Wheel end assembly and method of servicing

A wheel end assembly and a method of servicing. The wheel end assembly may include a wheel hub, a mounting ring, and a brake rotor. The mounting ring may be removably coupled to the wheel hub with a first set of fasteners. The brake rotor may be removably mounted to the mounting ring with a second set of fasteners.

TECHNICAL FIELD

This relates to a wheel end assembly and a method of servicing a wheel end assembly.

BACKGROUND

A two-component wheel hub is disclosed in U.S. Pat. No. 7,281,769.

SUMMARY

In at least one embodiment a wheel end assembly is provided. The wheel end assembly may include a wheel hub, a mounting ring, and a brake rotor. The wheel hub may be rotatable about an axis. The mounting ring may extend around the wheel hub and may be removably coupled to the wheel hub with a first set of fasteners. The brake rotor may encircle the wheel hub and may be removably mounted to the mounting ring with a second set of fasteners.

In at least one embodiment, a method of servicing a wheel end assembly is provided. The method may include removing a first set of fasteners to detach a mounting ring that encircles a wheel hub from the wheel hub. The wheel hub may be rotatable about an axis and may have an outboard end and an inboard end. A second set of fasteners may be removed to detach the brake rotor from the mounting ring. The mounting ring and the brake rotor may be removed from the wheel hub by moving the mounting ring and the brake rotor in an axial direction toward the outboard end of the wheel hub.

DETAILED DESCRIPTION

Referring toFIG.1, an example of a wheel end assembly10is shown. The wheel end assembly10may be provided with a vehicle like a truck, bus, farm equipment, military transport or weaponry vehicle, or cargo loading equipment for land, air, or marine vessels or a trailer that may be provided with a vehicle.

Referring toFIG.3, the wheel end assembly10may facilitate mounting and rotation of a wheel12upon which a tire may be mounted. For clarity, only a portion of the wheel12is shown inFIG.3. The wheel end assembly10may be associated with a driven wheel or a non-driven wheel. A driven wheel may receive torque from a torque source, such as an internal combustion engine or electric motor. For instance, a shaft such as an axle shaft may transmit torque from the torque source to the wheel end assembly10to rotate the wheel12. A non-driven wheel may not receive torque from a torque source. An axle shaft may not be provided in such a configuration.

Referring toFIGS.1-3, the wheel end assembly10may include a wheel hub20, a brake rotor22, and a mounting ring24. The wheel hub20, the brake rotor22, and the mounting ring24are separate components.

The wheel hub20may be rotatable about an axis30. As is best shown inFIG.3, the wheel hub20may be rotatable about the axis30with respect to a spindle32. The spindle32may be provided with or may be mounted to a structural component34, such as an axle assembly, a steerable knuckle, a non-steerable knuckle, or the like. In at least one configuration, the wheel hub20may be rotatably supported by one or more wheel bearings36that may be disposed on the spindle32. In the configuration shown, the wheel bearings36may encircle the spindle32and may be axially positioned between a hub cap38and a hub seal. In at least one configuration, the wheel hub20may include an outboard end40, an inboard end42, a hub cavity44, a mounting portion46, and a plurality of bosses48.

Referring toFIGS.2and3, the outboard end40may face away from the structural component34. The outboard end40may face toward and may engage the hub cap38. Alternatively, another component such as an axle shaft flange may engage the outboard end40. The bosses48may extend from the outboard end40in a direction that extends toward the mounting portion46.

The inboard end42may be disposed opposite the outboard end40. The inboard end42may face toward and may engage the structural component34.

The hub cavity44may extend around the axis30. The hub cavity44may receive various components that may be associated with the wheel end assembly10, such as the spindle32, wheel bearings36, seals, and the like.

The mounting portion46may facilitate mounting of the mounting ring24. The mounting portion46may be disposed opposite the hub cavity44and may at least partially extend around the axis30. For instance, the mounting portion46may protrude away from the axis30and may include a plurality of fastener holes50and a plurality of mounting bosses52as is best shown inFIG.2.

The fastener holes50may be arranged around the axis30and may extend parallel or generally parallel to the axis30. Each fastener hole50may receive a fastener that may attach the mounting ring24to the hub20as will be discussed in more detail below.

A plurality of mounting bosses52may be provided with the mounting portion46. The mounting bosses52may be arranged around the axis30and may be configured as lobes that may be spaced apart from each other such that a gap54may be provided between adjacent mounting bosses52. It is also contemplated that the gaps may be omitted, in which case the mounting portion46may be considered a single unified mounting boss. In at least one configuration, a fastener hole50may be provided with each mounting boss52. The mounting bosses52may help orient and/or support the brake rotor22. For instance, the mounting bosses52or both may define an outer circumferential surface56that may be disposed at a generally constant radial distance from the axis30and that may be configured to be received inside and may engage the brake rotor22.

Referring toFIG.2, a plurality of bosses48may be provided between the outboard end40and the mounting portion46. The bosses48may be arranged around the axis30and may be configured as lobes that may be spaced apart from each other such that a gap may be provided between adjacent bosses48.

Referring toFIGS.1-3, the brake rotor22may be associated with a disc brake and may have friction surfaces that may facilitate braking of the wheel12. The brake rotor22may be removably mountable to the mounting ring24. As such, the brake rotor22may be rotatable about the axis30with the wheel hub20and the mounting ring24when the mounting ring24and the brake rotor22are coupled to the wheel hub20. In addition, the brake rotor22may not be directly fastened to the wheel hub20. As is best shown inFIG.3, the brake rotor22and the wheel12may be disposed on opposite sides of the mounting ring24and may encircle or at least partially encircle the wheel hub20. In at least one configuration and as is best shown with Reference toFIGS.1and2, the brake rotor22may include a first panel60, a second panel62, a set of vanes64, a mounting portion66, or combinations thereof.

The first panel60may be configured as a ring that may extend around the axis30. In at least one configuration, the first panel60may have a first friction surface70and a first interior surface72.

The first friction surface70may be engaged by friction material of a first brake pad to slow rotation of the brake rotor22and the wheel12about the axis30. The first friction surface70may be substantially planar. In addition, the first friction surface70may be disposed substantially perpendicular to the axis30. The term “substantially perpendicular” is used to designate features or axes that are the same as or very close to perpendicular and includes features that are within ±2° of being perpendicular each other.

The first interior surface72may be disposed opposite the first friction surface70. The first interior surface72may face toward the second panel62and may be spaced apart from the second panel62. The first interior surface72may be disposed substantially parallel to the first friction surface70. The term “substantially parallel” means the same as or very close to parallel and includes features or axes that are within ±2° of being parallel each other.

The second panel62may be spaced apart from the first panel60. The first panel60and the second panel62may have substantially similar configurations. For instance, the first panel60and the second panel62may have mirror symmetry with respect to a center plane that may be disposed perpendicular to the axis30and that may be disposed between the first panel60and the second panel62. Accordingly, the second panel62may be configured as a ring that may extend around the axis30and may have a second friction surface80and a second interior surface82.

The second friction surface80may be engaged by friction material of second brake pad to slow rotation of the brake rotor22and the wheel12about the axis30. The second friction surface80may face away from the first friction surface70and may be substantially planar. In addition, the second friction surface80may be disposed substantially perpendicular to the axis30and may be disposed substantially parallel to the first friction surface70.

The second interior surface82may be disposed opposite the second friction surface80. The second interior surface82may face toward the first interior surface72of the first panel60and may be spaced apart from the first panel60. The second interior surface82may be disposed substantially parallel to the second friction surface80.

The set of vanes64may extend from the first panel60to the second panel62. More specifically, the vanes64may extend from the first interior surface72of the first panel60to the second interior surface82of the second panel62. The vanes64may be arranged around the axis30in a repeating pattern and may be spaced apart from each other. As such, the vanes64may interconnect the first panel60with the second panel62while providing an air gap between the first panel60and the second panel62that may facilitate cooling of the brake rotor22.

Referring primarily toFIG.2, the mounting portion66may at least partially encircle the wheel hub20. In addition, the mounting portion66may extend in an axial direction from the first panel60toward the mounting ring24or to the mounting ring24. In at least one configuration, the mounting portion66may at least partially define an inner side90and may include one or more fastener holes92.

The inner side90may face toward the axis30and may extend around the axis30. In addition, the inner side90may face toward and may engage the mounting portion46of the wheel hub20. For instance, the inner side90may face toward and may engage one or more outer circumferential surfaces56of the mounting bosses52. The inner side90may define an inside diameter of the brake rotor22and a brake rotor opening94through which the wheel hub20may extend. The inside diameter of the mounting portion66may be disposed further from the axis30than at least a portion of the wheel hub20that extends axially from the brake rotor22to the outboard end40to allow the brake rotor22to slide onto the wheel hub20to facilitate installation of the brake rotor22or slide off of the wheel hub20to facilitate removal of the brake rotor22. The inner side90may be disposed further from the axis30than the entire wheel hub20(e.g., the wheel hub20may be disposed closer to the axis30from the outboard end40to the inboard end42than the inner side90of the brake rotor22is disposed to the axis30) in one or more configurations.

The fastener holes92may facilitate coupling of the brake rotor22to the mounting ring24as will be discussed in more detail below. The fastener holes92may have any suitable configuration. For instance, the fastener holes92may be configured as through holes or as blind holes. In addition, the fastener holes92may be threaded holes or unthreaded holes.

Referring primarily toFIGS.2-4, the mounting ring24may facilitate mounting of the brake rotor22to the wheel hub20. For instance, the mounting ring24may be removably coupled to the wheel hub20with a first set of fasteners100and may be removably coupled to the brake rotor22with a second set of fasteners102. The mounting ring24may extend at least partially around the wheel hub20. For instance, the mounting ring24may encircle the wheel hub20and the axis30. In at least one configuration and as is best shown with reference toFIG.2, the mounting ring24may include a first side110, a second side112, and a mounting ring opening114. The mounting ring24may also include a set of mounting flanges116, a set of brake rotor fastener holes118, a set of lug bolt holes120, one or more rotational alignment features122, one or more pilot features124, or combinations thereof.

Referring toFIGS.2and3, the first side110may face toward the wheel12and may face away from the brake rotor22. The wheel12may be engageable with the first side110.

The second side112may be disposed opposite the first side110. As such, the second side112may face away from the wheel12and toward the brake rotor22. The brake rotor22may be engageable with the second side112.

Referring primarily toFIGS.2and4, the mounting ring opening114may receive wheel hub20. The mounting ring opening114may extend around the axis30and may be a through hole that may extend through the mounting ring24. The mounting ring opening114may have a larger diameter or may be disposed further away from the axis30than the wheel hub20. The wheel hub20may extend through the mounting ring opening114.

The set of mounting flanges116may be disposed in the mounting ring opening114. Each mounting flange116may face toward the axis30and may extend toward the axis30. In the configuration shown, six mounting flanges116are illustrated; however, it is contemplated that a greater or lesser number of mounting flanges116may be provided. The mounting flanges116are depicted as being spaced apart from each other such that a mounting flange116may be aligned with a corresponding gap54between adjacent mounting bosses52of the wheel hub20; however, it is contemplated that the mounting flanges116may have any suitable configuration that is compatible with the mounting portion46or arrangement of the mounting bosses52. For instance, one or more mounting flanges116may be contiguous such that a gap is not provided between them. In at least one configuration and as is best shown inFIG.2, a mounting flange116may define a mounting flange hole130that may receive a member of the first set of fasteners100.

The mounting flange hole130may be a through hole that may be aligned with a corresponding fastener hole50of the wheel hub20. In at least one configuration, the mounting flange holes130may be spaced apart from each other and may be disposed at a substantially constant radial distance from the axis30. A member of the first set of fasteners100may extend through the mounting flange hole130and into a corresponding fastener hole50of the wheel hub20to attach or couple the mounting ring24to the wheel hub20. The fasteners100may have any suitable configuration. For instance, a fastener100may be configured as a threaded fastener such as a bolt. A thread of the fastener100may mate with a thread of the fastener hole50of the wheel hub20when the fastener hole50is a threaded hole. Alternatively, it is contemplated that a fastener100may be secured with a nut, such as in a configuration in which the fastener100protrudes through a fastener hole50. It is also contemplated that one or more fasteners may be a dowel, such as a solid dowel or a split dowel.

Referring toFIGS.2and4, the set of brake rotor fastener holes118may be defined by the mounting ring24. A brake rotor fastener hole118may be configured as a through hole that may be aligned with a corresponding fastener hole92of the brake rotor22. Each brake rotor fastener hole118may include a counterbore140that may extend from the first side110toward the second side112. In at least one configuration, the brake rotor fastener holes118may be spaced apart from each other and may be disposed at a substantially constant radial distance from the axis30. The brake rotor fastener holes118may be disposed at a different distance from the axis30than the mounting flange holes130. For instance, the brake rotor fastener holes118may be disposed further from the axis30than the mounting flange holes130are disposed from the axis30.

A member of the second set of fasteners102may extend through a brake rotor fastener hole118and into a corresponding fastener hole92of the brake rotor22to attach or couple the brake rotor22to the mounting ring24. The fasteners102may have any suitable configuration. For instance, a fastener102may be configured as a threaded fastener such as a bolt. A thread of the fastener102may mate with a thread of the fastener hole92of the brake rotor22when the fastener hole92is a threaded hole. Alternatively, it is contemplated that a fastener102may be secured with a nut in a configuration in which the fastener102protrudes through a fastener hole92.

A head150of a member of the second set of fasteners102may be completely received inside the brake rotor fastener hole118. For instance, the head150of a fastener102may be received in the counterbore140of a brake rotor fastener hole118such that the head150may not protrude from the first side110, thereby allowing the wheel12to flushly engage the first side110of the mounting ring24.

The set of lug bolt holes120may be defined by the mounting ring24. A lug bolt hole120may be configured as a through hole that may extend from the first side110to the second side112of the mounting ring24. In at least one configuration, the lug bolt holes120may be positioned further from the axis30than the brake rotor fastener holes118. Each lug bolt hole120may receive a lug bolt160that may facilitate mounting of a wheel12. The lug bolts160may have a threaded shank that extend from the mounting ring24in a direction that may extend away from the brake rotor22. The lug bolts160may extend substantially parallel to the axis30and may extend through a corresponding holes in the wheel12. As is best shown inFIG.3, a lug nut162may be threaded onto the lug bolt160and may be disposed on a side of the wheel12that is disposed opposite the mounting ring24to secure the wheel12to the mounting ring24.

Referring toFIGS.2and4, one or more rotational alignment features122may be provided with the mounting ring24. In the configuration shown, two rotational alignment features122are depicted; however, it is contemplated that a greater or lesser number of rotational alignment features122may be provided. For convenience in reference, the two rotational alignment features that are shown may be referred to as a first rotational alignment feature122and a second rotational alignment feature122′. The first rotational alignment feature122and the second rotational alignment feature122′ may have different configurations.

The rotational alignment features122,122′ may be disposed in the mounting ring opening114and may extend toward the wheel hub20and the axis. The rotational alignment features122,122′ may be axially positioned between the wheel12and the brake rotor22. As is best shown inFIG.4, the rotational alignment features122,122′ may be spaced apart from each other and may be positioned between two different members of the set of mounting flanges116.

The rotational alignment features122,122′ may cooperate with the wheel hub20to permit the mounting ring24to be mounted to the wheel hub20in a limited number of rotational positions. For instance, the rotational alignment features122,122′ and the wheel hub20may permit the mounting ring22to be mounted in a single rotational position about the axis30. This may be accomplished in various ways. For instance, at least one rotational alignment feature122,122′ may extend toward the axis30by a different length than the mounting flanges116, have a different width than the mounting flanges116, or combinations thereof. For instance, at least one rotational alignment feature122,122′ may extend toward the axis30by a different length than the mounting flanges116and may only fit within one particular gap between the bosses48when properly installed. As another example, at least one rotational alignment feature122,122′ may have a different width or extend along a different angular distance with respect to the axis30than the mounting flanges116and the wheel hub20may be configured with corresponding gaps54between adjacent mounting bosses52in which the rotational alignment feature122,122′ may only fit within one particular gap between the bosses48when properly installed. As another example, the first rotational alignment feature122may have a different length and/or width than the second rotational alignment feature122′ and at least one of the rotational alignment features122,122′ may be receivable within a limited number of gaps between the bosses48when properly installed.

One or more pilot features124may extend from the mounting ring24. In at least one configuration, a pilot feature124may extend from the first side110in an axial direction that may extend away from the brake rotor22. A pilot feature124may be configured to help guide installation of the wheel12and help center the wheel12about the axis30. For instance, the pilot feature124may be received inside of a wheel opening that may be defined by an inside circumference of a wheel flange through which the lug bolts160may extend. The inside circumference of the wheel flange may or may not engage a pilot feature124once the lug bolts160are tightened.

The wheel end assembly10as described above may allow a brake rotor22to be removed from a wheel hub20or installed on a wheel hub20without disassembling the wheel hub20. Thus, a brake rotor22may be installed on or removed from the wheel hub20when the wheel hub20is installed on a vehicle. As an example, a brake rotor22may be serviced in the following manner.

First, the wheel12may be detached from and disengaged from the wheel end assembly10. The lug nuts162may be removed from the lug bolts160. Then, the wheel12may be removed from the lug bolts160by moving the wheel12along the axis30in a direction that extends away from the brake rotor22.

Next, the mounting ring24may be detached from the wheel hub20by removing the fasteners100.

Next, the mounting ring24and the brake rotor22may be removed from the wheel hub20. The mounting ring24and the brake rotor22may be removed either together or separately. The mounting ring24and the brake rotor22may be removed together by keeping the brake rotor22coupled to the mounting ring24with the second set of fasteners102and moving the mounting ring24and the brake rotor22together along the axis30toward the outboard end40of the wheel hub20. The mounting ring24may be subsequently detached from the brake rotor22by removing the second set of fasteners102. The mounting ring24and the brake rotor22may be removed separately by removing the second set of fasteners102to detach the mounting ring24from the brake rotor22before the mounting ring24is removed from the wheel hub20. The brake rotor22may then be repaired or replaced as appropriate.

A replacement brake rotor may be installed on the wheel hub20using a sequence of steps that may generally be a reverse sequence of the removal steps discussed above. A replacement brake rotor may be a different component than a previously installed brake rotor or may be the same component as the previously installed brake rotor. For instance, the replacement brake rotor may be the previously installed brake rotor after being inspected and/or reworked. For clarity, the term brake rotor is used below to generically designate either type of replacement brake rotor.

The brake rotor22may be positioned such that the brake rotor opening94is sufficiently aligned with the axis30. Then, the brake rotor22may be positioned on the wheel hub20by inserting the wheel hub20into the brake rotor opening94and moving the brake rotor22toward the inboard end42.

Next, the mounting ring24may be positioned such that the mounting ring opening114is sufficiently aligned with the wheel hub20and the axis30. If rotational alignment features are provided, the mounting ring24may be rotated about the axis30to obtain proper rotational alignment with the brake rotor22. Then, the mounting ring24may be positioned on the wheel hub20by inserting the mounting ring24into the mounting ring opening114and moving the mounting ring24axially inboard toward the brake rotor22.

Next, the brake rotor22may be fastened to the mounting ring24with the second set of fasteners102and the mounting ring24may be fastened to the wheel hub20with the first set of fasteners100. It is also contemplated that the brake rotor22may be fastened to the mounting ring24with the second set of fasteners102before the brake rotor22is positioned on the wheel hub20.

Finally, the wheel12may be mounted on the wheel end assembly10. The lug bolt holes in the wheel12may be aligned with the lug bolts160. Then, the wheel12moved along the axis30into engagement with the mounting ring24. The pilot features124may help align the wheel12to the wheel end assembly10during installation of the wheel12. The lug nuts162may be threaded onto the lug bolt160and tightened to secure the wheel12against the mounting ring24.

A wheel end assembly as described above may allow a brake rotor to be installed on a wheel hub or removed from a wheel hub without disassembling the wheel hub or removing the wheel hub from a vehicle, which may reduce assembly and disassembly time and help reduce associated costs. The seals of the wheel hub and preload force on the wheel bearings may not be disturbed and may not need to be reset or adjusted when disassembly of the wheel hub is avoided, thereby helping further reduce service time and costs. Providing the wheel hub and the brake rotor as separate components may make the wheel hub and the brake rotor easier to handle and may eliminate the need for special fitting tools or equipment for servicing the brake rotor. Providing a mounting ring that is a separate component from the wheel hub and the brake rotor may allow the mounting ring to function as an adapter that may accommodate different wheels and wheel hub configurations. For instance, mounting rings may be provided in various diameters or with various lug bolt mounting circles or lug bolt mounting patterns to accommodate different wheel sizes or wheel configurations. This in turn may allow the wheel hub, the brake rotor, or both to be standardized or commonized the across various vehicles. Additionally, the wheel end assembly may be compatible with hub-piloted wheels or stud-piloted wheels.