Patent Publication Number: US-11045862-B2

Title: Staking tool and method of using the same

Description:
BACKGROUND 
     Vehicles often include an axle onto which a spindle nut is tightened to secure a wheel hub onto the axle. The spindle nut typically screws onto an end of the axle and is tightened against the hub. In order to prevent the spindle nut from becoming unscrewed, the spindle nut may be staked. 
     Staking the spindle nut typically involves indenting a portion of the spindle nut into a cavity on an outside surface of the axle. Automated spindle staking machines are known that provide consistent and repeatable spindle nut staking. For known manual techniques, the stake may be completed by striking, with a mallet or hammer, a screwdriver, chisel, or other tool that is positioned perpendicular to the spindle nut and adjacent the cavity on the axle. However, this technique lacks a mechanism to ensure consistent application of the staking process. Too much striking force or a sharp profile on an angled tip of the tool may result in cracking or excessive deformation of the spindle nut. Conversely, too little striking force may result in an inadequate stake, allowing potential for the spindle nut to rotate. As such, there is need for a consistent and repeatable tool and method for staking a spindle nut onto an axle of a vehicle. 
     BRIEF SUMMARY 
     According to one aspect, a staking tool is provided that is coupled to an axle of a vehicle. The staking tool includes a collar and a striker. The collar includes a guide notch defined on an interior surface. The striker includes a shaft, an angled tip at a first end, and a handle at a second end. The striker is configured to slide longitudinally within the guide notch and stake a lip portion of the spindle nut into a staking notch of the axle. 
     According to another aspect, a system for securing a hub onto a vehicle is provided. The system includes an axle, a spindle nut, a staking tool, and a hammer. The axle includes a staking notch defined on an outer surface. The spindle nut includes a lip portion and a hex portion. The staking tool includes a collar and a striker. The collar includes a guide notch defined on an interior surface. The striker includes a handle, a shaft, and an angled tip. 
     According to another aspect, a method for staking a spindle nut is provided. The method includes positioning a collar over the spindle nut fastened on an axle of a vehicle, aligning a guide notch on the collar with a staking notch on the axle, inserting a striker into the guide notch, and striking the striker with a hammer. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
       To easily identify the discussion of any particular element or act, the most significant digit or digits in a reference number refer to the figure number in which that element is first introduced. 
         FIG. 1  is a perspective view of an exemplary embodiment of a spindle nut installed on an axle. 
         FIG. 2  is a first perspective view of an exemplary embodiment of a staking tool positioned on the spindle nut and axle shown in  FIG. 1 . 
         FIG. 3  is a second perspective view of the staking tool shown in  FIG. 2 . 
         FIG. 4  is a front view of the collar shown in  FIG. 2 . 
         FIG. 5  is a side view of the collar shown in  FIG. 2 . 
         FIG. 6  is a perspective view of the striker shown in  FIG. 2 . 
         FIG. 7  is a perspective view of an exemplary embodiment of an axle. 
         FIG. 8  is a perspective view of an exemplary embodiment of a spindle nut. 
         FIG. 9  is a flow chart of a method of staking a spindle nut onto an axle using a staking tool, for example, the staking tool shown in  FIG. 2 . 
     
    
    
     DETAILED DESCRIPTION 
     With reference now to the figures wherein the illustrations are for purposes of illustrating one or more exemplary embodiments and not for purposes of limiting the same, there is shown a staking tool. 
       FIG. 1  is a perspective view of an exemplary embodiment of a spindle nut  102  installed on an axle  104  of a vehicle. The spindle nut  102  is screwed onto the axle  104  and tightened to a desired torque value against a vehicle component  106  such as a wheel hub assembly, for example. Due to high forces on the axle  104  and spindle nut  102 , the spindle nut  102  is often secured to the axle  104  in some manner to prevent rotation away from the vehicle component. One method of securing the spindle nut  102  to the axle  104  is by staking the spindle nut  102 , which involves indenting a lip portion  108  of the spindle nut  102  into a cavity defined in the axle  104  to physically prevent the spindle nut  102  from rotating. The cavity in the axle  104  is referred to as a staking notch  110  hereinafter. The spindle nut  102  also includes a hex portion for use in rotating the spindle nut  102  on the axle  104  using a wrench or socket. 
       FIG. 2  is a first perspective view of an exemplary embodiment of a staking tool  202  positioned on the spindle nut  102  and axle  104  shown in  FIG. 1 . The staking tool  202  is used to stake the spindle nut  102  in the staking notch  110  of the axle  104  and prevent rotation of the spindle nut  102  away from the vehicle component  106 . The staking tool  202  provided in the depicted embodiment includes a collar  204  and a striker  206 . The collar  204  is positioned over the spindle nut  102  such that a guide notch  208  of the collar  204  is aligned with the staking notch  110 . The striker  206  is configured to slide longitudinally (i.e., substantially parallel to the axle  104 ) within the guide notch  208  wherein an angled tip  210  of the striker is configured to contact the lip portion  108  of the spindle nut  102 . A hammer  212  or mallet is used to impact the striker  206  to cause the striker  206  to partially indent, or stake, the lip portion  108  into the staking notch  110 . More specifically, as the striker  206  is inserted into the guide notch  208 , a distance of an inner surface of the angled tip  210  from a center of the axle  104  is reduced, causing the lip portion  108  to indent into the staking notch  110 . 
     The collar  204  may be radially aligned with the spindle nut  102  at either the lip portion  108  or the hex portion  112 . More specifically, the collar  204  may include a circular recess  404  defined therein, which will be described further with respect to  FIG. 4 , into which the hex portion  112  may be disposed in order to radially align the collar  204  with respect to the spindle nut  102  and axle  104 . Alternatively, the collar  204  includes a cylindrical aperture  302 , which will be described further with respect to  FIG. 3 , into which the lip portion  108  may be inserted to radially align the collar  204  with the spindle nut  102 . For alignment purposes, the recess  404  or interior surface  402  may have a diameter that is slightly larger than a diameter of the hex portion  112  or lip portion  108 , respectively. Radially aligning the collar  204  with respect to the spindle nut  102  maintains a constant distance between the shaft  308  of the striker  206 , when inserted into the guide notch  208 , and the center of the axle  104 . 
       FIG. 3  is a second perspective view of the staking tool  202  shown in  FIG. 2 . As previously described, the staking tool  202  comprises a collar  204  and a striker  206 . In the exemplary embodiment, the collar  204  is substantially cylindrical in shape and includes a cylindrical aperture  302  defined through a center portion of the collar  204  from a vehicle-side face  304  to an opposing outside face  306 . During use, the vehicle-side face  304  of the collar  204  faces the vehicle component  106 , such as the hub assembly, while the outside face  306  faces away from the vehicle. In other words, during use the outside face  306  of the collar may face an operator using the staking tool  202 . As previously described, the collar  204  also includes the guide notch  208  defined on a surface of the cylindrical aperture  302  and extending from the vehicle-side face  304  to the outside face  306 . The guide notch  208  has a rectangular profile in the depicted embodiment. 
     In the exemplary embodiment, the striker  206  includes a shaft  308  and a handle  310 . The angled tip  210  is formed on the shaft  308  at a first end  312  of the striker  206 . For example, the angled tip  210  may be an integral portion of the shaft  308 . Alternatively, the angled tip  210  may be coupled to the first end  312 . The angled tip  210  is angled in the depicted embodiment and configured to provide an indentation of the lip portion  108  of the spindle nut  102  in a direction perpendicular to the longitudinal travel direction of the shaft  308  along the guide notch  208 . 
     A length of the shaft  308 , shown as shaft length  314 , a length of the collar  204 , shown as collar length  316 , and the angle of the angled tip  210  determine the profile of indentation of the lip portion  108 . The shaft length  314  is measured from the end of the angled tip  210 , or the first end  312 , to a bottom surface  318  of the handle  310 . The shaft  308  will only extend through the guide notch  208  until the bottom surface  318  of the handle  310  contacts the outside face  306  of the collar  204 . The shaft length  314  and collar length  316  are chosen to determine a depth of the indentation in the lip portion  108 . Controlling the depth in an accurate and repeatable manner prevents damaging the lip portion  108  with a stake that is overly deep, and ensures the stake is deep enough to prevent rotation of the spindle nut  102 . A steeper angle will cause the angled tip  210  to create a sharper indentation in the lip portion  108  than will a shallower angle. 
     The shaft  308  has a T-shaped profile in the depicted embodiment. The profile of the shaft  308  and rectangular profile of the guide notch  208  are configured to allow the shaft  308  to slide longitudinally within the guide notch  208  and maintain a radial orientation of the striker  206  with respect to the collar  204 . In other words, the profile of the shaft  308  and corresponding profile of the guide notch  208  prevent the shaft  308  from rotating with respect to the guide notch  208 . In other embodiments, the profile of the shaft  308  and corresponding profile of the guide notch  208  may comprise a triangle, semi-circle, or other shape configured to prevent the shaft  308  from rotating with respect to the collar  204 . The specific profile of the shaft  308  in the disclosed embodiment will be discussed further with respect to  FIG. 6 . By preventing rotation of the shaft  308  with respect to the collar  204 , the angled tip  210  strikes the lip portion  108  at a consistent angle to provide a consistent indentation. 
     The handle  310  includes a gripping portion  320  and a striking surface  322 . The gripping portion  320  is held by the operator to position the striker  206  in the collar  204  and against the spindle nut  102 ; more specifically, the shaft  308  of the striker  206  within the guide notch  208 , and the angled tip  210  against the lip portion  108  of the spindle nut  102 . The surface of the gripping portion  320  is exposed metal in the depicted embodiment, but may include a covering to reduce vibration that may be transferred through the striker  206 , and to provide added comfort to the operator operating the staking tool  202 . The covering may include a wrap or a sleeve covering. 
     The striking surface  322  is configured to receive an impact force from an impacting tool such as the hammer  212  provided in  FIG. 2 . The striking surface  322  in the depicted embodiment is formed from the same material as the handle  310 . However, the striking surface  322  may include a replaceable striking pad in other embodiments. The striking pad may comprise a steel, aluminum, or copper material. The striking pad may serve as a wear component of the striker  206  to extend the life of the staking tool  202 . In further embodiments the striking pad may alternatively comprise a plastic material to provide more comfort to the operator utilizing the staking tool  202 . The plastic material may absorb a portion of the impact force and/or reduce noise created by the impact of the hammer  212  against the striking surface  322 . 
       FIG. 4  is a front view of an exemplary embodiment a collar. The collar may be, for example, the collar  204  shown in  FIGS. 2 and 3 . As previously described, the collar  204  is cylindrical in shape and includes the cylindrical aperture  302  defined in a center portion and extending from the vehicle-side face  304  to the outside face  306 . A surface of the cylindrical aperture  302  is shown as the interior surface  402  in  FIG. 4 . The guide notch  208  is defined on the interior surface  402  and comprises a substantially rectangular profile corresponding to the profile of a portion of the shaft  308  of the striker  206  and extends from the vehicle-side face  304  to the outside face  306 . The cylindrical aperture  302  of the collar is configured to fit over the axle  104 , and may be configured to fit over the lip portion  108  of the spindle nut  102  in alternative embodiments as described with respect to  FIG. 2 . A circular recess  404  is provided on the vehicle-side face  304  and configured to fit over the hex portion  112  of the spindle nut  102 . It should be noted that the recess  404  is circular and not hex-shaped to allow the collar  204  to rotate around an axis of the spindle nut  102  and axle  104  to allow alignment of the guide notch  208  with the staking notch  110  of the axle  104 . The collar  204  is comprised of a metallic material such as steel or aluminum. 
     The collar  204  may also include an insert  406  to allow for easy removal of the striker  206 . Specifically, the collar may include an insert  406  portion, wherein the guide notch  208  is disposed, comprising a different material and/or surface treatment than the remainder of the collar  204 . For example, the insert  406  may comprise a rolled steel material, and the remainder of the collar  204  may comprise a different type of steel material or an aluminum material. The insert  406  may be welded, pressed, glued, or coupled using other known fastening methods to the remainder of the collar  204 . 
     The surface of the guide notch  208  may be polished or include a wear-resistant coating or surface treatment. The surface treatment of the guide notch  208  may be chosen for optimal properties related to slidability to facilitate removal of the striker  206  by the operator, and the surface treatment of the remainder of the collar  204  may be chosen for optimal properties related to wear to increase the service life of the collar  204 . Similarly, in an embodiment that includes an insert  406 , such as the exemplary embodiment shown, the material of the insert  406  may be chosen for optimal properties related to slidability, and the material of the remainder of the collar  204  may be chosen for optimal properties related to wear. 
       FIG. 5  is a side view of the collar  204 . As previously described, the guide notch  208  extends from the vehicle-side face  304  to the outside face  306 . The recess  404  is defined within the vehicle-side face  304  as a shallow cylindrical cut-out that is configured to accommodate the hex portion  112  of the spindle nut  102 . 
       FIG. 6  is a perspective view of an exemplary embodiment of a striker. The striker may be, for example, the striker  206  shown in  FIGS. 2 and 3 . As previously described, the striker  206  includes the shaft  308  and the handle  310 . The handle  310  includes the bottom surface  318  configured to contact the outside face  306  of the collar  204  after staking is completed. The handle  310  is disposed at a second end  602  of the striker  206 . The striker  206  may be formed from a metallic material, such as steel or aluminum, a plastic material, and/or any other material that allows the striker  206  to deform the spindle nut  102  and otherwise function as described herein. 
     The shaft  308  further includes the angled tip  210  at the first end  312 . The shaft  308  and angled tip  210  further comprise a T-shaped profile configured to indent the lip portion  108  of the spindle nut  102  into the staking notch  110 . The upper part of the “T,” identified as an upper profile  604  in  FIG. 6 , is configured to slide within the guide notch  208  of the collar  204 . The lower part of the “T,” identified as a lower profile  606 , is configured to indent the lip portion  108 . The width of the lower profile  606 , along with the angle of the angled tip  210  determine the profile of the indentation created by the striker  206  on the lip portion  108 . The width of the lower profile  606  and angle of the angled tip  210  are further configured to provide a consistent indent of the lip portion  108  into the staking notch  110  without cracking or otherwise damaging the lip portion  108  beyond the intended indentation. The T-shaped profile extends partially along the shaft  308  in the exemplary embodiment; however, the T-shaped profile may extend the entire length of the shaft  308  (e.g., to the bottom surface  318  of the handle  310 ) in other embodiments. 
       FIG. 7  is a perspective view of an exemplary embodiment of an axle; for example, the axle  104  shown in  FIG. 1 . The axle  104  is a substantially rod-shaped component of the vehicle that couples to various other vehicle components such as the hub and a brake assembly. The axle  104  comprises the shaft  308  configured to receive a spindle nut, such as the spindle nut  102  provided in  FIG. 1 , at a threaded portion of the shaft  308 . The threaded portion includes screw threads that may extend the entire length of the axle  104 , or may only partially extend through the portion of the axle  104  configured to be engaged by the spindle nut  102 . As previously described, the axle  104  also includes the staking notch  110  defined therein. The staking notch  110  is defined on an outer radius of the axle  104  and may extend longitudinally through the threaded portion of the shaft  308 . The staking notch  110  may extend longitudinally along the axle  104  beyond the threaded portion in other embodiments wherein the threaded portion does not extend the entire length of the axle  104 . 
       FIG. 8  is a perspective view of an exemplary embodiment of a spindle nut; for example, the spindle nut  102  shown in  FIG. 1 . The spindle nut  102  comprises the lip portion  108 , hex portion  112 , and a flange portion  802 . The hex portion  112  forms a main body of the spindle nut  102 , wherein the lip portion  108  and flange portion  802  are disposed on opposing surfaces of the hex portion  112 . As previously described, the hex portion  112  is configured to be manipulated (e.g., rotated) by a wrench or socket. The flange portion  802  defines a vehicle-side portion of the spindle nut  102  that contacts a vehicle component when fully fastened (e.g., screwed) onto the axle  104 . The lip portion  108  may have a substantially cylindrical shape; more specifically, a shape resembling a short, thin-walled, circular pipe. The lip portion  108  is configured to be indented into the staking notch of the axle  104  by the staking tool  202 . Indenting the lip portion  108  into the staking notch  110  physically prevents the spindle nut  102  from unscrewing away from the vehicle component. The indentation is formed by the angled tip  210  of the staking tool  202  as described herein. 
       FIG. 9  is a flow chart of a method  900  of staking a spindle nut onto an axle using a staking tool, for example, the staking tool shown in  FIG. 2 . In an exemplary embodiment, the method  900  includes positioning  902  a collar, aligning  904  a guide notch, inserting  906  a striker, and striking  908  the striker. The collar and striker may be the collar  204  and striker  206  provided in  FIG. 2 . 
     Positioning  902  the collar  204  includes placing the collar  204  over the spindle nut  102  that is fastened on the axle  104  of a vehicle. The spindle nut  102  is configured to fit over the spindle nut  102  and allow a rotational movement of the collar  204  with respect to the spindle nut  102 . In an alternative embodiment, positioning  902  the collar  204  may include verifying that a vehicle-side face  304  of the collar  204  is adjacent a flange portion  802  of the spindle nut  102  to ensure that the collar  204  is fully seated in position. 
     Aligning  904  the guide notch  208  includes aligning the guide notch  208  of the collar  204  with a staking notch  110  of the axle  104 . The guide notch  208  is defined on an interior surface of a cylindrical aperture  302  defined in a center section of the collar  204 , and the staking notch  110  is defined on an outer surface of the axle  104 . In an alternative embodiment, aligning  904  the guide notch  208  may include rotating the collar  204  around the spindle nut  102  to perform the alignment of the guide notch  208  with the staking notch  110 . 
     Inserting  906  the striker  206  includes inserting the striker  206  into the guide notch  208  on the collar  204 . In an alternative embodiment, inserting  906  the striker  206  may include inserting a shaft  308  of the striker  206  into the guide notch  208  until an angled tip  210  of the shaft  308  is adjacent the spindle nut  102 ; more specifically, inserting the shaft  308  until the angled tip  210  contacts a lip portion  108  of the spindle nut  102 . 
     Striking  908  the striker  206  includes impacting the striker  206  with a hammer  212  or a mallet. In an alternative embodiment, striking  908  the striker  206  includes repeatedly impacting a striking surface  322  of the handle  310  of the striker  206  until the bottom surface  318  of the handle  310  is adjacent the outside face  306  of the collar  204  (e.g., the shaft  308  of the striker  206  is fully inserted into the guide notch  208  of the collar  204 ). The striking surface  322  is located on an opposing end of the striker  206  as the angled tip  210 . Striking  908  the striker  206  causes the angled tip  210  to form an indentation of the lip portion  108  of the collar  204  into the staking notch  110  of the axle  104  when the bottom surface  318  is adjacent the outside face  306 . 
     The foregoing detailed description of exemplary embodiments is included for illustrative purposes only. It should be understood that other embodiments could be used, or modifications and additions could be made to the described embodiments. Therefore, the disclosure is not limited to the embodiments shown, but rather should be construed in breadth and scope in accordance with the recitations of the appended claims.