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 wheel end assembly for a mass transit vehicle includes an output shaft mounted to a wheel hub for driving a vehicle wheel. The output shaft is driven by a gear assembly mounted within a gear housing and operably coupled to an input shaft. The gear assembly includes an input gear driven by the input shaft, a first reduction gear in meshing engagement with the input gear, a second reduction gear operably coupled to the first reduction gear for rotation therewith, and an output gear in meshing engagement with the second reduction gear. The first and second reduction gears are supported on a common shaft that is positioned between the input and output shafts. The input gear and first reduction gear are positioned outboard from the output gear and associated bearings. This double reduction configuration allows vehicle aisle width to be maintained while providing a deeper drop allowing the vehicle floor to be lowered to a position closer to the ground.

Abstract: A wheel end assembly includes an output shaft mounted to a wheel hub for driving a vehicle wheel. The output shaft is driven by a gear assembly mounted within a gear housing and operably coupled to an input shaft. The gear assembly includes an input gear driven by the input shaft, intermediate gears in meshing engagement with the input gear, and an output gear in meshing engagement with the intermediate gears. A tube has one end press-fit into the gear housing with an opposite end extending into a wheel hub cavity. Bearings are mounted directly between the tube and the wheel hub to support the wheel hub for rotation relative to the tube. The output shaft is received within the tube with an inboard end in direct driving engagement with the output gear and with an outboard end directly mounted to the wheel hub.

Abstract: A drive unit assembly utilizes a single input to drive a pair of laterally spaced wheel ends. Each wheel end is suspended independently from the other. The input is operatively coupled to only one of the wheel ends and an exposed axle shaft assembly interconnects the input to the opposite wheel end. The axle shaft assembly includes multiple shaft members to interconnect the laterally spaced wheel ends. One of the axle shaft members is mounted to a vehicle floor structure with a bearing mount and includes connection joints at either end to accommodate the independent motion of each wheel end. The floor and the shaft member move together during suspension travel, allowing the floor to have a lower profile than is traditionally available.

Abstract: A wheel end assembly includes an output shaft that is directly mountable to a wheel adapter to drive a vehicle wheel. A gear assembly is coupled to the output shaft to transfer driving force from an input to the output shaft. The gear assembly includes an output gear that is directly coupled to the output shaft. Thus, the wheel adapter and output gear are both supported directly on the output shaft. The gear assembly and output shaft are substantially enclosed within a housing that is mounted to a non-rotating vehicle component. The output shaft is solely supported by a pair of bearings for rotation relative to the housing. The bearings are installed for direct engagement with the output shaft and housing.

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 transfer case assembly includes an input gear, an idler gear, and an output gear. The idler gear is mounted on an idler shaft, which is rotatably supported by a bearing retained within a carrier. The carrier fits within an arcuate slot. The arcuate slot defines a multiple of idler shaft predetermined mounting locations. Each of the idler shaft predetermined mounting locations are equidistant from the third axis, and vary in distance from the first axis. For each of the idler shaft predetermined mounting locations a gear, of a predetermined size is provided to achieve a proper gear mesh for the desired gear ratio.

Abstract: A tubular axle beam with variable wall thickness for a vehicle is provided including a first beam portion extending longitudinally between first ends and including spaced apart first longitudinal edges. A second beam portion extends longitudinally between second ends and includes spaced apart second longitudinal edges. Weld beads secure the first longitudinal edges to the second longitudinal edges to define a cavity between the beam portions with the first and second ends arranged adjacent to one another. Preferably, the tubular axle beam is constructed by stamping a first blank to form a first half of the beam, and a second blank is stamped to form a second half of the beam. The first and second portions are welded to one another to define a cavity between the portions. In another embodiment of the invention, a tubular axle beam includes a hollow beam extending longitudinally between opposing ends.

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: A suspension system for a low floor vehicle includes an independent suspension system which includes a spring strut of the McPherson type. The spring strut essentially combines a spring and shock into a load bearing member of the suspension. The spring strut is mounted to the hub support structure and the top of each wheel box. An input gear box such as a differential is mounted to the vehicle underside or directly to a hub gear box.

Abstract: A suspension system includes a swing arm which pivots about a pivot axis. A hub assembly, hub gear box and input gear box are mounted to an independently pivoting swing arm. The pivot axis is located below (closer to the ground) than a rotational axis defined by the hub assemblies and the input gear box. A coupling extends from the input gear box to receive an input driveline from a drive source such as vehicle engine. The coupling is located proximate the pivot axis to minimize relative movement during articulation of the swing arm. An axle housing extends between the input gear box and an opposite hub gear box to support a drive shaft and serves as a torsion bar between the independent swing arms.

Abstract: A drive unit assembly utilizes a single input to drive a pair of laterally spaced wheel ends. Each wheel end is suspended independently from the other. The input is operatively coupled to only one of the wheel ends and an exposed axle shaft assembly interconnects the input to the opposite wheel end. The axle shaft assembly includes multiple shaft members to interconnect the laterally spaced wheel ends. One of the axle shaft members is mounted to a vehicle floor structure with a bearing mount and includes connection joints at either end to accommodate the independent motion of each wheel end. The floor and the shaft member move together during suspension travel, allowing the floor to have a lower profile than is traditionally available.

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 tubular axle beam with variable wall thickness for a vehicle is provided including a first beam portion extending longitudinally between first ends and including spaced apart first longitudinal edges. A second beam portion extends longitudinally between second ends and includes spaced apart second longitudinal edges. Weld beads secure the first longitudinal edges to the second longitudinal edges to define a cavity between the beam portions with the first and second ends arranged adjacent to one another. Preferably, the tubular axle beam is constructed by stamping a first blank to form a first half of the beam, and a second blank is stamped to form a second half of the beam. The first and second portions are welded to one another to define a cavity between the portions. In another embodiment of the invention, a tubular axle beam includes a hollow beam extending longitudinally between opposing ends.

Abstract: An independent suspension undercarriage module includes a first subframe segment and a second subframe segment. The subframe is manufactured of a composite material to provide a truss-like structural unibody which is mounted as a unit to the underside of a low floor vehicle through a plurality of resilient dampers. Passengers are thereby provided with a secondary vibration isolation structure separate from the suspension systems which filter out high frequency content generated by the suspension systems.

Abstract: A steering system for a vehicle is provided that includes a steering knuckle which is rotatable about an axis. The steering knuckle includes an upper attachment point and a lower attachment point. The attachment points define the steer axis. A rotational drive unit is connected to the steering knuckle for rotating the steering knuckle about the steer axis. A control module receives a steering input corresponding to the desired Ackerman angle and commands the rotational drive unit to rotate the steering knuckle about the axis to the desired Ackerman angle. Rotational drive units for each side of the vehicle ensure that the wheels are turned to the appropriate Ackerman angle for each wheel. The rotational drive unit may include an electric motor, or a pneumatic or hydraulic pump. In one preferred embodiment, the rotational drive unit includes a fluid housing and the shaft connected to the steering knuckle. The shaft includes a vane extending therefrom and into the housing.

Abstract: A steering system for a vehicle is provided that includes a steering knuckle which is rotatable about an axis. The steering knuckle includes an upper attachment point and a lower attachment point. The attachment points define the steer axis. A rotational drive unit is connected to the steering knuckle for rotating the steering knuckle about the steer axis. A control module receives a steering input corresponding to the desired Ackerman angle and commands the rotational drive unit to rotate the steering knuckle about the axis to the desired Ackerman angle. Rotational drive units for each side of the vehicle ensure that the wheels are turned to the appropriate Ackerman angle for each wheel. The rotational drive unit may include an electric motor, or a pneumatic or hydraulic pump. In one preferred embodiment, the rotational drive unit includes a fluid housing and the shaft connected to the steering knuckle. The shaft includes a vane extending therefrom and into the housing.

Abstract: A steering system is provided for a vehicle including a frame. Upper and lower control arms have first end portions that are pivotally supported on the frame at first spaced apart connections. The control arms also each include second end portions that are pivotally connected to an intermediate support member at second spaced apart connections. A steer knuckle is pivotally supported by the intermediate support member at third spaced apart connections that define a king pin axis. A drive motor is mounted on the intermediate support member and is coupled to the steering knuckle to rotate the steering knuckle about the king pin axis relative to the intermediate support member. A gear set may also be used in conjunction with the drive motor and steering knuckle. The intermediate support member is constrained against forward and aft movement, but is permitted to move upward and downward with the control arms.