in various locations to reduce the weight of the bracket. The bracket may be formed through an additive manufacturing process and in a manner that achieve at least one of a predetermined torsional stiffness and attenuation of a predetermined natural frequency.

Abstract: An integrated brake spider and mounting bracket arrangement for a drum brake includes a brake spider with a spider mounting section, having openings through which fasteners may pass to secure the brake spider to an axle flange of a vehicle. The spider is also provided with a base section having an attachment surface for a bracket, and the bracket is secured by way of a metal fabrication process to the attachment surface of the base section and to actuator support structure adapted to support an actuator for the drum brake.

Abstract: A one piece drum brake spider construction eliminates welds and distortion, at least relative to a typically fabricated spider, and should improve brake performance. The spider includes a main body plate having opposed flat sides, an outer perimeter, and an inner perimeter configured to receive an axle tube. Vibration control structure is preferably formed on at least one of the opposed flat sides of the main body plate, and the brake drum spider additionally includes weight minimizing features. At least the main body plate may be produced by any of a casting technique, a stamping technique, a machining technique, and an additive manufacturing technique. The invention also concerns a process of producing such a brake drum spider.

Abstract: A bracket for a brake assembly and a brake actuator includes a unitary body including a tube configured to receive a camshaft of the brake assembly and an actuator mounting arm disposed proximate a first end of the tube and configured to receive the brake actuator. In some embodiments, the tube includes one or more helical ribs formed on a radially inner surface. The bracket further includes either a brake spider or a brake spider mounting flange disposed proximate a second end of the tube. In either embodiment, material may be omitted in various locations to reduce the weight of the bracket. The bracket may be formed through an additive manufacturing process and in a manner that achieve at least one of a predetermined torsional stiffness and attenuation of a predetermined natural frequency.

Abstract: A method of manufacturing a camshaft for a drum brake includes designing a tubular camshaft and thereafter forming the camshaft as a unitary body through, for example, an additive manufacturing process. The camshaft is designed with a first end portion configured for coupling to a brake actuator, a second end portion defining a cam configured to engage cam followers coupled to first and second brake shoes, rotation of the cam causing the first and second brake shoes to move between positions of engagement and disengagement with an associated braking surface, and an intermediate portion disposed between the first and second end portions. A wall thickness of at least one of the end portions and the intermediate portion is configured to achieve at least one of a predetermined torsional stiffness in the camshaft and vibration damping in the camshaft at a selected frequency.

Abstract: The rotor of an electric motor unit has a web portion partially enclosing the remainder of the unit and terminating in a circumferentially extending rim. The brake drum defines an engagement surface for drum brake linings, and has an outboard end defining a flange securable to the wheel hub. The brake drum also includes an open inboard end, partly covered over by a dust guard, and a circumferential wall extending between the outboard and inboard ends and surrounding the engagement surface. By way of keys and slots or recesses, a reinforcing ring interlocks the circumferentially extending rim of the web portion and the circumferential brake drum wall. The reinforcing ring is secured to the circumferentially extending rim and to the wall of the brake drum at a location disposed axially between the rim of the web portion and the brake drum lining engagement surface.

Abstract: A brake shoe for a drum brake includes a unitary body defining a brake table and one or more webs supporting the brake table. Each web has first and second ends. The first end is configured for pivotally coupling to an associated brake spider of the drum brake and the second end is configured to respond to a force applied by an actuator that causes the brake shoe to move between positions of engagement and disengagement with an associated braking surface. The unitary body further defines one or more supports extending between the two webs and/or between one of the webs and the brake table. In some embodiments, the supports comprise vibration dampers configured to deflect from an unloaded position to a loaded position in the presence of a load and to return to the unloaded position in the absence of the load.

Abstract: A drum brake assembly for use with a wheel end electric drive motor arrangement can generate brake dust, which may accumulate on the electric motor and cause heat retention problems that are detrimental to motor performance and longevity. These issues are addressed by providing an assembly including a support attachable to a vehicle axle element, brake shoes pivotally mountable on the support, and a wheel spindle interconnected with one end of the axle element. A wheel hub is rotatable around the spindle, and an electric motor unit is disposed between an end of the axle element and the spindle to produce rotation of the hub relative to the axle element. A brake drum is securable to the hub for rotation with the hub relative to the spindle by way of the electric motor unit. The brake drum includes a circumferential perimeter wall overlying the brake shoes, and a fan rotor is interconnected with that wall for rotation together with the drum and the wheel hub relative to the spindle.

Abstract: An assembly method is provided for a vehicle having an axle assembly. The assembly method comprises fastening a drum brake assembly having a brake spider to a brake flange of an axle assembly and routing electrical lines through the brake spider and the brake flange of the axle assembly. The assembly method further comprises coupling an electric drive motor to an axle of the axle assembly, attaching the electrical lines to the electric drive motor and coupling a wheel hub to the axle assembly. The assembly method further comprises disposing the drum brake assembly inside a chamber of a brake drum portion, the brake drum portion located coaxial to the axle and disposing the electric drive motor inside a chamber of a brake adapter portion, the brake adapter portion located coaxial to the axle.

Abstract: A drum brake apparatus is provided for a vehicle air braking system. The drum brake apparatus comprises a wheel drum having a first interior chamber. The drum brake apparatus also comprises a drum brake assembly disposed in the first interior chamber of the wheel drum and mounted on inboard side of the wheel drum. The drum apparatus further comprises a brake drum adapter mounted on outboard side of the wheel drum and providing a second interior chamber in which an electric drive motor can be disposed. The drum brake apparatus also comprises a wheel hub disposed in the second interior chamber of the brake drum adapter and to which a wheel rim can be mounted.

Abstract: A drum brake apparatus is provided for a vehicle air braking system. The drum brake apparatus comprises a wheel drum having a first interior chamber. The drum brake apparatus also comprises a drum brake assembly disposed in the first interior chamber of the wheel drum and mounted on inboard side of the wheel drum. The drum apparatus further comprises a brake drum adapter mounted on outboard side of the wheel drum and providing a second interior chamber in which an electric drive motor can be disposed. The drum brake apparatus also comprises a wheel hub disposed in the second interior chamber of the brake drum adapter and to which a wheel rim can be mounted.

Abstract: A hybrid structural apparatus is provided for a vehicle air braking system. The hybrid structural apparatus comprises a member including a non-pressure plate of a brake actuator and an arm portion that extends from the non-pressure plate. The member is made of a first material. The hybrid structural apparatus further comprises a first flange made of a second material fastened to the arm portion of the member. The second material is different from the first material. The hybrid structural apparatus also includes a second flange for fastening to a brake spider, and a camshaft support tube interconnecting the first and second flanges.

Abstract: A lock washer for releasably locking a fastener to an object is provided. The washer includes a body defining a bore configured for alignment with a bore disposed in the object. The bores are configured to receive a shank of the fastener and are disposed about a center axis along which the fastener extends. The washer further includes one or more fingers each having a first end coupled to the body and a second end configured to selectively engage a flat on either a head of the fastener or a nut. The finger is movable between a disengaged position wherein the second end of the finger is configured for disengagement from the flat and an engaged position wherein the second end of the finger is configured for engagement with the flat. The finger is biased towards the engaged position.