Abstract:
An integrated fifth-wheel hitch and axle suspension assembly for mounting on a truck with a pair of spaced apart frame rails comprises a fifth-wheel hitch carriage adapted for mounting a fifth-wheel hitch, a pair of suspension brackets for mounting an axle suspension component and an integrating connector rigidly connecting the fifth-wheel hitch carriage to the suspension brackets at opposite sides of the hitch carriage. The integrating connector, the hitch carriage and the suspension brackets define an elongated opening for slidably receiving the truck frame rails so that the integrated fifth-wheel hitch and axle suspension assembly can slide as a unit onto the truck frame rails. An integrated connection interface includes a plurality of electronic and pneumatic connectors in a connector harness for selectively connecting electronic and pneumatic systems on a truck with electronic and pneumatic components of an integrated fifth-wheel hitch and axle suspension assembly.

Description:
BACKGROUND OF THE INVENTION  
         [0001]    1. Field of the Invention  
           [0002]    The invention relates to fifth-wheel hitch and frame suspensions for truck frames. In one of its aspects, the invention relates to an integrated fifth wheel hitch and frame suspension. In another of its aspects, the invention relates to a modular assembly that integrates a fifth-wheel hitch and truck trailing arm suspension for installation in a truck frame as an integral unit. In another of its aspects, the invention relates to subassemblies of a fifth-wheel hitch and assembled suspension components for installation in a truck frame as a unit. In another of its aspects, the invention relates to a truck with an integrated fifth wheel hitch and axle suspension.  
           [0003]    2. Description of the Related Art  
           [0004]    Truck manufacturers assemble individual components or subassemblies on the vehicle frame. These installations require that the system be built up piece-by-piece from components including a fifth-wheel hitch assembly, vehicle suspension components including frame brackets, electrical harness and connections to the vehicle electrical system, and pneumatic system components and connections such as for brake and height control systems. The installation can be time-consuming and cost-ineffective, and can face issues of system incompatibilities.  
           [0005]    U.S. Pat. No. 3,580,611, issued May 25, 1971, to McNitt, discloses a fifth wheel support platform for installation on a truck tractor, wherein the tractor is prepared for installation of the support platform by the vehicle manufacturer. Spring brackets are installed on the tractor side rails. The brackets include an offset upper portion that creates a gap designed to accommodate a depending flange of the fifth wheel support platform.  
           [0006]    U.S. Pat. No. 5,449,191, issued Sep. 12, 1995, to Cattau, discloses a fifth wheel slide assembly, including a plate mountable onto parallel truck frame rails. The assembly includes a fifth-wheel hitch that is adjustable for the purpose of distributing load on the truck frame, and the hitch is assisted in rolling by rollers that project through apertures in the plate.  
           [0007]    It would be advantageous, reducing installation time and system incompatibilities, to provide an integrated assembly of a fifth-wheel hitch and suspension frame brackets that can be installed on a truck frame as a unit. It would further be desirable to include electrical and pneumatic systems in the integrated assembly.  
         SUMMARY OF THE INVENTION  
         [0008]    According to the invention, an integrated fifth-wheel hitch and axle suspension assembly for mounting on a truck with a pair of spaced apart frame rails comprises a fifth-wheel hitch carriage adapted for mounting a fifth-wheel hitch, a pair of suspension brackets for mounting an axle suspension component and an integrating connector rigidly connecting the fifth-wheel hitch carriage to the suspension brackets at opposite sides of the hitch carriage. The integrating connector, the hitch carriage and the suspension brackets define an elongated opening for slidably receiving the truck frame rails so that the integrated fifth-wheel hitch and axle suspension assembly can slide as a unit onto the truck frame rails.  
           [0009]    Further according to the invention, a truck with a pair of spaced-apart frame rails has an integrated fifth-wheel hitch and axle suspension assembly comprising a fifth-wheel hitch carriage mounting a fifth-wheel hitch, a pair of suspension brackets mounting an axle suspension component, and an integrating connector rigidly connecting the fifth-wheel hitch carriage to the suspension brackets at opposite sides of the hitch carriage. The integrating connector, the hitch carriage and the suspension brackets define an elongated opening slidably received on the truck frame rails and are rigidly connected thereto.  
           [0010]    In one embodiment, the integrating connector comprises a rail plate mounted to each side of the fifth-wheel hitch carriage, each of the rail plates mounting one of the suspension brackets. In another embodiment of the invention, the integrating connector comprises a cross-member extending between the suspension brackets.  
           [0011]    In the first embodiment, the elongated opening is defined by the rail plates and the fifth-wheel hitch carriage. In a second embodiment, the elongated opening comprises a pair of frame rail slots formed between the cross member and the suspension brackets.  
           [0012]    Further, a fifth-wheel hitch is mounted to the fifth-wheel hitch carriage. The suspension component is preferably a trailing arm for mounting an axle and pivotally mounted to each of the pair of suspension brackets. Preferably, an air spring is connected to each trailing arm and to the integrating connector or to the rails. Further, a shock absorber can be connected to each trailing arm and to the integrating connector or to the rails.  
           [0013]    In one embodiment, pneumatic components are carried by the hitch carriage and the suspension brackets and an integrated pneumatic interface having a single connector harness is connected to the pneumatic components for selectively connecting a pneumatic system on the truck and the pneumatic components of the integrated fifth-wheel hitch and axle suspension assembly.  
           [0014]    In another embodiment, electronic components are carried by the hitch carriage and the suspension brackets and an integrated electronic interface having a single connector harness is connected to the electronic components for selectively connecting an electronic system on the truck and electronic components of the integrated fifth-wheel hitch and axle suspension assembly.  
           [0015]    Further according to the invention, an integrated fifth-wheel hitch and axle suspension assembly for mounting on a truck with a pair of spaced apart frame rails comprises a fifth-wheel hitch carriage adapted for mounting a fifth-wheel hitch, a pair of suspension brackets for mounting an axle suspension component and an integrating connector rigidly connecting the fifth-wheel hitch carriage to the suspension brackets at opposite sides of the hitch carriage. Electronic and/or pneumatic components are carried by the fifth-wheel hitch carriage and the suspension brackets. A connector harness that includes a plurality of electronic and pneumatic connectors is connected to the electronic and/or pneumatic components to form an integrated connection interface for selectively connecting electronic and pneumatic systems on a truck with the electronic and/or pneumatic components of the an integrated fifth-wheel hitch and axle suspension assembly.  
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0016]    In the drawings:  
         [0017]    [0017]FIG. 1 is a perspective view of an integral fifth-wheel hitch and frame suspension assembly according to a first embodiment of the invention received within the parallel rails of a truck frame.  
         [0018]    [0018]FIG. 2 is a perspective view of the integral fifth-wheel hitch and frame suspension assembly of FIG. 1.  
         [0019]    [0019]FIG. 3 is a rear view of the assembly of FIGS. 1 and 2.  
         [0020]    [0020]FIG. 4 is a cross-sectional view taken along line  4 - 4  of FIG. 3.  
         [0021]    [0021]FIG. 5 is a cross-sectional view taken along line  5 - 5  of FIG. 4.  
         [0022]    [0022]FIG. 6 is a schematic diagram of a pneumatic and electronic interface of the integral fifth-wheel hitch and frame suspension assembly of FIG. 1.  
         [0023]    [0023]FIG. 7 is a perspective view of an integral fifth-wheel hitch and frame suspension assembly according to a second embodiment of the invention.  
         [0024]    [0024]FIG. 8 is perspective view of the integral fifth-wheel hitch and frame suspension assembly of FIG. 7 mounted on a truck frame.  
         [0025]    [0025]FIG. 9 is a side view of the integral fifth-wheel hitch and frame suspension assembly of FIGS. 7 and 8 mounted on the truck frame.  
         [0026]    [0026]FIG. 10 is a rear view of the assembly of FIGS. 8 and 9.  
         [0027]    [0027]FIG. 11 is a plan view of the assembly of FIGS. 8 and 9. 
     
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0028]    Referring now to the drawings and to FIGS.  1 - 5  in particular, a fifth wheel and frame suspension  10 , for attaching to truck frame rails  12 , comprises a cross member  14 , at least one suspension bracket  16 , and a fifth-wheel hitch assembly  18 .  
         [0029]    The cross member  14  comprises an inverted U-channel  20 , including upper web  22  and two side flanges  26 . The cross member  14  further comprises a lower flange  24  fixed to the side flanges  26 , such as by welding or other mechanical means, in a generally parallel relationship to the cross member web  22 . The cross member  14  further comprises a pair of end caps  28  and a reinforcing gusset plate  30  affixing the end caps  28  to the side flanges  26  of the cross member  14 . Each end cap  28  comprises a section of U-channel having an end cap web  34  and end cap flanges  36 , a plurality of fastener apertures  38  being formed in the end cap web  34 . The cross member  14  further comprises a plurality of apertures  32  formed in each side flange  26 , proximate each end cap  28  and aligned with a corresponding aperture  32  on the opposing side flange  26 .  
         [0030]    Truck frame rails  12  are parallel inwardly facing U-channels comprising a rail web  40 , an upper flange  42 , and a lower flange  44 . Rail web  40  further comprises a plurality of fastener apertures  46  passing therethrough for alignment with fastener apertures  38  of the end cap  28 .  
         [0031]    Suspension bracket  16  comprises a suspension bracket inner leg  50 , a suspension bracket outer leg  52 , and a suspension bracket upper portion  54 . Suspension bracket inner leg  50  comprises an inner leg web  60  including a suspension mounting aperture  64  and a supplemental aperture  66  passing therethrough. The suspension bracket outer leg  52  comprises an outer leg web  62  having a suspension mounting aperture  64  and supplemental aperture  66  passing therethrough. Suspension mounting apertures  64  of the inner and outer leg webs  60 ,  62  are aligned. The suspension bracket  16  further comprises a common flange  68  passing about the exterior of the bracket and affixed to the inner leg web  60  and outer leg web  62  by welding or other mechanical means. The common flange  68  further includes supplemental aperture  66 . The suspension bracket  16  further comprises an outer mounting plate  56  having mounting plate bracket apertures  70  and mounting plate rail apertures  72 . The outer leg web  62  further comprises bracket plate apertures  74  passing therethrough.  
         [0032]    Fifth-wheel hitch assembly  18  comprises a fifth-wheel hitch carriage  80  comprising central recessed portions  82  and parallel first and second longitudinal rail portions  84 ,  86 . Rail portions  84 ,  86  are co-planar and are received on the upper flanges  42  of truck frame rails  12 . Recessed portions  82  are planar and parallel to first and second rail portions  84 ,  86 , and are integral therewith through first and second transition portions  88 ,  90 . Recessed portions  82  further comprise apertures  83  for alignment with fastener apertures (not shown) in cross member upper web.  22 , for receiving mechanical fasteners such as bolts  76  to secure carriage  80  to cross members  14 . Fifth wheel carriage  80  further comprises longitudinal angle brackets  110  having fastener apertures  112 . Fifth-wheel hitch assembly  18  further comprises a slidable low-profile fifth-wheel hitch  100  having adjustment rails  116  mounted on first and second rail portions  84 ,  86 . Hitch  100  and adjustment rails  116  are common in fifth wheel assemblies.  
         [0033]    One of the suspension brackets  16  is affixed to each end of cross member  14 . Upper portion  54  is affixed, by welding or mechanical fasteners, to lower flange  24  of the cross member  14  and lower end cap flange  37 . Upper portion  54  of suspension bracket  16  includes an offset region  55 . Upper portion  54  and end cap flange  37 , when assembled, define a gap  57  for receiving rail lower flange  44 . At least a second cross member  14  is likewise assembled with suspension brackets  16 . Recessed portion  82  of fifth wheel carriage  80  is mounted to web  22  of cross member  14  by welding or other mechanical fasteners, holding cross members  14  in a fixed spacing parallel to each other and perpendicular to rail portions  84 ,  86 .  
         [0034]    The fifth wheel and flame suspension  10 , comprising the fifth-wheel hitch assembly  18 , at least two cross members  14 , and suspension brackets  16  is mounted within truck rails  12  by sliding the assembly longitudinally between the truck rails  12 . End caps  28  slide within truck flame rails  12 , with each rail lower flange  44  residing in gap  57  between bracket upper portion  54  and end cap lower flange  37 . End cap lower flanges  37  are thereby kept flush against rail lower flange  44  so that a gap  48  is formed between end cap flange  36  and rail upper flange  42 . Carriage  80  is configured such that transition portions  88 ,  90  offset rail portions  84 ,  86  above recessed portion  82  to place rail portions  84 ,  86  in flush contact with the upper surface of rail upper flanges  42 . Carriage  80  is thereby supported by rail upper flanges  42  and cross members  14 , which are in turn supported at end caps  28  by suspension brackets  16 . Rail lower flanges  44  are further supported by bracket upper portions  54 .  
         [0035]    With the fifth wheel and flame suspension  10  in place within the frame rails  12 , apertures  38  align with apertures  46  in rail webs  40  for receiving a mechanical fastener such as a bolt  76 , which is tightened to provide mechanical fastening. Further, bracket-plate apertures  74  are aligned with apertures  46  to correspond to the layout of apertures  70 ,  72  of outer mounting plate  56 , so that outer mounting plate  56  is received against outer leg web  62  with mounting plate bracket apertures  70  aligned with bracket-plate apertures  74 , and mounting plate rail apertures  72  aligned with truck frame rail apertures  46 , for receiving a mechanical fastener such as bolts  76 . Apertures  112  in angle bracket  110  are further aligned with apertures  46  in rail web  40  for receiving mechanical fasteners. Fifth wheel and frame suspension  10  is thus secured to frame rails  12  by mechanical fasteners securing end caps  28  to rail webs  40 , and suspension brackets  16  to rail webs  40  through outer mounting plates  56 . Carriage  80  is further secured to rails  12  through angle bracket  110 . Whereas securing the fifth wheel and suspension  10  to rails  12  has been described as using mechanical fasteners passed through aligned apertures in the respective components, it is contemplated that other methods of securing, such as welding, can be used within the scope of the invention.  
         [0036]    The integral fifth wheel and frame suspension assembly  10  further encompasses an integrated pneumatic and electronic plug interface  120  pre-configured to be aligned with, and provide expeditious connection to, the pneumatic and electronic systems of the base vehicle, as shown in FIG. 6. The base vehicle is provided with a matching connector  122 , for receiving the integrated plug interface  120 . The integrated plug interface  120  provides connectors for such pneumatic requirements  130  as the drive train differential lock, air suspension components, brake system components, and other pneumatic requirements such as load sensing and tire inflation. The integrated plug interface  120  provides connectors for such electronic requirements  140  as drive sensors (oil temperature, RPM, torque output), air suspension height and air pressure sensors, air controls), brake system components (control valves and connections for ABS system including reservoirs), and fifth wheel position and engagement sensing systems, load sensing, and tire inflation The integrated plug interface  120  is further anticipated to contain other pneumatic and electronic systems connecting the base vehicle and the integral fifth wheel and frame suspension assembly  10  as known to those of ordinary skill in the art.  
         [0037]    A second embodiment of the integrated fifth-wheel hitch assembly is shown in FIGS.  7 - 11  in which like numerals have been used to designate like parts. In this embodiment, a cross member  220  extends between and rigidly connects the truck frame rails  12 . The integrated fifth wheel frame assembly  210  is configured to be lowered over the truck frame rail, or in instances where suspension components are pre-installed, it may be necessary to slide the integrated fifth wheel frame assembly  210  longitudinally onto the truck frame rails  12  from the rear of the truck frame rails  12 .  
         [0038]    The integrated fifth wheel frame assembly  210  comprises a fifth wheel carriage  280  and a pair of rail plates  228  depending from the fifth wheel carriage  280 . The rail plates  228  comprise an upper flange  236  and a rail plate web  234 , first suspension bracket  216 , second suspension bracket  316  and third suspension bracket  416 . The carriage  280  and the rail plates  228  are rigidly joined together by welding or other suitable fasteners. A pair of cross members  220  extend between the suspension brackets  216  and are rigidly joined thereto. The cross members are bolted to the frame rails  12  when the frame assembly  210  is assembled onto the frame rails  12 .  
         [0039]    A trailing arm  500  is pivotally mounted at one end to a first suspension bracket  216  through a conventional trailing arm pivot  502 . The trailing arm  500  pivotally mounts an axle housing  510  through an axle bracket  508  and a trailing arm drive axle pivot  504  at an intermediate portion of the trailing arm  500 . The axle housing  510  carries an axle (not shown) and is part of a drive axle assembly  540 . A trailing arm air spring brace  506  is mounted to another end portion of the trailing arm  500  and mounts a cross brace  512 . Air springs  530  are mounted to the cross brace  512 . The air springs  530  are connected between the third suspension bracket  416  and to the trailing arm cross brace  512 . A torsion beam  514  is rigidly mounted at each end to the air spring brace  506 .  
         [0040]    A trailing arm shock absorber  520  has an upper shock mount  522  connected to the second suspension bracket  316  and a lower shock mount  524  connected to the trailing arm  500  through bracket  524 .  
         [0041]    This second embodiment of the integrated fifth wheel frame assembly provides the original equipment manufacturer the flexibility of utilizing its own truck frame construction and drive train. The original equipment manufacturer can then use the integrated fifth wheel and frame suspension without modifying the truck frame itself.  
         [0042]    The embodiment of FIGS.  7 - 11  includes a trailing arm  500 , an axle  510  and a air spring  530 . Although not shown in FIGS.  1 - 5 , these same components are typically mounted to the suspension brackets  16  and between the trailing arm and the frame in the same manner as they are mounted to the  516  in the embodiment of FIGS.  7 - 11 .  
         [0043]    While the invention has been specifically described in connection with certain embodiments thereof, it is to be understood that this is by way of illustration and not of limitation. Reasonable variation and modification are possible within the scope of the foregoing disclosure without departing from the spirit or gist of the invention.