Patent Publication Number: US-2018044101-A1

Title: Bracket system

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims the benefit of U.S. Provisional Patent Application Ser. No. 62/372,420 filed Aug. 9, 2016. 
    
    
     TECHNICAL FIELD 
     This application generally relates to structure for arranging, packaging and shipping axle assemblies that are used in heavy-duty vehicles. Particularly, this application relates to a bracket configuration and method for arranging, packaging and shipping multiple axle assemblies in a stacked and spaced relationship. 
     BACKGROUND 
     It is known to ship vehicle parts, such as heavy-duty vehicle axle assemblies from an axle assembly fabrication plant to a heavy-duty vehicle assembly plant by truck or tractor and trailer. One such heavy-duty vehicle axle assembly is of the non-integrated axle type. That is, the axle assembly does not necessarily include suspension components. The axle assembly typically includes wheel end assemblies with or without brake systems. The axle assemblies are typically large, heavy and difficult to handle and package for shipping. The axle assemblies are subject to damage if they contact one another during packaging and/or transport or if they contact other structure associated with shipping. 
     The cost of shipping over-the-road, usually by tractor and trailer, is affected by the number of axle assemblies that can be shipped on a typical trailer. Typically, the axle assemblies were shipped in a package of two using a first wood pallet, wood blocks and steel strapping that are relatively expensive and discarded to cause an unrecoverable cost of shipping. 
     It is possible to stack a second wood pallet on the first wood pallet package. This requires even more wood blocks to space and support the second wood pallet relative to the first wood pallet since the second wood pallet would not be stable if resting on axle assemblies on the first pallet. Even more steel strapping secures the pallets together. The wood pallets, wood blocks and steel strapping are typically discarded after a single shipment. This known packaging and shipping method generally allows a maximum of twenty-six axle assemblies to be shipped in a single trailer load. 
     Thus, it would be desirable to provide a way to ship more axle assemblies in a single trailer load; eliminate the use of shipping materials that are discarded; be able to recover and reuse structures that support, arrange, package and ship the axle assemblies in a manner that prevents or minimizes the possibility of damage by contact with other axle assemblies or other structure; and provide a structure that is relatively easy to manufacture. 
     SUMMARY 
     A summary is provided to introduce concepts in a form that are described below. This summary is not intended to identify key factors or essential features of the subject matter of this application, nor is it intended to be used to limit the scope of the subject matter or the appended claims. 
     One aspect of this application is a system for packaging axle assemblies in a stacked and spaced arrangement. Each axle assembly has a pair of wheel end assemblies and a pair of brake assemblies mounted at opposite ends of an axle. Each wheel end assembly includes a hub with studs extending from the hub. 
     The system includes a base bracket with a main body portion. The main body portion has a receiving surface to engage and support a portion of a first axle assembly, such as a lower portion of the first axle assembly. The main body portion has at least one slot extending from the receiving surface to accept one of the studs. The main body portion also has at least one end portion extending transversely from the main body portion to stand the base bracket upright and stabilize the base bracket on a support surface. The end portion extends a distance at least equal to a distance that the hub and studs extend from the main body portion to protect the hub and studs from damage by contact with truck/trailer structure, other structure when being moved or material handling equipment. 
     The system also includes an intermediate bracket with a first receiving surface located at a lower or first end of the intermediate bracket. The first receiving surface of the intermediate bracket receives and engages another portion of the first axle assembly, such as an upper portion of the first axle assembly. At least one slot extends from the first receiving surface of the intermediate bracket to accept another stud of the first axle assembly. A second receiving surface is located at an upper or opposite second end of the intermediate bracket. The second receiving surface engages and supports a portion of a second axle assembly, such as a lower portion of the second axle assembly, in a position above the first axle assembly. At least one slot extends from the second receiving surface to accept a stud of the second axle assembly. 
     Two end portions extend in the same direction transversely from the main body portion. At least one of the end portions extends a distance at least equal to a distance that the hub and studs extend from the main body portion. Another receiving surface on the base bracket receives a portion of another axle assembly. Another receiving surface on the intermediate bracket receives a portion of the other axle assembly. 
     Another base bracket receives and supports a second end portion of the first axle assembly. Another intermediate bracket receives and secures a second end portion of the first axle assembly. The receiving surface has at least one arcuate surface. Structure is provided for at least one brake assembly to engage and inhibit rotation of the brake assembly. 
     A cover material is on at least one of the receiving surface and slot of at least one of the base bracket and intermediate bracket to protect components of the axle assembly. More than one stud slot extends from the receiving surface of at least one of the base bracket and intermediate bracket. A fastener is threaded onto the stud to clamp and secure an axle assembly to a bracket and inhibit relative movement in all directions between the bracket and the wheel end assembly. 
     Another aspect of this application is a method of packaging axle assemblies in a stacked and spaced arrangement. The method includes providing a base bracket according to the structure described above. A first axle assembly is placed in the base bracket so a portion of the first axle engages a receiving surface of the main body portion and a stud is received in a slot. 
     The method also includes providing an intermediate bracket according to the structure described above. The intermediate bracket is placed on the first axle assembly so a portion of a first axle engages a downward facing receiving surface of the intermediate bracket and another stud of the first axle assembly is received in a slot extending from the downward facing receiving surface. Then a second axle assembly is placed on the intermediate bracket so a portion of the second axle engages and is supported by an upward facing second receiving surface of the intermediate bracket and a stud is received in a slot extending from the upward facing receiving surface. Fasteners, such as wheel nuts, are threaded onto studs extending from the brackets to provide a structure or package suitable for shipping. 
    
    
     
       DESCRIPTION OF THE DRAWINGS 
       The following description and drawings set forth certain illustrative aspects and implementations for the subject matter of this application. These are indicative of but a few of the various ways in which one or more aspects and/or implementations may be employed. Further features of the subject matter of this application will become apparent from reading the description with reference to the accompanying drawings, in which: 
         FIG. 1  is an overall perspective view of a package of axle assemblies using a bracket system and method, according to aspects of this application; 
         FIG. 2  is an exploded perspective view of the package of axle assemblies and the bracket system illustrated in  FIG. 1 ; 
         FIG. 3  is an enlarged elevational view of the package of axle assemblies and the bracket system illustrated in  FIG. 1 ; 
         FIG. 4  is a perspective view of a portion the bracket system illustrated in  FIGS. 1-3 ; 
         FIG. 5  is a front elevational view of a portion of the bracket system illustrated in  FIG. 4 ; 
         FIG. 6  is a side elevational view of the bracket system illustrated in  FIG. 5 , taken approximately along line  6 - 6  of  FIG. 5 ; and 
         FIG. 7  is a top plan view of the bracket system illustrated in  FIG. 5 , taken approximately along line  7 - 7  of  FIG. 5 . 
     
    
    
     DESCRIPTION 
     The subject matter of this application is described with reference to the drawings, in which like reference numerals are used to refer to like elements. In the description, for purposes of explanation, specific details are set forth in order to provide an understanding of the subject matter. It will be understood, however, that the subject matter may be practiced without these specific details. 
     A package  20  of four axle assemblies  22 , according to an aspect of this application, is illustrated in  FIGS. 1-3 . The package  20  of four axle assemblies  22  is intended to be shipped by suitable transport means, such as a trailer pulled by a tractor. By way of example, a representative axle assembly  22  may be a TRLAXLE® trailer axle assembly available from Hendrickson Trailer Commercial Vehicle Systems in Canton, Ohio. A reusable bracket system  40  (best seen in  FIGS. 4-5 ) forms the package  20  of four axle assemblies  22 , as illustrated in  FIGS. 1-3 . The bracket system  40  receives and supports the axle assemblies  22  in a stacked and spaced arrangement suitable for handling and shipping. 
     The package  20  of four axle assemblies  22  is supported by the bracket system  40 , constructed according to one aspect. Each of a pair of bracket systems  40  are used on respective opposite ends of the axle assemblies  22 . The description for one side of the package  20  of axle assemblies  22  and the bracket system  40 , such as that shown in  FIG. 3 , will also apply to the opposite side. 
     The lowermost pair of axle assemblies  22  in the package  20 , as shown in the drawings, is supported on a pair of lower, bottom or base brackets  42  at opposite end portions of the axle assemblies. The base brackets  42  are intended to receive, support and secure the lowermost pair of axle assemblies  22  in a spaced relationship with one another and above or off of a support surface, such as a floor or a trailer bed. The base brackets receive and support a lower portion of each end of the respective axle assemblies  22 . A pair of intermediate brackets  44  receives and engages an upper portion of each end of the respective axle assemblies  22 . The uppermost pair or secondary level of axle assemblies  22  of the package  20  is supported from below and spaced from each other and the lowermost axle assemblies by the pair of intermediate brackets  44 . 
     Each axle assembly  22  includes an axle  60  ( FIGS. 1-2 ). Each axle assembly  22  also has a pair of wheel end assemblies  62  mounted at opposite end portions of the axle  60 . Each wheel end assembly  62  includes a hub  64  with a plurality of studs  66  arranged in a circular array extending in an outward direction from the hub. Each hub  64  is shown with ten (10) interference fit studs  66  extending through the hub, but it will be apparent that any suitable number of studs may be employed. The hub  64  and studs  66  are intended to operatively mount a tire and wheel assembly (not shown) to the axle assembly  22 , as is known. Suitable fasteners, such as wheel nuts  68  are provided to be threaded onto respective studs  66  to secure and clamp the axle assemblies  22  to the base bracket  42  and to the intermediate bracket  44  of the bracket system  40 . This securement creates a structurally strong and stable package  20  suitable for shipping with the axle assemblies  22  securely stacked and spaced apart. 
     Each axle assembly  22  may include a pair of brake assemblies  70  mounted on opposite end portions of the axle  60  on respective wheel end assemblies  62 . The brake assemblies  70  may be of any suitable brake system, for example a drum brake system or an air disc brake system, such as that shown. Components of the brake assemblies  70  can be damaged with improper handling, packaging and/or shipping. 
     The base bracket  42  of the bracket system  40  has a central or main body portion  80  ( FIGS. 4-6 ) with a lower or bottom surface that provides contact with a supporting foundation, such as a floor or a bed of a truck or trailer. The base bracket  42  also may include a pair of opposite end portions  82  extending transversely from the main body portion  80 . The end portions  82  are preferably formed integrally with the main body portion  80  by bending a cut steel plate. The base bracket  42  is preferably made from a suitable metal, such as ASTM Grade 50 steel plate about ⅜ inch thick. It is contemplated that other suitable metals could be employed, such as aluminum, or sufficiently strong plastics, such as fiber reinforced plastic. 
     The end portions  82  stabilize the base bracket  42  on a support surface, such as a floor or a bed of a truck or trailer. Each opposite end portion  82  extends transversely from the main body portion  80  at a suitable angle A as viewed in  FIG. 7 , such as about 15°. At least one of the end portions  82  extends a distance D ( FIGS. 6-7 ) away from the main body portion  80  that is at least equal to, and preferably more than, a distance that the hub  64  and/or studs  66  extend from the main body portion when the package  20  is formed. This distance D that the end portions  82  extend from the main body portion  80  protects the hub  64  and studs  66  from damage by contact with a truck/trailer body, such as a sidewall extending upwardly from a bed, contact with structure or equipment that the package  20  would be moved past or contacted by unintentional material handling equipment, such as a forklift. 
     Each base bracket  42  has an upper receiving surface  100  (best seen in  FIGS. 4-5 ) to engage and support a portion of one of the lowermost pair or at least a first one of the axle assemblies  22 . While one receiving surface  100  will be described in detail, it will be apparent that the description equally applies to a base bracket  42  with more than one receiving surface that can receive, support and secure more than one axle assembly  22 , such as the two receiving surfaces illustrated in  FIGS. 4-5 . The receiving surface  100  is preferably arcuate in shape that can be divided and distributed between two or more arcuate portions. The arcuate receiving surface  100  is of a radius that closely matches the outer periphery of a portion of the wheel end assembly  62  of the axle assembly  22  that it supports. 
     The base bracket  42  also has a surface defining at least one scalloped slot  102  that extends from the receiving surface  100 . The slot  102  may accept one of the studs  66 . Preferably, multiple slots  102 , such as the four shown in  FIGS. 4-5 , extend from each receiving surface  100 . The slots  102  are arranged to extend substantially parallel to one another so the slots can simultaneously receive respective studs  66  when an axle assembly  22  is lowered onto the receiving surface  100  of the base bracket  42 . The arcuate end surface of each slot  102  is not necessarily intended to engage a stud  66  and support a portion of the weight of an axle assembly  22 , because it is preferred that the receiving surface  100  performs this support and the loadbearing function. It will be appreciated that through holes or openings could be used in place of the slots  102  for receiving studs  66  and that this design choice would require additional maneuvering of the base bracket  42  and/or axle assembly  22  to place and properly support the axle assembly in the base bracket. 
     The base bracket  42  has a lower surface, as viewed in the drawings, on the main body portion  80  and in portions  82  that is adapted to rest on a support surface, such as a floor or bed or depth of a truck or trailer. The lower surface of the base bracket  42  may have a surface defining an elevated or relief portion  104  that serves to allow manual manipulation of the base bracket to move it or for access by material handling equipment, such as a forklift. The lower surface of the base bracket  42  may have more than one relief portion  104 . The upper surface of the base bracket  42  also has an upper relief portion  106  that augments manual manipulation to move the base bracket or for access by material handling equipment. 
     When a wheel end assembly  62  of an axle assembly  22  is placed on a receiving surface  100  of the base bracket  42 , at least one or more (four in the illustrated aspect) of the studs  66  may be received in respective slots  102  in the base bracket. Wheel nuts  68  are then threaded and tightened on the studs  66  against the outer surface of the base bracket  42  to clamp a portion of the hub  64  to the inner surface of the base bracket. Clamping the hubs  64  to the base bracket secures the axle assembly  22  to the base bracket  42  and minimizes or prevents relative movement in all directions. Clamping the hub  64  to the base bracket  42 , thus, creates a structure that serves as a foundation for the package  20  that is strong, stable and suitable for shipping. 
     The base bracket  42  may accommodate a single axle assembly  22 , but preferably a pair of axle assemblies are mounted on the base bracket. It will be apparent that a pair of base brackets  42  are used in the bracket system  40  at opposite ends of the axle assembly or assemblies  22 . The base bracket  42  may include a cover material, such as plastic, rubber or the like, on at least one surface defining the receiving surface  100  and/or slots  102  and/or even the major side surfaces of the base bracket. This cover material can act as a cushion to prevent or minimize damaging the axle assemblies  22  from being scratched or other contact with the bracket system  40 . 
     Straps or banding material may be used to connect at least a portion each of the brake assemblies  70  to one another, to one of the axles  60  or to the base bracket  42  to prevent or minimize relative rotation of the brake assemblies and potential damage during transit or handling. The base bracket  42  may include structure (not shown) that can be welded or otherwise attached to the base bracket to engage a portion of the brake assembly  70  and prevent or minimize relative rotation of the brake assembly. Optionally, the bracket system  40  may include a rod or “key” that can be inserted into a brake component of the brake assembly  70  to engage structure, such as the base bracket  42  or axle assembly  22 , to prevent or minimize relative rotation of the brake assembly. Alternatively, the brake assembly  70  may be manipulated so at least one friction brake pad engages an associated rotor to prevent or minimize relative rotation of the brake assembly. 
     The bracket system  40  also includes the second, upper or intermediate bracket  44 . The intermediate bracket  44  is preferably made from a suitable metal, such as ASTM Grade 50 steel plate about ⅜ inch thick. It is contemplated that other suitable metals could be employed, such as aluminum, or sufficiently strong plastics, such as fiber reinforced plastic. The intermediate bracket  44  has a lower end with a first receiving surface  120  (best seen in  FIGS. 4-5 ). While one receiving surface  120  will be described in detail, it will be apparent that the description applies to an intermediate bracket  44  with more than one downward facing receiving surface that can receive, engage and secure a portion of more than one axle assembly  22 , such as the two illustrated in  FIGS. 4-5 . The receiving surface  120  is preferably arcuate in shape of a radius that can be divided and distributed between two or more arcuate portions. The arcuate receiving surface  120  is of a radius that closely matches the outer periphery of a portion of the wheel end assembly  62  of the axle assembly  22  that it supports. 
     The intermediate bracket  44  also has a surface defining at least one scalloped slot  122  that extends from the receiving surface  120 . The slot  122  may accept one of the studs  66 . Preferably, multiple slots  122 , such as the four shown in  FIGS. 4-5 , extend from each receiving surface  120 . The slots  122  are arranged to extend substantially parallel to one another so the slots can simultaneously receive respective studs  66  when the receiving surface  120  of intermediate bracket  44  is placed on a wheel end assembly  62  of an axle assembly  22 . The arcuate end surface of each slot  122  is not necessarily intended to engage a stud  66 . It will be appreciated that through holes could be used in place of the slots  122  for receiving studs  66  that would also require additional maneuvering of the intermediate bracket  44  and/or axle assembly  22  to properly place the intermediate bracket on and receive the axle assembly. 
     The lower receiving surface  120  of the intermediate bracket  44  engages a portion of an axle assembly  22 . At least one slot  122  extends from the first receiving surface  120  of the intermediate bracket  44  to accept a stud  66  of the lower axle assembly  22 . Once the intermediate bracket  44  is placed on the axle assembly  22 , at least one (four in the illustrated aspect) of the studs  66  is received in respective slots  122  in the intermediate bracket. Wheel nuts  68  are threaded and tightened on the studs  66  against the outer surface of the intermediate bracket  44  to clamp the hub  64  to the inner surface of the intermediate bracket. Clamping the hub  64  to the intermediate bracket secures the intermediate bracket  44  to the the axle assembly  22  and minimizes or prevents relative movement in all directions. Clamping the hubs  64  to the intermediate bracket  44  provides a strong, secure and solid structure that can receive at least one other axle assembly  22 . 
     The intermediate bracket  44  may include a cover material, such as plastic, rubber or the like, on surfaces defining the receiving surface  120  and slots  122  to cushion and/or protect the hub  64  and studs  66 . Such cover material can prevent or minimize damaging the axle assemblies  22  from being scratched or other contact with the bracket system  40 . 
     The intermediate bracket  44  also has three second or upper receiving surfaces  140  (best seen in  FIGS. 4-5 ) located at a second end of the intermediate bracket opposite from the lower receiving surfaces  120 . While one receiving surface  140  will be described in detail, it will be apparent that the description applies to an intermediate bracket  44  with more than one upward facing receiving surface, such as the three illustrated in  FIGS. 3-5 , that can receive and support more than one axle assembly  22 . The receiving surface  140  is preferably arcuate in shape of a radius that can be divided and distributed between two or more arcuate portions. The arcuate receiving surface  140  is of a radius that closely matches the outer periphery of a portion of the wheel end assembly  62  of the axle assembly  22  that it supports. 
     One of the upper receiving surfaces  140  on the second end of the intermediate bracket  44  engages and supports a portion of at least one second or upper axle assembly  22  in a position above the lower axle assemblies. If a package  20  of four axle assemblies  22  is desired, the outermost pair of the three receiving surfaces  140  are used to receive and support the two axle assemblies. If a package  20  of five total axle assemblies  22  is desired, the central of the three receiving surfaces  140  is used to receive and support the third axle assembly in the secondary level of axle assemblies. 
     The intermediate bracket  44  has a surface defining at least one scalloped slot  142  that extends from the receiving surface  140 . The slot  142  may accept one of the studs  66 . Preferably, multiple slots  142 , such as the four shown in  FIGS. 4-5 , extend from each receiving surface  140 . The slots  142  are arranged to extend substantially parallel to one another so the slots can simultaneously receive respective studs  66  when the receiving surface  140  of intermediate bracket  44  receives an axle assembly  22 . The arcuate end surface of each slot  142  is not necessarily intended to engage a stud  66 , because it is preferred that the receiving surface  140  performs this loadbearing support function. It will be appreciated that through holes could be used in place of the slots  142  for receiving studs  66  and that this would require additional maneuvering of the intermediate bracket  44  and/or axle assembly  22  to properly receive and support the axle assembly. 
     The intermediate bracket  44  may include a cover material, such as plastic, rubber or the like, on at least one surface defining the receiving surface  140  and slots  142  to cushion and/or protect the hub  64  and studs  66 . Such cover material can prevent or minimize damaging the axle assemblies  22  from being scratched or other contact with the bracket system  40 . 
     The intermediate bracket  44  may accommodate a single axle assembly  22 , but preferably at least a pair of axle assemblies, mounted on the intermediate bracket. It will be apparent that a pair of intermediate brackets  44  are used in the bracket system  40  at opposite ends of each axle assembly  22 . 
     Straps or banding material can be used to connect the brake assemblies  70  of the axle assemblies  22  to one another or to the intermediate bracket  44  to prevent rotation of the brake assemblies during transit or handling. The intermediate bracket  44  may include structure (not shown) that can be welded or otherwise attached to the base bracket to engage a portion of the brake assembly  70  and prevent or minimize relative rotation of the brake assembly. Optionally, the bracket system  40  may include a rod or “key” that can be inserted into a brake component of the brake assembly  70  to engage structure, such as intermediate bracket  44  or axle assembly  22 , to prevent or minimize relative rotation of the brake assembly. Alternatively, the brake assembly  70  may be manipulated so at least one friction brake pad engages an associated rotor to prevent or minimize relative rotation of the brake assembly. 
     Once an axle assembly  22  is placed on a receiving surface  140  of the intermediate bracket  44 , several studs  66  (four in the illustrated aspect) are received in respective slots  142  in the intermediate bracket. Wheel nuts  68  are threaded and tightened on the studs  66  against the outer surface of the intermediate bracket  44  to clamp a portion of the hub  64  to the inner surface of the intermediate bracket. Clamping the hub  64  to the intermediate bracket  44  secures the axle assembly  22  to the intermediate bracket and minimizes or prevents relative movement in all directions. Clamping the hubs  64  to the intermediate bracket  44  secures the axle assembly  22  to the intermediate bracket and creates a strong structure that creates the package  20  of three, four or five axle assemblies that is secure, stable and suitable for shipping. It should be apparent that one, two or three more axle assemblies  22  could be placed on the package  20  of four or five axle assemblies to create a package of five six, seven or eight axle assemblies by using another pair of intermediate brackets  44 . 
     The base bracket  42  and intermediate bracket  44  are relatively easy to manufacture. For example, the base bracket  42  and intermediate bracket  44  can be formed from plate metal and cut to the desired shape by various cutting means, such as by laser, flame, plasma, or high-pressure fluid. The base bracket  42 , once cut to a desired shape, can then have its end portions  82  bent to the desired angle A relative to the main body portion  80 . The base bracket  42  and intermediate bracket  44  generally then do not require any further processing, other than maybe removing sharp corners that resulted from cutting and maybe painting and/or depositing cover material. 
     It has been found that by employing the reusable bracket system  40  constructed according to an aspect of this application, fifty-two axle assemblies  22  can be shipped on the same trailer load as previous shipping systems that were only able to accommodate twenty-six axle assemblies. This essentially doubles the number of axle assemblies that was previously carried on a trailer with wood pallets, wood blocks and steel bands. Further, the brackets  42  and  44  can be recovered, returned and reused, thereby eliminating the waste associated with the wood pallets, wood blocks and steel bands of the previous shipping systems. Thus, the bracket system  40  is economical, eco-friendly, easy to manufacture and lowers the possibility of damage. 
     Another aspect of this application is a method of building a package  20  of axle assemblies  22  in a stacked and spaced arrangement with the bracket system  40 . The method includes the step of providing a pair of the base brackets  42  that are constructed as described above. The base brackets  42  are spaced apart with their end portions  82  facing in a direction opposite or away from one another. A first axle assembly  22  is placed on the pair of base brackets  42  so a portion of the hub of the first axle assembly engages the receiving surface  100  of the main body portion  80  of a respective one of the base brackets. Four studs  66  on each hub  64  are concurrently received in slots  102 . Wheel nuts  68  are then threaded onto at least one, and preferably two or more, such as at least the laterally outermost studs  66  that are received in the slots  102 . It will be appreciated that three or four wheel nuts  68  may be threaded onto respective studs  66  that are also received in the slots  102 . The more of wheel nuts  68  being used will tend to provide a stronger clamping force and a more stable package  20 . 
     The wheel nuts  68  are threaded and tightened to a desired torque against the outer surface of the base bracket  42  so a portion of the hub  64  is drawn against the inner surface of the base bracket. This clamps the hub  64 , and thus one end of the axle assembly  22 , to the inner surface of one of the base brackets  42 . Clamping the hubs  64  to the base brackets  42  secures the axle assembly  22  to the base brackets and minimizes or prevents relative movement in all directions. Clamping the hubs  64  to the base brackets  42  provides a structure that serves as a foundation for the package  20  that is strong, sturdy, secure, stable and suitable for shipping. 
     This procedure may then be followed for another lower or first level axle assembly  22 . The other axle assembly  22  is placed on the pair of base brackets  42  so a portion of the hub of the other first axle assembly engages another receiving surface  100  of the main body portion  80  of a respective one of the base brackets. Four studs  66  on each hub  64  are concurrently received in slots  102 . Wheel nuts  68  are then tightened onto studs  66  to clamp portions of each hub  64  to a respective base bracket  42 . 
     The method also includes providing a pair of intermediate brackets  44  that are constructed as described above. Each intermediate bracket  44  is placed on respective end portions of the pair of the lower or first level axle assemblies  22  from above so the portions of the axle assemblies engage a respective receiving surface  120  of the intermediate brackets. Four studs  66  on each end of the axle assemblies  22  are concurrently received in respective slots  122  of the intermediate bracket  44 . Wheel nuts  68  are then threaded onto at least one, and preferably two, of the laterally outermost studs  66  that are received in the slots  102 . Wheel nuts  68  are tightened against the outer surface of the intermediate bracket  44  so the hub is drawn against the inner surface of the intermediate bracket. It will be appreciated that three or four wheel nuts  68  may be threaded onto respective studs  66  that are also received in the slots  102 . This clamps each of the hubs  64 , and thus one end of the axle assemblies  22 , to the respective inner surfaces of the intermediate bracket  44 . Clamping the hubs  64  of the lower axle assemblies  22  to the intermediate brackets  44  secures the axle assemblies to the intermediate bracket and minimizes or prevents relative movement in all directions. 
     Then at least one other, upper or second level axle assembly  22  is placed on the intermediate brackets  44  so a hub  64  on each end portion of the second axle assembly engages and is supported by the second receiving surfaces  140  of the intermediate bracket. If only one second level axle assembly  22  is to be packaged and shipped, the center receiving surface  140  of the intermediate bracket is used. If two axle assemblies  22  are to be packaged, the two outer receiving surfaces  140  are used. If three axle assemblies  22  are to be packaged, then all three of the receiving surfaces  140  are used. Four other studs  66  on each hub  64  of the second axle assembly are received in respective slots  122  of the intermediate bracket  44 . Wheel nuts  68  are threaded onto at least one, and preferably two, of the laterally outermost studs  66  of each hub  64  of the second level axle assemblies  22  that are received in the slots  102 . It will be appreciated that three or four wheel nuts  68  may be threaded onto respective studs  66  that are also received in the slots  102 . 
     Wheel nuts  68  are tightened against the outer surfaces of the intermediate brackets  44  so the hubs  64  are drawn against the inner surfaces of the intermediate brackets. This clamps the hubs  64 , and thus both ends of the second level axle assembly  22  to the inner surface of the intermediate brackets  44 . Clamping the hubs  64  to the intermediate brackets  44  secures the upper or second level axle assembly  22  to the intermediate brackets and minimizes or prevents relative movement in all directions. Clamping the hubs  64  to the intermediate brackets  44  provides the package  20  of at least three axle assemblies  22  that is stable and suitable for shipping without requiring steel band material to secure any of the axle assemblies to brackets  42 ,  44  of the package  20 . If two or three additional upper or second level axle assemblies  22  are desired to be packaged and shipped in the bracket system  40 , these same steps for each second level axle assembly are used to secure the additional axle assemblies to the intermediate bracket  44  in the appropriate other receiving surfaces  140 . 
     It should be apparent that one, two or three more axle assemblies  22  could be placed on the package  20  of four or five axle assemblies to create a package of five six, seven or eight axle assemblies by using another pair of intermediate brackets  44  according to steps of this method. Accordingly, the improved bracket system  40  and method of shipping a package  20  of axle assemblies  22  are simple and effective and overcome disadvantages of operating previously known ways to ship. 
     The subject matter of this application has been described and illustrated with reference to at least one specific aspect. It is understood that the description and illustration are by way of example and not by way of limitation. From the above description and illustration, those skilled in the art will perceive improvements, changes and modifications. Such improvements, changes and modifications are intended to be covered by the subject matter of this application. 
     It is to be understood that the structure of the above-described bracket system may be altered or rearranged, or certain components modified, omitted or added, without affecting the overall concept or operation of the subject matter. For example, the location and arrangement of components may be adjusted based on specific design requirements. It is to be further understood that the subject matter of this application finds use in types of axle assemblies for heavy-duty vehicles, other than those shown and described herein, without affecting the concept or operation of the disclosed subject matter. 
     Certain terminology is used herein for purposes of reference only, and thus is not intended to be limiting. Such terminology may include the words specifically mentioned, derivatives thereof, and words of similar import. Similarly, the terms “upper”, “lower”, “first”, “second” and other positional or numerical terms referring to structures do not imply a sequence or order unless clearly indicated by the context.