Patent Publication Number: US-2009224510-A1

Title: Vehicle  extender

Description:
FIELD OF THE INVENTION 
     This invention relates generally to the vehicle art, and, more particularly to vehicle extenders. 
     BACKGROUND OF THE INVENTION 
     U.S. Pat. No. 1,250,066 provides a trailer attachment for automobiles which may be attached to the chassis of an automobile and which is provided with means for turning the wheels of the trailer to aid in steering the assembly in an attempt to turn in less space than would ordinarily be required. 
     U.S. Pat. No. 3,312,479 provides a load distributing tractor-trailer assembly for maintaining both the tractor driving wheels and the auxiliary supporting wheels in surface engagement irrespective of the surface conditions encountered. 
     U.S. Pat. No. 4,635,742 provides an extendable chassis with an additional axle which is moved to a position with the wheels on the ground when the chassis is extended and to a position with the wheels off the ground when the chassis is retracted. 
     U.S. Pat. No. 4,679,634 provides an apparatus for extending the frame of a tractor so that an agricultural implement may be mounted between the front and rear wheels of the tractor. 
     U.S. Pat. No. 4,955,629 provides a convertible chassis for a semi-trailer that converts to an elongated, telescoped chassis to support both the semi-trailer and a trailer towed behind the semi-trailer. 
     U.S. Pat. No. 5,375,866 provides an extension axle apparatus for over-the-road trailer assemblies which includes a rigid connecting beam affixed to the end of the trailer bed. A parallelogram structure which connects the unit to follow directly behind the trailer. 
     U.S. Pat. No. 6,199,894 for an apparatus and method for a truck frame extender one end of which includes a connection that can be received by and secured into the back end of a truck frame either in the same general plane as the truck frame or it can be secured to the truck frame at a different lower or higher position. 
     U.S. Pat. No. 6,695,328 for a vehicle frame assembly and split-frame vehicle in which the front and rear sub-frames may rotate relative to one another along a longitudinal axis that runs generally parallel to the ground. 
     U.S. Pat. No. 6,969,104 provides an adjustable length chassis which is capable of being reduced in length and includes a gooseneck assembly and a rear frame assembly. 
     U.S. Published Patent Application Publication No. 2004/0017054 for vehicles in which the rear of a vehicle and the front of an extension unit are provided with complementary locating formations and clamping means are provided for clamping the front of the extension unit to the rear of the vehicle. 
     In the truck market there are requirements for many varied vehicles to support various needs. In some cases a smaller, lighter and more transportable vehicle is needed while in other cases the ability to carry more payload or personnel is needed. Typically, these varied needs result in many differently designed vehicles which are uniquely configured to support one, or a few, different needs. This causes increased costs and manufacturing complexity, as well as increased support/life cycle costs for the customer. For example, it may be necessary to have a comparatively small 4 wheeled vehicle for internal or external air transport that would allow for rapid deployment to a given location. In another case it may be necessary to have a larger vehicle, such as one with 6 wheels, to carry added payload and personnel. 
     There have been attempts to solve this, or similar, problems before. One example is the use of a “Tag” axle. This is an axle which is normally up off of the road surface until enough payload is placed on the vehicle to cause it to contact the ground. While this is helpful to vehicle mobility and increases payload capacity, it does not change the size or weight of the vehicle when not in use. This can be seen in various vehicles such as dump trucks and log haulers. 
     Another example, is a 6×6 extender frame vehicle which does not fulfill all of the needs which modern extender frame vehicles are required to handle. 
     Prior art structures in the vehicle field are much more cumbersome in design. They do not use quick connects nor are they self supporting. In some prior designs a rear section must be removed, the axle removed, and the rear section remounted. While some of them attempt to offer similar arrangements as the present invention they are more difficult and cumbersome in performing similar operations, and require cranes/hoists to manipulate the sections. This results in less flexibility in the field and requires much time to remove and remount. 
     SUMMARY OF THE PRESENT INVENTION 
     The present invention provides for two types of vehicles in one venue at any given time, namely a 4×4 and a 6×6 vehicle. 
     In one embodiment of the present invention an add-on axle on an extender is provided that can convert a 4×4 vehicle into a 6×6 vehicle. The third axle can be a driven axle, if desired. The arrangement uses elements in the vehicle frame to allow for attachment, such as via bolts. All connections (brakes, electrical, suspension air, and CTIS air) are made with quick connect couplings. The third axle has supports built in that allow for easy handling when separated from the main vehicle. Removal or installation of the third axle can be accomplished in 30-45 minutes with the truck&#39;s basic tools. 
     The present invention provides a vehicle system which facilitates the rapid and easy reconfiguration of a vehicle by adding or removing axles to meet various needs. While one arrangement is used to convert a 4×4 vehicle into a 6×6 vehicle, other vehicle configurations could be arranged in a similar fashion. Additionally, it is not a requirement that all axles be driven axles. This same basic arrangement can apply to added un-driven axles as well. In this manner it is possible to deploy one vehicle type and reconfigure it in the field to support any given need and any given time. This increases vehicle commonality and reduces design time and cost, as well as manufacturing and support costs. These extender axles arrangements could be shipped at a later time so as not to impact the rapid deployment of the base 4 wheeled vehicle. 
     The axle extender axle can convert a 4 wheel drive vehicle into a 6 wheel drive vehicle. This extender axle is easily attached to the base vehicle by use of mechanical hardware and quick connects for air, brakes and electrical services. The third axle has its own cargo bed section which mates to the rear of the 4 wheeled vehicles cargo bed. This increases cargo capacity by 10,000 lbs, while only adding 3,000 lbs to vehicle weight. Additionally it increases personnel carrying capability by up to 6 people. The third axle is connected to the original vehicle by three bolts per side, as well as a clamp device which utilizes a tie down hole in the base vehicle and two additional bolts. A thru-shaft differential may be incorporated into the base vehicle&#39;s second axle so that an additional prop shaft could be attached and provide drive torque to the third axle when attached. Five quick connects can be used to connect services to the third axle: two for brakes, two for suspension air lines, and one for central tire inflation (CTIS). There may also be an electrical connector for power in the third axle (such as for lights, etc.). For proper alignment of the third axle frame two wedges, perpendicular to each other, can be located on the third axle frame. These wedges may be mated to notched blocks which may be welded onto the base vehicle frame. 
     To further simplify the process of installation/removal of the third axle mounts are designed into the extender frame which could receive dolly wheels (similar to a trailer jack wheel), and tip stands are built into the rear of the frame. In this way the third axle is totally self supporting and stable when not attached to the base vehicle. This also facilitates ease of mounting/dismounting by allowing the base vehicle to be driven up to, or away from, the extender frame. This feature makes the job fairly simple, and negates the need for heavy cranes/hoists to place the third axle into position. The entire job of mounting or dismounting can be completed in less than one hour with a two person crew, and no special tools. 
     The solution provided by the present invention is a much simpler in design and the operation can be accomplished in much less time and without special tools and hoists. Also, unlike the tag axle, it can reduce vehicle transport weight and length making it easier to move the vehicle to another location via aircraft/rail/ship. 
     Currently there is a need for many vehicles of different configurations. Sometimes vehicles available in the motor pool are larger or smaller than needed for a current activity. Additionally there is a desire to have as much commonality as possible between vehicles in a fleet. 
     Thus, the present invention provides an add-able/removable axle that can be quickly installed/removed to allow for rapid reconfiguration of a vehicle with no special tools. 
     The present invention allows one vehicle to serve multiple functions. The add on axle can greatly increase payload capability. Conversely the axle can be removed to lighten the vehicle and improve transportability. This reconfiguration can be done quickly with no special tools. The present invention provides maximum flexibility in the fleet with reduced cost. Additionally it improves parts commonality across the fleet. 
     As previously mentioned above, there have been previous attempts to solve this problem. However, while there are numerous advancements over the prior art as contained in the above listed patents, they do not address the attachment and/or the use of an additional axle that is similar to the present invention. For example, in the present invention the added axle is driven, there is the use of quick connects for air and brake lines, and better methods of attachment 
     This invention could apply to commercial vehicles as well as military vehicles. 
     The present invention together with the above and other advantages may best be understood from the following detailed description of the embodiments of the invention illustrated in the drawings, wherein: 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a diagrammatic isometric view of the vehicle system of the present invention in the 6×6 configuration. 
         FIG. 2  is a frontal isometric view showing the entire vehicle in the 6×6 configuration. 
         FIG. 3  is a frontal isometric view showing the entire vehicle in the 4×4 configuration 
         FIG. 4  is a front isometric view of the extender showing the position of the parts of the vehicle when the extender is about to be connected. 
         FIG. 5  is a rear isometric view showing details of the rear connections when the vehicle is being changed from a 4×4 to a 6×6 vehicle, and showing the prop shaft connection and the quick couplings of the vehicle. 
         FIG. 6  is a side view showing the rear end of the 4×4 vehicle connected to the extender, and showing the driver&#39;s side mounting bolts and clamp and the dolly wheel mount for the 6×6 vehicle. 
         FIG. 7  is a diagrammatic isometric view of a part of the vehicle showing the lower bolt mount location. 
         FIG. 8  is a diagrammatic isometric view of a part of the vehicle showing the positioning clamp from the third to the second axle. 
         FIG. 9  is a diagrammatic plan view showing the second and third axle sections. 
         FIG. 10  is a diagrammatic isometric view showing the extender frame 
         FIG. 11  is a diagrammatic isometric view showing details of the structure shown in  FIG. 10 , including the wedge blocks. 
         FIG. 12  is a diagrammatic isometric view showing the base vehicle main frame. 
         FIG. 13  is a diagrammatic isometric view showing details of the structure shown in  FIG. 12 , including the V-grooves. 
         FIG. 14  shows the rear tip supports of the 6×6 vehicle in the folded up position. 
         FIG. 15  is an isometric view is an isometric view of a part of the vehicle showing the upper bolt location for connection of the third axle. 
     
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
     The present invention provides a tactical military vehicle  10  ( FIGS. 1-4 ), which could also be a civilian vehicle, having a driver section  11  and a cargo bed section  12 . In this figure the vehicle is a 6×6 vehicle showing it with a third axle attached by attaching an extender  14  with a third axle  16 . In  FIG. 1  most of the body has been removed to show the support and connection structures. The complete vehicle in the 6×6 configuration is shown in  FIG. 2  in which the cargo bed  12  of the main vehicle is aligned with the cargo bed  18  of the extender to form a larger cargo bed. 
     The 4×4 vehicle is shown in  FIG. 3 . The third axle  16  and the extender  14  are shown in  FIG. 4 , which has been removed from the main vehicle.  FIG. 4  shows the front of extender  14 , which attaches to the rear of the main vehicle. The extender  14  has dolly legs  20  attached to the extender so that it can be positioned to be attached to the main vehicle by being wheeled into place using the two wheels  22  of the dolly legs and the two wheels  24  of the extender. The dolly is formed by the two wheeled legs  20  with wheels  22  so that the structure has four wheels when it is not being used and can be wheeled to the back of the 4×4 vehicle when attachment of the extender is desired. When the extender is attached to the main vehicle, the dolly legs and wheels can be pivoted out of the way or removed, as desired. 
     As shown in  FIG. 14 , which provides a view of the back of the extender, there are two tip legs  76 , having wheels  78 , to prevent the extender from tipping when it is not connected to a vehicle.  FIG. 14  shows the tip legs in folded position. When they are to be used they are moved out of the folded or pivoted position. 
       FIG. 5  shows the back of the 4×4 vehicle which includes a prop output shaft  28  which is provided to be connected to the extender and to drive the two wheels  24  of the extender as explained below (when the driven wheeled extender embodiment is used). Above the prop shaft there is a plate  30  which provides connections for the brake line  32 , the CTIS air line  34 , and the suspension air connections  36  (the two outer connectors). There are also electrical line connectors (not shown). There are tow eyes  38  for connection to the extender or which may be used to tow another type of equipment.  FIGS. 4-6  show a cross piece  40  at the top of the dolly supported structure which has threaded holes  42  ( FIG. 4 ) in the ends so that bolts  44  may be inserted through the tow eyes  38  and threaded into the cross piece to connect the parts together. 
     The frame  46  of the 4×4 base vehicle is shown in  FIG. 12  and an enlarged portion of it is shown in  FIG. 13 . The frame  48  of the extender is shown in  FIG. 10  and an enlarged portion of it is shown in  FIG. 11 . The parts  50  and  52  shown in  FIGS. 11 and 13  mesh together in such manner that the V-protrusions or wedge blocks  50  of the extender frame shown in  FIGS. 10 and 11  fit into the V-block notches or V-grooves  52  of the main frame shown in  FIGS. 12 and 13  to provide an accurate connection between the parts. The wedge blocks  50  are on an inclined support  51  and the V-grooves  52  are formed in a matching inclined support  53 . In  FIG. 6  the mating line where the supports  51  and  53  meet is designated at  71 . (For purposes of clarity there is a slight space shown in the drawing, but the parts are actually in contact.) 
     The extender  14  shown in  FIG. 4  has a shaft extension  54  which connects to the output shaft  28  shown in  FIG. 5 . There are two boxes  56 , one on each side of the extender support  51  as shown in  FIGS. 4 ,  7 ,  8 ,  10  and  11 . A pin  58  passes through the large hole  60  in the main frame adjacent to the V-grooves  52  as shown in  FIGS. 7 ,  8  and  13 . The pin  58  has an opening through which bolts  64  pass. These bolts  64  also pass through openings  62  in the boxes  56  and are held in place by nuts  66 . This pin  58  and bolt  64  connection is shown in more detail in  FIGS. 7 and 8 , and when the nut is tightened on the bolt a clamping action of the parts takes place. 
     The extender frame  48  structure (See  FIGS. 10 and 11 ) has a leg  68  on each side, the upper ends of which have two holes  70  each. These legs  68  are bolted to the main frame which has threaded blocks  72  in the vehicle frame to receive the bolts  74 , as seen in  FIG. 6 . 
     Thus, there are three connection areas. The upper one is shown in  FIGS. 6 and 15  and is provided by bolts  44  through the tow eyes  38  and into the upper cross piece  40 . The middle one is provided by positioning clamps and is shown in  FIGS. 7-9 , and is provided by the pin  58  in the hole  60  in the frame  46 , and bolts  64  through the pin  58  and through the holes  62  in the boxes  56  (there are two boxes on each side of each main frame side leg) as shown in  FIG. 9 . and also in  FIGS. 7 and 8 . The lower one is shown in  FIGS. 6 ,  7  and  11  and is provided by the leg  68  on each side of the extender frame  48  by two bolts  74  passing through the holes  70  in the leg and into threaded blocks  72  on the main frame. 
     Thus, the present invention satisfies a need for many vehicles of different configurations. Sometimes vehicles available in the motor pool are larger or smaller than needed for a current activity. Additionally there is a desire to have as much commonality as possible between vehicles in the fleet. The present invention provides an addable/removable axle that can be quickly installed/removed to allow for rapid reconfiguration of a vehicle with no special tools. This allows one vehicle to serve multiple functions. The add-on axle can greatly increase payload capability. Conversely, the axle can be removed to lighten the vehicle and improve transportability. This reconfiguration can be done quickly with no special tools. It provides maximum flexibility in the fleet with reduced cost. Additionally, it improves parts commonality across the fleet. 
     It is to be understood that the above-described embodiments are simply illustrative of the principles of the invention. Various and other modifications and changes may be made by those skilled in the art which will embody the principles of the invention and fall within the spirit and scope thereof.