Abstract: A method of machining a carrier housing for an axle assembly comprises obtaining a carrier housing including circumferentially spaced apart tabs and positioning a datum setting tool in engagement with the carrier housing. The carrier housing is clamped to a fixture to position the carrier housing at a first orientation relative to a coordinate system within a work cell. The datum setting tool is disengaged from the carrier housing. Portions of the carrier housing along a first side are machined to define features including a carrier mounting flange and a cylindrical bearing bore extending perpendicular to the carrier mounting flange while the carrier housing remains clamped at the first orientation. Different portions of the carrier housing, on a second opposite side of the carrier housing, are machined to define additional geometrical feature while the initial clamped orientation continues to be maintained.

Abstract: A modular tooling die for an axle housing includes a plurality of separable and coaxially aligned die sets. Each die set may include a cam driver that is engageable with first and second cam slide assemblies. The cam slide assemblies move toward one another along an axis that extends perpendicularly to an axis along which the cam driver translates. Multiple die sets are provided for possible use in a single press depending on the particular axle housing geometry to be manufactured. A wide variety of different geometrical configurations may be formed by simply replacing one or more die sets and inserting a differently sized or shaped blank within the press. A method of manufacturing various axle housings and the associated modular tooling is described.

Abstract: A vehicle axle assembly including an axle housing, carrier assembly, and first and second axle shafts. The axle housing is formed from an upper beam and a lower beam that are positioned in a clam-shell arrangement. The carrier assembly includes a carrier housing and a differential that includes a ring gear arranged in meshing engagement with a pinion. The first and second axle shafts extend outwardly from the differential in opposite directions. The pinion is rotatably supported by a self-lubricating cartridge pinion input bearing and the outboard ends of the first and second axle shafts are rotatably supported by self-lubricating and unitized grease wheel end bearings. These bearings do not require lubrication from oil contained inside the axle housing allowing for a reduced oil fill level in the axle housing, creating less viscous losses and better efficiency.

Abstract: A method of machining a carrier housing for an axle assembly comprises obtaining a carrier housing including circumferentially spaced apart tabs and positioning a datum setting tool in engagement with the carrier housing. The carrier housing is clamped to a fixture to position the carrier housing at a first orientation relative to a coordinate system within a work cell. The datum setting tool is disengaged from the carrier housing. Portions of the carrier housing along a first side are machined to define features including a carrier mounting flange and a cylindrical bearing bore extending perpendicular to the carrier mounting flange while the carrier housing remains clamped at the first orientation. Different portions of the carrier housing, on a second opposite side of the carrier housing, are machined to define additional geometrical feature while the initial clamped orientation continues to be maintained.

Abstract: A vehicle axle assembly including an axle housing, carrier assembly, and first and second axle shafts. The axle housing is formed from an upper beam and a lower beam that are positioned in a clam-shell arrangement. The carrier assembly includes a carrier housing and a differential that includes a ring gear arranged in meshing engagement with a pinion. The first and second axle shafts extend outwardly from the differential in opposite directions. The pinion is rotatably supported by a self-lubricating cartridge pinion input bearing and the outboard ends of the first and second axle shafts are rotatably supported by self-lubricating and unitized grease wheel end bearings. These bearings do not require lubrication from oil contained inside the axle housing allowing for a reduced oil fill level in the axle housing, creating less viscous losses and better efficiency.

Abstract: A modular tooling die for an axle housing includes a plurality of separable and coaxially aligned die sets. Each die set may include a cam driver that is engageable with first and second cam slide assemblies. The cam slide assemblies move toward one another along an axis that extends perpendicularly to an axis along which the cam driver translates. Multiple die sets are provided for possible use in a single press depending on the particular axle housing geometry to be manufactured. A wide variety of different geometrical configurations may be formed by simply replacing one or more die sets and inserting a differently sized or shaped blank within the press. A method of manufacturing various axle housings and the associated modular tooling is described.

Abstract: A vehicle axle assembly includes an axle housing and a carrier assembly. The carrier assembly includes a carrier housing and a differential assembly that includes a ring gear arranged in meshing engagement with a pinion gear. The gears are urged away from one another by separation forces during torque transfer. The carrier housing includes a curved wall circumscribed by a mounting flange as well as a plurality of integrally formed and parallel spaced apart gussets interconnecting the curved wall and the mounting flange. The gussets extend in a direction parallel to the gear separation forces to resist bending of the carrier housing. Other features increasing the structural rigidity of the one-piece carrier housing are discussed.

Abstract: A suspension interconnection assembly comprises first and second saddle brackets and a fastener. Each saddle bracket comprises a base, a pair of arms spaced apart and have the base disposed therebetween, and a pair of shoulders. Each shoulder is disposed between the base and a respective arm. Each shoulder has a first beveled surface. The pair of shoulders cooperates with the base and the pair of arms to at least partially define a U-shaped pocket. The U-shaped pockets of each saddle bracket are sized to partially receive an axle housing. The fastener interconnects the saddle brackets to couple the saddle brackets and a spring to the axle housing. The beveled surfaces of each saddle bracket are adapted to operatively engage the peripheral wall. The pairs of arms of each saddle bracket are adapted to operatively engage one another after the beveled surfaces operatively engage the peripheral wall.

Abstract: A suspension interconnection assembly comprises first and second saddle brackets and a fastener. Each saddle bracket comprises a base, a pair of arms spaced apart and have the base disposed therebetween, and a pair of shoulders. Each shoulder is disposed between the base and a respective arm. Each shoulder has a first beveled surface. The pair of shoulders cooperates with the base and the pair of arms to at least partially define a U-shaped pocket. The U-shaped pockets of each saddle bracket are sized to partially receive an axle housing. The fastener interconnects the saddle brackets to couple the saddle brackets and a spring to the axle housing. The beveled surfaces of each saddle bracket are adapted to operatively engage the peripheral wall. The pairs of arms of each saddle bracket are adapted to operatively engage one another after the beveled surfaces operatively engage the peripheral wall.

Abstract: A suspension interconnection assembly for a vehicle adapted to move along a surface of the ground includes an axle housing and a spring seat. The spring seat includes a pocket defined by a U-shaped saddle having a bottom wall that extends between a first leg and a second leg. The first and second legs include claw portions that are adapted to engage an upper portion of the axle housing. Welds secure the first and second claw portions to the axle housing so that areas of the axle housing adjacent the welds are in a state of residual tensile stress based on forming. The position of the welds provides a stress cancelling effect upon application of the load to the axle housing in a direction perpendicular to the surface of the ground.

Abstract: A suspension interconnection assembly for a vehicle adapted to move along a surface of the ground includes an axle housing and a spring seat. The spring seat includes a pocket defined by a U-shaped saddle having a bottom wall that extends between a first leg and a second leg. The first and second legs include claw portions that are adapted to engage an upper portion of the axle housing. Welds secure the first and second claw portions to the axle housing so that areas of the axle housing adjacent the welds are in a state of residual tensile stress based on forming. The position of the welds provides a stress cancelling effect upon application of the load to the axle housing in a direction perpendicular to the surface of the ground.

Abstract: A disc brake rotor including a hub portion and a brake disc is provided. The brake disc extends radially outward from the hub portion and includes an outboard disc face and an inboard disc face. A plurality of channels are disposed in the brake disc that are circumferentially spaced from one another. Any one channel in the plurality of channels is open to either the outboard disc face or the inboard disc face. The brake disc includes an outer ring and an inner ring that are circumferentially continuous and uninterrupted along at least the outboard disc face and the inboard disc face. The outer ring is radially spaced from the inner ring with the plurality of channels disposed radially between the outer ring and the inner ring. Advantageously, this arrangement increases shear strength of the brake disc while providing enhanced cooling.

Abstract: A disc brake rotor including a hub portion and a brake disc is provided. The brake disc extends radially outward from the hub portion and includes an outboard disc face and an inboard disc face. A plurality of channels are disposed in the brake disc that are circumferentially spaced from one another. Any one channel in the plurality of channels is open to either the outboard disc face or the inboard disc face. The brake disc includes an outer ring and an inner ring that are circumferentially continuous and uninterrupted along at least the outboard disc face and the inboard disc face. The outer ring is radially spaced from the inner ring with the plurality of channels disposed radially between the outer ring and the inner ring. Advantageously, this arrangement increases shear strength of the brake disc while providing enhanced cooling.

Abstract: An apparatus for manufacturing a discrete curved product from a feed stock includes a source of heat that is adapted to impose a focused beam of light on at least one surface of a work piece to cause the surface of the work piece to expand and thereby move in the general direction of the heat source so as to impart a predetermined radius of curvature to the work piece. In addition, a method of manufacturing a discrete curved product from feed stock is also disclosed.

Abstract: An apparatus for manufacturing a discrete curved product from a feed stock includes a source of heat that is adapted to impose a focused beam of light on at least one surface of a work piece to cause the surface of the work piece to expand and thereby move in the general direction of the heat source so as to impart a predetermined radius of curvature to the work piece. In addition, a method of manufacturing a discrete curved product from feed stock is also disclosed.

Abstract: An apparatus for manufacturing a discrete curved product from a feed stock includes a source of heat that is adapted to impose a focused beam of light on at least one surface of a work piece to cause the surface of the work piece to expand and thereby move in the general direction of the heat source so as to impart a predetermined radius of curvature to the work piece. The apparatus is described in connection with one example where it may be employed to manufacture a curved backbone for a beam blade windshield wiper assembly from feed stock. In addition, a method of manufacturing a discrete curved product from feed stock, generally, as well as a discrete curved backbone for a beam blade windshield wiper assembly from feed stock, specifically, is also disclosed.

Abstract: An apparatus for manufacturing a discrete curved product from a feed stock includes a source of heat that is adapted to impose a focused beam of light on at least one surface of a work piece to cause the surface of the work piece to expand and thereby move in the general direction of the heat source so as to impart a predetermined radius of curvature to the work piece. The apparatus is described in connection with one example where it may be employed to manufacture a curved backbone for a beam blade windshield wiper assembly from feed stock. In addition, a method of manufacturing a discrete curved product from feed stock, generally, as well as a discrete curved backbone for a beam blade windshield wiper assembly from feed stock, specifically, is also disclosed.

Abstract: A safety edge switch which may be utilized to sense an obstruction present in a window opening upon closure of the respective window of an automotive vehicle. The switch may be secured to a window opening by adhesive attachment. The switch includes an outer peripheral portion preferably shaped as an oval and constructed of a resilient material which defines a central aperture. A second smaller structure constructed of conductive elastomer is located in the central aperture and secured to an internal wall thereof. A portion of the outer peripheral member opposite the second smaller oval shaped structure features a conductive elastomeric portion extending parallel thereto and maintained separate therefrom by the resilient physical properties of the outer peripheral portion.