Continuous radius axle and fabricated spindle assembly

Abstract

Axles and spindle assemblies for wheeled vehicles. More particularly, in at least one embodiment, this invention relates to a substantially curvilinear axle for wheeled vehicles, alone or in combination with a spindle assembly, having a substantially continuous radius of curvature extending from one end of the axle to the other. In at least one additional embodiment, this invention relates to fabricated spindle assemblies having gusset arms for mechanical attachment to axle ends.

1 . An axle for a wheeled vehicle comprising: 
 a first axle end portion carrying a first spindle thereon for supporting a first rotatable wheel;    a second axle end portion carrying a second spindle thereon for supporting a second rotatable wheel;    a middle beam portion connecting and extending between said first axle end portion and said second axle end portion, said middle beam portion having a substantially curvilinear configuration exhibiting a substantially continuous radius of curvature throughout at least a portion of the length thereof.    
   
   
       2 . An axle according to  claim 1  wherein configuring said middle beam portion into said substantially continuous radius of curvature substantially eliminates stress risers in said middle beam portion of said axle.  
   
   
       3 . An axle according to  claim 1  wherein said middle beam portion of said axle is, at least in part, selected from a substantially tubular in cross-sectional configuration, or a substantially square cross-sectional configuration.  
   
   
       4 . An axle according to  claim 3  wherein said axle is comprised of multiple radii of curvature and wherein said axle is substantially free of stress risers.  
   
   
       5 . An axle according to  claim 4  wherein said middle beam portion of said axle is comprised of tubing having a substantially rectangular cross-sectional configuration.  
   
   
       6 . An axle according to  claim 4  wherein said middle beam portion of said axle is comprised of single, unitary tubular beam, said beam being bent into said substantially curvilinear configuration thereby to form said substantially continuous radius of curvature therein.  
   
   
       7 . An axle according to  claim 6  wherein said first and second spindles are connected to said first and second axle end portions as components of fabricated spindle assemblies mechanically bonded proximal said first and second axle ends respectively.  
   
   
       8 . An axle according to  claim 4  wherein said middle beam portion of said axle is a fabricated structure constructed from at least two stamped and formed halves bonded together to form a beam having a tubular cross-sectional configuration.  
   
   
       9 . An axle according to  claim 4  wherein said axle is steerable and further includes a first steering knuckle carrying said first spindle and a second steering knuckle carrying said second spindle, said first and second steering knuckles connected to said first and second axle end portions, respectively.  
   
   
       10 . An axle according to  claim 9  wherein said first and second steering knuckles are pivotally connected to said first and second axle end portions via first and second kingpins respectively, said first and second kingpins permitting said first and second spindles to be rotatable about axes of said first and second king pins respectively.  
   
   
       11 . An axle according to  claim 4  further including first and second suspension mounting members connected to said axle proximal said middle beam portion, said suspension mounting members including a suspension beam mounting portion and an air spring mounting portion.  
   
   
       12 . The axle according to  claim 11  wherein said axle is an auxiliary lift axle operatively connected to a lift suspension.  
   
   
       13 . In combination, a motorized wheeled vehicle having installed thereon the axle according to  claim 3 .  
   
   
       14 . An axle according to  claim 5  wherein said tubing having said substantially rectangular cross-sectional configuration is comprised of a pair of spaced apart substantially vertical side walls extending between a pair of spaced apart substantially horizontal top and bottom walls.  
   
   
       15 . An axle according to  claim 14  wherein said vertical walls of said configuration are greater in length than said horizontal walls.  
   
   
       16 . An axle according to  claim 14  wherein said pair of spaced apart substantially vertical side walls are oriented substantially parallel to each other and wherein said pair of spaced apart substantially horizontal top and bottom walls are oriented substantially parallel to each other.  
   
   
       17 . An axle according to  claim 3  wherein said first and second spindles are connected to said first and second axle end portions as components of fabricated spindle assemblies mechanically bonded proximal said first and second axle ends respectively, each said fabricated spindle assembly comprising: 
 a mount plate having a spindle connected thereto,    first and second arms connected to and extending from said mount plate, said first and second arms being welded to side surfaces of said middle beam portion of said axle.    
   
   
       18 . An axle according to  claim 17  wherein said mount plate includes at least one substantially planar surface, said substantially planar surface being welded to one of said first and second axle ends.  
   
   
       19 . An axle according to  claim 17  wherein said middle beam portion of said axle is comprised of tubing having a substantially square cross-sectional configuration.  
   
   
       20 . An axle according to  claim 19  wherein said tubing having said substantially square cross-sectional configuration is comprised of a pair of spaced apart substantially vertical side walls extending between a pair of spaced apart substantially horizontal top and bottom walls; and 
 wherein said first and second arms are welded to said side walls of said middle beam portion of said axle along upper facing edge surfaces of said first and second arms.    
   
   
       21 . The axle according to  claim 20  wherein said middle beam portion of said axle is comprised of single, unitary tubular beam, said beam being bent into said substantially curvilinear configuration thereby to form said substantially continuous radius of curvature therein.  
   
   
       22 . The axle according to  claim 21  wherein forming said substantially curvilinear configuration in said middle beam portion substantially eliminates stress risers in said middle beam portion.  
   
   
       23 . The axle according to  claim 21  wherein said axle is steerable and further includes a first steering knuckle carrying said first spindle and a second steering knuckle carrying said second spindle, said first and second steering knuckles connected to said first and second axle end portions, respectively.  
   
   
       24 . The axle according to  claim 23  wherein said first and second steering knuckles are pivotally connected to said first and second axle end portions via first and second kingpins respectively, said first and second kingpins permitting said first and second spindles to be rotatable about axes of said first and second king pins respectively.  
   
   
       25 . The axle according to  claim 24  further including first and second suspension mounting members connected to said axle proximal said middle beam portion, said suspension mounting members including a suspension beam mounting portion and an air spring mounting portion.  
   
   
       26 . The axle according to  claim 25  wherein said axle is an auxiliary lift axle operatively connected to a lift suspension.  
   
   
       27 . In combination, a motorized wheeled vehicle having installed thereon the axle according to  claim 21 .  
   
   
       28 . A method of manufacturing a drop-type axle for a wheeled vehicle comprising: 
 selecting a stock beam material;    affixing to a first end of said axle beam a first axle end portion including a first spindle for supporting a first rotatable wheel; and    affixing to a second end of said axle beam a second axle end portion including a second spindle for supporting a second rotatable wheel.    
   
   
       29 . The method according to  claim 28  wherein said first and second axle end portions each comprise, respectively: 
 a mount plate having a spindle connected thereto, said mount plate having first and second arms extending outwardly therefrom; and wherein said method further comprises:    welding said first and second arms and said mount plate to said first and second axle end portions of said first and second ends of said axle beam, respectively.    
   
   
       30 . The method according to  claim 29  wherein said axle beam is comprised of at least first and second side surfaces; said method further comprising: 
 welding said first arm to said first side surface of said axle beam;    welding said second arm to said second side surface of said axle beam.    
   
   
       31 . The method according to  claim 30  wherein each said first and said second arm includes upper and lower facing surfaces; said method further comprising: 
 welding said first arm to said first side surface along said upper facing surface of said first arm;    welding said second arm to said second side surface along said upper facing surface of said second arm.    
   
   
       32 . The method according to  claim 31  wherein said mount plate is substantially planar and wherein said method further comprises welding said mount plate to one of said axle ends.  
   
   
       33 . The method according to  claim 28  wherein said stock beam material is formed into said substantially curvilinear axle beam by feeding said beam between at least a pair of rollers, at least one of said rollers being actuated to impart a force to said beam which is sufficient to form a desired curvature therein.  
   
   
       34 . The method according to  claim 32  wherein each weld connecting said first or second axle end portion to said axle beam is a non-tension type weld.  
   
   
       35 . An axle for a wheeled vehicle comprising: 
 a curvilinear axle beam portion having a substantially continuous radius of curvature and having first and second axle end portions;    a first wheel carrying means connected to said first axle end portion; and    a second wheel carrying means connected to said second axle end portion.    
   
   
       36 . The axle according to  claim 35  wherein said first and second wheel carrying means are pivotable with respect to said first and second axle end portions, respectively, thereby to provide steerability to said axle.  
   
   
       37 . The axle according to  claim 35  further including suspension mounting means located on said curvilinear axle beam portion.  
   
   
       38 . The axle according to  claim 35  wherein said curvilinear axle beam portion is at least partially tubular in cross section.  
   
   
       39 . The axle according to  claim 38  wherein said curvilinear axle beam portion is substantially square in cross section.  
   
   
       40 . The axle according to  claim 39  wherein said curvilinear axle beam portion is substantially rectangular in cross section.  
   
   
       41 . An axle for a wheeled vehicle in combination with a fabricated spindle assembly for carrying a vehicle wheel comprising: 
 an axle beam have an axle end portion, said axle beam having at least first and second side walls;    a mount plate connected to said axle end portion via welds;    a gusset attached to said mount plate and having first and second gusset arms extending outwardly therefrom, each said first and second gusset arm having upper and lower surfaces;    said first gusset arm being welded to said first side wall along said upper surface of said first gusset arm;    said second gusset arm being welded to said second side wall along said upper surface of said second gusset arm; and    a spindle shaft connected to and extending from said mount plate in a direction substantially opposite said extension of said gusset arms.    
   
   
       42 . The combination according to  claim 41  wherein: 
 said axle includes upper and lower surfaces;    said gusset having at least a portion thereof extending below a portion of said lower surface of said axle;    said first gusset arm having a first longitudinal axle contacting surface having an upper edge and a lower edge;    said second gusset arm having a second longitudinal axle contacting surface having an upper edge and a lower edge;    wherein said first gusset arm is welded to said first axle side wall along a length of said upper edge of said first longitudinal axle contacting surface; and    wherein said second gusset arm is welded to said second axle side wall along a length of said upper edge of said second longitudinal axle contacting surface.    
   
   
       43 . The combination according to  claim 42  wherein said mount plate is welded to said axle end portion via welds located proximal at least said upper and lower axle surfaces.  
   
   
       44 . The combination according to  claim 43  wherein said gusset includes a base portion welded to said mount plate.  
   
   
       45 . The combination according to  claim 44  wherein said welds along said first and second longitudinal axle contacting surfaces are non-tension type welds.  
   
   
       46 . The combination according to  claim 41  wherein said mount plate includes an aperture and said spindle shaft is press fit into said aperture.  
   
   
       47 . The combination according to  claim 44  wherein said base portion is welded in shear to said mount plate.  
   
   
       48 . The combination according to  claim 41  wherein said axle is a drop-type axle.  
   
   
       49 . The combination according to  claim 48  wherein said axle has a central portion which is located at a height lower than said axles end portions.  
   
   
       50 . The combination according to  claim 41  wherein said axle comprises: 
 a first axle end portion carrying a first spindle thereon for supporting a first rotatable wheel;    a second axle end portion carrying a second spindle thereon for supporting a second rotatable wheel;    a middle beam portion connecting and extending between said first axle end portion and said second axle end portion, said middle beam portion having a substantially curvilinear configuration exhibiting a substantially continuous radius of curvature throughout the length thereof.    
   
   
       51 . An axle for a wheeled vehicle in combination with a steering knuckle for carrying a vehicle wheel comprising: 
 an axle beam having axle end portions, said axle beam having at least first and second side walls;    an axle mount plate mechanically connected to one of said axle end portions;    a spindle shaft connected to and extending from a spindle mount plate;    a kingpin interconnecting said spindle mount plate and said axle mount plate such that said spindle is rotatable about an axis of said kingpin thereby to provide steerability to said axle;    a gusset attached to said axle mount plate and having first and second gusset arms extending outwardly therefrom, each said first and second gusset arm having upper and lower surfaces;    said first gusset arm being welded to said first side wall along said upper surface of said first gusset arm;    said second gusset arm being welded to said second side wall along said upper surface of said second gusset arm.    
   
   
       52 . The combination according to  claim 51  wherein said kingpin is mounted to said axle mount plate and said spindle mount plate includes a knuckle portion rotatably connected to said king pin for providing steerability to said axle.  
   
   
       53 . The combination according to  claim 51  wherein said king pin is mounted to said spindle mount plate and said axle mount plate includes a knuckle portion rotatably connected to said kingpin for providing steerability to said axle.  
   
   
       54 . A fabricated spindle assembly for an axle of a wheeled vehicle comprising: 
 a mount plate having a spindle aperture for carrying a spindle therein;    a gusset attached to said mount plate and having first and second gusset arms extending outwardly therefrom;    a spindle shaft press fit into said spindle aperture and extending from said mount plate in a direction substantially opposite said extension of said gusset arms.    
   
   
       55 . The fabricated spindle assembly according to  claim 54  wherein said gusset is substantially U-shaped.  
   
   
       56 . In combination, a motorized wheeled vehicle having installed thereon the axle and fabricated spindle assembly combination according to  claim 50 .  
   
   
       57 . In combination, a motorized wheeled vehicle having installed thereon the axle and fabricated spindle assembly according to  claim 50 , wherein said spindle assembly includes a spindle plate comprised of weldable steel and a spindle pin therein, said spindle plate being weldable to axle.  
   
   
       58 . The combination of  claim 57 , wherein said axle is at least in part tubular and said spindle plate is weldable to said tubular part of said axle.