Patent Description:
In the agriculture, construction and forestry industries, various work machines, such as loaders, may be utilized in lifting and moving various materials. In certain examples, a loader may include a bucket pivotally coupled by a loader boom arms to the vehicle chassis. One or more hydraulic cylinders move the loader boom arms and/or the bucket to move the bucket between positions relative to the chassis to lift and move materials.

Various factors are considered when designing or selecting the loader boom arms and bucket arrangement used, for example, the durability and wear resistance of the loader boom arms, and the weight of material the loader boom arms can lift. These factors typically indicate that the loader boom arms be made of heavy steel plate construction to handle large volumes of material and the corresponding weight and other forces associated with loading and carrying the heavy material. This also requires a robust hydraulic system with correspondingly large-capacity pumps, accumulators, valves and cylinders. Further, wear or damage to the loader boom arms may also require replacement or vehicle downtime to repair the heavy-duty components. <CIT> discloses a loader boom arm formed from front and rear boom subassemblies, and a bottom plate.

The disclosure provides a hybrid loader boom arm assembly in which an arm assembly and a second arm assembly formed of a lightweight material are interconnected by a torque transfer tube formed of a lightweight material.

In one aspect, the disclosure provides a hybrid loader boom arm assembly for a loader work vehicle. The loader boom arm includes an arm assembly that includes a first hollow beam formed from a material having a weight lighter than steel and a second hollow beam formed from the material. The loader boom arm includes a connection assembly having a first angled intermediate plate and a pair of knee plates formed from the material. A portion of the first angled intermediate plate is received within the first beam at an end and a portion of the first angled intermediate plate is received within the second beam at a second end. The pair of knee plates cooperate to define a first channel that receives the end of the first beam and a second channel that receives the second end of the second beam such that the end of the first beam and the second end of the second beam are between the pair of knee plates. The first angled intermediate plate and the pair of knee plates are configured for interconnecting the first beam with the second beam.

Further provided is a method for assembling a hybrid loader boom arm for a loader work vehicle. The method includes coupling a first angled intermediate plate within a first end of a first hollow beam formed from a material having a weight lighter than steel and within a second end of a second hollow beam formed from the material to form an arm assembly. The method includes coupling a first knee plate to the end of the first hollow beam and to the second end of the second hollow beam. The first knee plate defines a first channel portion that receives a portion of the end of the first hollow beam and a second channel portion that receives a portion of the second end of the second hollow beam. The method includes coupling a second knee plate to the end of the first hollow beam and to the second end of the second hollow beam. The second knee plate defines a third channel portion that receives a second portion of the end of the first hollow beam and a fourth channel portion that receives a second portion of the second end of the second hollow beam. The method includes interconnecting the first knee plate and the second knee plate.

Other features and advantages will become apparent from the description, the drawings, and the claims.

The following describes one or more example embodiments of the disclosed hybrid loader boom arm assembly, as shown in the accompanying figures of the drawings described briefly above. Various modifications to the example embodiments may be contemplated by one of skill in the art.

As used herein, unless otherwise limited or modified, lists with elements that are separated by conjunctive terms (e.g., "and") and that are also preceded by the phrase "one or more of" or "at least one of" indicate configurations or arrangements that potentially include individual elements of the list, or any combination thereof. For example, "at least one of A, B, and C" or "one or more of A, B, and C" indicates the possibilities of only A, only B, only C, or any combination of two or more of A, B, and C (e.g., A and B; Band C; A and C; or A, B, and C).

Conventional loader boom arms for use in various construction and agricultural applications to couple a work implement to a work vehicle for hauling materials (e.g., dirt, sand, aggregate and so on) are typically cast or fabricated of heavy-duty construction using high-strength materials (e.g., steel). The heavy-duty construction affords conventional loader boom arms the ability to undergo extreme lifting and treatment during use. In addition to the material itself, the weight of the heavy-duty loader boom arms must be accommodated by the host machine, and specifically by its hydraulic system, to ensure that the machine performs as expected, that is will raise and lower the loader boom arms at the rate and range of motion desired. Further, as heavy and rugged as they are, encountering sufficient loading, abrasion or other forces can cause damage to conventional loader boom arms. The loader boom arms may yield (i.e., crack) due to impact or stress concentrations, or they may experience wear that may impact the performance of the machine. Damage or worn loader boom arms may need to be replaced or repaired at significant expense or operational downtime of the machine.

This disclosure provides an alternative to the conventional loader boom arms through the use of a hybrid loader boom arm assembly that is configured to couple to the work vehicle and the bucket. The disclosed hybrid loader boom arm assembly has a light-duty construction, and is composed of generally lightweight materials. For example, the disclosed hybrid loader boom arm assembly ("HLBAA") may have arm assemblies composed of a first beam, a second beam and a torque transfer tube, each of which is composed of a lightweight material. As used herein "lightweight material" generally denotes a material that has a weight that is less than a weight of steel, such that an arm assembly of the HLBAA has a weight that is less than a weight of a conventional steel arm assembly. Exemplary lightweight materials include, but are not limited to, aluminum, polymer-based material, glass-fiber reinforced polymer-based materials, carbon-fiber reinforced polymer-based materials, G10 material, and the like. The HLBAA generally has a weight that is about <NUM>% to about <NUM>% lighter than conventional steel loader boom arms. This reduces fuel consumption, and may enable the use of a light-duty hydraulic system. In this way, the disclosed HLBAA may have both lightweight and low-cost attributes.

Generally, the lightweight construction of the HBLAA enables the HBLAA to be packaged in regular packaging, and transported in a disassembled state, which reduces shipping and transportation costs. The HBLAA may be assembled at the customer's location or other location remote from the manufacturing facility, which increases a volume of HBLAA that may be transported in a transportation vehicle, for example. In this regard, the HBLAA may be packaged in containers, for example, which may be stacked within the transportation vehicle. Generally, the HBLAA is assembled with a plurality of blind oversized mechanical (BOM) fasteners, which enable the customer to assemble the HBLAA at their desired location. Once the HBLAA is assembled, in order to disassemble the HBLAA, special tools, such as drills, may be used to remove the BOM fasteners to replace damaged parts, for example.

The following describes one or more example implementations of the disclosed HLBAA. The HLBAA may be utilized with various machines or work vehicles, including loaders and other machines for lifting and moving various materials in the agricultural and construction industries. Referring to <FIG> and <FIG>, in some embodiments, the HLBAA may be used with an agricultural loader <NUM>. It will be understood that the configuration of the loader <NUM> is presented as an example only. In this regard, the disclosed HLBAA may be implemented as a front loader removably coupled to a work vehicle, such as a tractor. Other work vehicles, such as dedicated wheel loaders used in the construction industry, may benefit from the disclosed HLBAA as well. Further, the HLBAA may be used with a skid-steer or other work vehicles that employ one or more boom arms to couple work implements to the work vehicle.

Generally, the loader <NUM> includes a source of propulsion, such as an engine <NUM> that supplies power to a transmission <NUM>. In one example, the engine <NUM> is an internal combustion engine, such as a diesel engine, that is controlled by an engine control module. The transmission <NUM> transfers power from the engine <NUM> to a suitable driveline coupled to one or more driven wheels <NUM> of the loader <NUM> to enable the loader <NUM> to move. The engine <NUM>, the transmission <NUM> and the rest of the driveline are supported by a vehicle chassis <NUM>, which is supported off the ground by the wheels <NUM>. As is known to one skilled in the art, the transmission <NUM> can include a suitable gear transmission, which can be operated in a variety of ranges containing one or more gears, including, but not limited to a park range, a neutral range, a reverse range, a drive range, a low range, a high range, etc. The transmission <NUM> may be controlled by a transmission control module, which is, along with the engine control module, in communication with a master controller <NUM> (or group of controllers).

The controller <NUM> may control various aspects of the operation of the loader <NUM> and may be configured as a computing device with associated processor devices and memory architectures, as a hard-wired computing circuit (or circuits), as a programmable circuit, as a hydraulic, electrical or electro-hydraulic controller, or otherwise. As such, the controller <NUM> may be configured to execute various computational and control functionality with respect to the loader <NUM> (or other machinery). In some embodiments, the controller <NUM> may be configured to receive input signals in various formats (e.g., as hydraulic signals, voltage signals, current signals, and so on), and to output command signals in various formats (e.g., as hydraulic signals, voltage signals, current signals, mechanical movements, and so on). In some embodiments, the controller <NUM> (or a portion thereof) may be configured as an assembly of hydraulic components (e.g., valves, flow lines, pistons and cylinders, and so on), such that control of various devices (e.g., pumps or motors) may be effected with, and based upon, hydraulic, mechanical, or other signals and movements.

The controller <NUM> may be in electronic, hydraulic, mechanical, or other communication with various other systems or devices of the loader <NUM> (or other machinery). For example, the controller <NUM> may be in electronic or hydraulic communication with various actuators, sensors, and other devices within (or outside of) the loader <NUM>, including various devices associated with a hydraulic system. The controller <NUM> may communicate with other systems or devices (including other controllers) in various known ways, including via a CAN bus (not shown) of the loader <NUM>, via wireless or hydraulic communication means, or otherwise. An example location for the controller <NUM> is depicted in <FIG>. It will be understood, however, that other locations are possible including other locations on the loader <NUM>, or various remote locations. In some embodiments, the controller <NUM> may be configured to receive input commands and to interface with an operator via a human-machine interface <NUM>, which may be disposed inside a cab <NUM> of the loader <NUM> for easy access by the operator. The human-machine interface <NUM> may be configured in a variety of ways and may include one or more joysticks, various switches or levers, one or more buttons, a touchscreen interface that may be overlaid on a display, a keyboard, a speaker, a microphone associated with a speech recognition system, or various other human-machine interface devices.

The loader <NUM> also has a hydraulic system that includes one or more pumps and accumulators (designated generally by reference number <NUM>), which may be driven by the engine <NUM> of the loader <NUM>. Flow from the pumps <NUM> may be routed through various control valves and various conduits (e.g., flexible hoses) to drive various hydraulic cylinders, such as hydraulic cylinders <NUM>, <NUM>, <NUM>, shown in <FIG>. Flow from the pumps (and accumulators) <NUM> may also power various other components of the loader <NUM>. The flow from the pumps <NUM> may be controlled in various ways (e.g., through control of various electro-hydraulic control valves <NUM>) to cause movement of the hydraulic cylinders <NUM>, <NUM>, <NUM>, and thus, a HLBAA <NUM> relative to the loader <NUM>. In this way, for example, movement of the HLBAA <NUM> between various positions relative to the chassis <NUM> of the loader <NUM> may be implemented by various control signals to the pumps <NUM>, control valves <NUM>, and so on.

In the embodiment depicted, a bucket <NUM> is pivotally mounted to the HLBAA <NUM>. The bucket <NUM> may comprise a conventional steel bucket, or may comprise a hybrid loader bucket assembly. As will be discussed in greater detail herein, the HLBAA <NUM> includes a first or arm assembly <NUM> and a second arm assembly <NUM>, which are interconnected via a hollow torque transfer tube <NUM> to operate in parallel. The arm assemblies <NUM>, <NUM> are each coupled to the chassis <NUM>, directly or via another frame portion of the loader <NUM>, at one end, and are coupled at an opposite end to the bucket <NUM> via a carrier <NUM>, which is pivoted via first and second (left and right) pivot linkages <NUM>, <NUM>. In the illustrated example, the carrier <NUM> comprises first and second (left and right) couplers <NUM>, <NUM>, connected by a cross-rod <NUM>, that mount to the distal ends of the respective arm assemblies <NUM>, <NUM> via coupling pins <NUM>. Additional pins pivotally couple the pivot linkages <NUM>, <NUM> between the arm assemblies <NUM>, <NUM> and the respective first and second couplers <NUM>, <NUM>. The pivot linkages <NUM>, <NUM> enable pivotal movement of the bucket <NUM> upon actuation of the hydraulic cylinders <NUM>, <NUM>.

The hydraulic cylinders may be actuated to raise and lower the HLBAA <NUM> relative to the loader <NUM>. In the illustrated example, the HLBAA <NUM> includes two hydraulic cylinders, namely the hydraulic cylinder <NUM> coupled between the chassis <NUM> and the arm assembly <NUM> and a corresponding cylinder on the opposite side of the loader (not shown) coupled between the chassis <NUM> and the second arm assembly <NUM>. It should be noted that the loader <NUM> may have any number of hydraulic cylinders, such as one, three, etc. Each of the hydraulic cylinders <NUM> includes an end coupled to the chassis <NUM> (e.g., via a coupling pin) and an end mounted to the respective one of the arm assembly <NUM> and the second arm assembly <NUM> (e.g., via another pin). Upon activation of the hydraulic cylinders <NUM>, the HLBAA <NUM> may be moved between various positions to elevate the HLBAA <NUM>, and thus the bucket <NUM>, relative to the chassis <NUM> of the loader <NUM>.

One or more hydraulic cylinders <NUM> are mounted to the arm assembly <NUM> and the first pivot linkage <NUM>, and one or more hydraulic cylinders <NUM> are mounted to the second arm assembly <NUM> and the second pivot linkage <NUM>. In the illustrated example, the loader <NUM> includes a single hydraulic cylinder <NUM>, <NUM> associated with a respective one of the arm assembly <NUM> and the second arm assembly <NUM>, respectively. Each of the hydraulic cylinders <NUM>, <NUM> includes an end mounted to the respective one of the arm assembly <NUM> and the second arm assembly <NUM> (via another pin) and an end mounted to the respective one of the first pivot linkage <NUM> and the second pivot linkage <NUM> (via another pin). Upon activation of the hydraulic cylinders <NUM>, <NUM>, the bucket <NUM> may be moved between various positions, namely to pivot the carrier <NUM>, and thereby the bucket <NUM>, relative to the HLBAA <NUM>.

Thus, in the embodiment depicted, the bucket <NUM> is pivotable about the carrier <NUM> of the HLBAA <NUM> by the hydraulic cylinders <NUM>, <NUM>. As noted, in some embodiments, a different number or configuration of hydraulic cylinders or other actuators may be used. Thus, it will be understood that the configuration of the hydraulic system and the HLBAA <NUM> is presented as an example only. In this regard, in other contexts, a hoist boom (e.g. the HLBAA <NUM>) may be generally viewed as a boom that is pivotally attached to a vehicle frame, and that is also pivotally attached to an end effector (e.g., the bucket <NUM>). Similarly, the carrier <NUM> (e.g., the couplers <NUM>, <NUM>) may be generally viewed as a component effecting pivotal attachment of a bucket (e.g. the bucket <NUM>) to a vehicle frame. In this light, a tilt actuator (e.g., the hydraulic cylinders <NUM>, <NUM>) may be generally viewed as an actuator for pivoting a receptacle with respect to a hoist boom, and the hoist actuator (e.g. the hydraulic cylinders <NUM>) may be generally viewed as an actuator for pivoting a hoist boom with respect to a vehicle frame.

In certain applications, sensors (e.g., pressure, flow or other sensors) may be provided to observe various conditions associated with the loader <NUM>. For example, the sensors may include one or more pressure sensors that observe a pressure within the hydraulic circuit, such as a pressure associated with at least one of the pumps <NUM>, the control valves <NUM> and/or one or more hydraulic cylinders <NUM>, <NUM>, <NUM> to observe a pressure within the hydraulic cylinders and generate sensor signals based thereon. In some cases, various sensors may be disposed on or near the carrier <NUM> and/or the bucket <NUM>. For example, sensors (e.g. inertial measurement sensors) may be coupled on or near the bucket <NUM> to observe or measure parameters including the acceleration of the HLBAA <NUM> and/or the bucket <NUM> and generate sensor signals, which may indicate if the HLBAA <NUM> and/or the bucket <NUM> is accelerating or decelerating. In some embodiments, various sensors (e.g., angular position sensors) may be configured to detect the angular orientation of the bucket <NUM> relative to the HLBAA <NUM>, or to detect the angular orientation of the HLBAA <NUM> relative to the chassis <NUM>, and various other indicators of the current orientation or position of the bucket <NUM>. For example, rotary angular positon sensors may be used or linear position or displacement sensors may be used to determine the length of the hydraulic cylinders <NUM>, <NUM>, <NUM> relative to the HLBAA <NUM>.

The bucket <NUM> generally defines a receptacle for carrying various materials, such as dirt, rocks, wet dirt, sand, hay, etc. In one example, the bucket <NUM> may receive about two cubic yards of material to over about five cubic yards of material. The bucket <NUM> is movable upon actuation of the hydraulic cylinders <NUM>, <NUM> between a level position, a roll-back position and a dump position, along with various positions in between. In the level position, the bucket <NUM> can receive various materials. In the roll-back position, the bucket <NUM> is pivoted upward relative to the earth's surface or ground by the actuation of the hydraulic cylinders <NUM>, <NUM> such that the bucket <NUM> may be loaded with and retain the various materials. In the dump position, the bucket <NUM> is pivoted downward relative to the earth's surface or ground by the actuation of the hydraulic cylinders <NUM>, <NUM> such that the various materials may fall from the bucket <NUM> to substantially empty the bucket <NUM>.

Referring to <FIG>, in some embodiments, the HLBAA <NUM> may be used with a compact utility tractor <NUM> having a front loader <NUM> removably coupled to the compact utility tractor <NUM>. It will be understood that the implementation of the HLBAA <NUM> with the compact utility tractor <NUM> is presented as an example only. Generally, the compact utility tractor <NUM> includes a source of propulsion, such as an engine <NUM> that supplies power to a transmission <NUM>. In one example, the engine <NUM> is an internal combustion engine, such as a diesel engine, that is controlled by an engine control module. The transmission <NUM> transfers power from the engine <NUM> to a suitable driveline coupled to one or more driven wheels <NUM> of the compact utility tractor <NUM> to enable the compact utility tractor <NUM> to move. The engine <NUM>, the transmission <NUM> and the rest of the driveline are supported by a vehicle chassis <NUM>, which is supported off the ground by the wheels <NUM>. As is known to one skilled in the art, the transmission <NUM> can include a suitable gear transmission, which can be operated in a variety of ranges. The transmission <NUM> may be controlled by a transmission control module, which is, along with the engine control module, in communication with a master controller <NUM> (or group of controllers).

The controller <NUM> may control various aspects of the operation of the compact utility tractor <NUM> and may be configured as a computing device with associated processor devices and memory architectures, as a hard-wired computing circuit (or circuits), as a programmable circuit, as a hydraulic, electrical or electro-hydraulic controller, or otherwise. As such, the controller <NUM> may be configured to execute various computational and control functionality with respect to the compact utility tractor <NUM> (or other machinery). In some embodiments, the controller <NUM> may be configured to receive input signals in various formats (e.g., as hydraulic signals, voltage signals, current signals, and so on), and to output command signals in various formats (e.g., as hydraulic signals, voltage signals, current signals, mechanical movements, and so on). In some embodiments, the controller <NUM> (or a portion thereof) may be configured as an assembly of hydraulic components (e.g., valves, flow lines, pistons and cylinders, and so on), such that control of various devices (e.g., pumps or motors) may be effected with, and based upon, hydraulic, mechanical, or other signals and movements.

The controller <NUM> may be in electronic, hydraulic, mechanical, or other communication with various other systems or devices of the compact utility tractor <NUM> (or other machinery), including the front loader <NUM>. For example, the controller <NUM> may be in electronic or hydraulic communication with various actuators, sensors, and other devices within (or outside of) the compact utility tractor <NUM>, including various devices associated with a hydraulic system of the front loader <NUM>. The controller <NUM> may communicate with other systems or devices (including other controllers) in various known ways, including via a CAN bus (not shown) of the compact utility tractor <NUM>, via wireless or hydraulic communication means, or otherwise. An example location for the controller <NUM> is depicted in <FIG>. It will be understood, however, that other locations are possible including other locations on the compact utility tractor <NUM>, or various remote locations. In some embodiments, the controller <NUM> may be configured to receive input commands and to interface with an operator via a human-machine interface <NUM>, which may be disposed for easy access by the operator. The human-machine interface <NUM> is in communication with the controller <NUM> over a suitable communication architecture, such as a CAN bus. The human-machine interface <NUM> may be configured in a variety of ways and may include one or more joysticks, various switches or levers, a steering wheel, one or more buttons, a touchscreen interface that may be overlaid on a display, a keyboard, a speaker, a microphone associated with a speech recognition system, or various other human-machine interface devices.

The compact utility tractor <NUM> also has a hydraulic system that includes one or more pumps and accumulators (designated generally by reference number <NUM>), which may be driven by the engine <NUM> of the compact utility tractor <NUM>. Flow from the pumps <NUM> may be routed through various control valves and various conduits (e.g., flexible hoses) to drive various hydraulic cylinders, such as hydraulic cylinders <NUM>, <NUM>, <NUM> associated with the front loader <NUM>, shown in <FIG>. Flow from the pumps (and accumulators) <NUM> may also power various other components of the compact utility tractor <NUM>. The flow from the pumps <NUM> may be controlled in various ways (e.g., through control of various electro-hydraulic control valves <NUM>) to cause movement of the hydraulic cylinders <NUM>, <NUM>, <NUM>, and thus, the front loader <NUM> relative to the compact utility tractor <NUM> when the front loader <NUM> is mounted on the compact utility tractor <NUM> through a suitable mounting arrangement. In this way, for example, movement of the front loader <NUM> between various positions relative to the chassis <NUM> of the compact utility tractor <NUM> may be implemented by various control signals to the pumps <NUM>, control valves <NUM>, and so on.

In the embodiment depicted, the front loader <NUM> includes the bucket <NUM> pivotally mounted to the HLBAA <NUM>. The arm assemblies <NUM>, <NUM> are each configured to be coupled to the chassis <NUM> via a suitable mounting arrangement, at one end, and are coupled at an opposite end to the bucket <NUM> via the carrier <NUM>. The mounting arrangement may include a mast <NUM> on each side of the front loader <NUM> that cooperates with a mounting frame on each side of the compact utility tractor <NUM> to removably couple the front loader <NUM> to the compact utility tractor <NUM>.

As discussed with regard to <FIG> and <FIG>, the hydraulic cylinders <NUM> may be actuated to raise and lower the HLBAA <NUM> relative to the compact utility tractor <NUM>. In the illustrated example, the HLBAA <NUM> includes two hydraulic cylinders, namely the hydraulic cylinder <NUM> coupled between the mast <NUM> of the front loader <NUM> and the arm assembly <NUM> and a corresponding cylinder on the opposite side of the loader (not shown) coupled between the mast <NUM> and the second arm assembly <NUM>. It should be noted that the compact utility tractor <NUM> may have any number of hydraulic cylinders, such as one, three, etc. Each of the hydraulic cylinders <NUM> includes an end coupled to the mast <NUM> (e.g., via a coupling pin) and an end mounted to the respective one of the arm assemblies <NUM>, <NUM> (e.g., via another pin). Upon activation of the hydraulic cylinders <NUM>, the HLBAA <NUM> may be moved between various positions to elevate the HLBAA <NUM>, and thus the bucket <NUM>, relative to the chassis <NUM> of the compact utility tractor <NUM>.

The one or more hydraulic cylinders <NUM> are mounted to the arm assembly <NUM> and the first pivot linkage <NUM>, and the one or more hydraulic cylinders <NUM> are mounted to the second arm assembly <NUM> and the second pivot linkage <NUM>. In the illustrated example, the front loader <NUM> includes a single hydraulic cylinder <NUM>, <NUM> associated with a respective one of the arm assemblies <NUM>, <NUM>, respectively. Each of the hydraulic cylinders <NUM>, <NUM> includes an end mounted to a respective one of the arm assemblies <NUM>, <NUM> (via a pin) and an end mounted to the respective one of the first pivot linkage <NUM> and the second pivot linkage <NUM> (via another pin). Upon activation of the hydraulic cylinders <NUM>, <NUM>, the bucket <NUM> may be moved between various positions, namely to pivot the carrier <NUM>, and thereby the bucket <NUM>, relative to the HLBAA <NUM>. Thus, in the embodiment depicted, the bucket <NUM> is pivotable about the carrier <NUM> of the HLBAA <NUM> by the hydraulic cylinders <NUM>, <NUM>. As noted, in some embodiments, a different number or configuration of hydraulic cylinders or other actuators may be used. Accordingly, it will be understood that the configuration of the hydraulic system and the HLBAA <NUM> is presented as an example only.

Referring also to <FIG>, the example HLBAA <NUM> will now be detailed. In one example, the HLBAA <NUM> includes an arm assembly <NUM>, a second arm assembly <NUM> and a hollow torque transfer tube <NUM> that interconnects the arm assembly <NUM> and the second arm assembly <NUM>. Each of the arm assembly <NUM> and the second arm assembly <NUM> include a first beam <NUM>, a second beam <NUM>, a vehicle mounting subassembly <NUM>, a respective bucket mount bracket or bucket mount bracket subassembly <NUM>, <NUM> and a knee mounting subassembly <NUM>.

The first beam <NUM>, the second beam <NUM> and the torque transfer tube <NUM> are each formed from the lightweight material. In one example, the first beam <NUM>, the second beam <NUM> and the torque transfer tube <NUM> are each formed from the lightweight material, including, but not limited to, aluminum. The first beam <NUM>, the second beam <NUM> and the torque transfer tube <NUM> are each formed using extrusion; however, other suitable forming techniques may be used. In this example, each of the first beam <NUM>, the second beam <NUM> and the torque transfer tube <NUM> have the same cross-section. In one example, the cross-section is substantially I-shaped.

With reference to <FIG>, the cross-section of the first beam <NUM> is shown, with the understanding that the cross-section of the second beam <NUM> and the torque transfer tube <NUM> is the same. As shown in <FIG>, the cross-section of the first beam <NUM> defines a first chamber <NUM>, a second chamber <NUM> and a third chamber <NUM>. With reference to <FIG>, the first chamber <NUM> and the second chamber <NUM> extend along a respective axis A5, A6, which is substantially parallel to a longitudinal axis L1 of the first beam <NUM>. The third chamber <NUM> extends along an axis A7 that is substantially perpendicular to the longitudinal axis L1. In this example, with reference back to <FIG>, a first end 526a of the third chamber <NUM> is defined by a first pair of oblique surfaces <NUM> that extend into the first chamber <NUM>, and a second end 526b of the third chamber <NUM> is defined by a second pair of oblique surfaces <NUM> that extend into the second chamber <NUM>. Generally, the first chamber <NUM> and the second chamber <NUM> extend outwardly on either side of the third chamber <NUM> and cooperate to define a pair of channels <NUM> on opposing sides of the cross-section. As will be discussed, the opposing channels <NUM> of the first beam <NUM> and the second beam <NUM> cooperate to receive a portion of the knee mounting subassembly <NUM>.

With reference to <FIG>, the first beam <NUM> includes a first end 510a and an opposite second end 510b. The first end 510a defines a respective first end of the arm assembly <NUM> and the second arm assembly <NUM>. The first beam <NUM> defines a plurality of first through bores (generally identified by reference numeral <NUM>) at the first end 510a, and defines a plurality of second through bores (generally identified by reference numeral <NUM>) at the second end 510b. The first through bore <NUM> receives a portion of the vehicle mounting subassembly <NUM> to couple the vehicle mounting subassembly <NUM> to the first beam <NUM>. The second through bores <NUM> are for coupling the first beam <NUM> to the knee mounting subassembly <NUM>. It should be understood that each of the first through bore <NUM> and the second through bores <NUM> are defined in the first beam <NUM> so as to extend through the first beam <NUM>. In one example, the second end 510b of the first beam <NUM> is beveled. By beveling the second end 510b, the second end 510b of the first beam <NUM> may be positioned against a cooperating bevel defined on a third end 512a of the second beam <NUM> so that the second beam <NUM> extends at an angle relative to the first beam <NUM>.

The second beam <NUM> includes the third end 512a and an opposite fourth end 512b. The fourth end 512b defines a respective second end of the arm assembly <NUM> and the second arm assembly <NUM>. In one example, the third end 512a of the second beam <NUM> is beveled. By beveling the third end 512a, the second beam <NUM> extends at an angle relative to the first beam <NUM> to assist in coupling the bucket <NUM> (<FIG>) to the HLBAA <NUM>. The second beam <NUM> defines a plurality of third through bores (generally identified by reference numeral <NUM>) at the third end 512a, and defines a plurality of fourth through bores (generally identified by reference numeral <NUM>) at the fourth end 512b. The third through bores <NUM> are for coupling the second beam <NUM> to the knee mounting subassembly <NUM>. It should be understood that each of the third through bores <NUM> is defined in the second beam <NUM> so as to extend through the second beam <NUM>. The fourth through bores <NUM> each receive a portion of the respective bucket mount bracket subassembly <NUM>, <NUM> and the torque transfer tube <NUM> to couple the bucket mount bracket subassembly <NUM>, <NUM> and the torque transfer tube <NUM> to the respective second beam <NUM>.

The vehicle mounting subassembly <NUM> is coupled to the first end 510a of each first beam <NUM> of the arm assembly <NUM> and the second arm assembly <NUM>. Stated another way, the vehicle mounting subassembly <NUM> is coupled to the first end of each of the arm assembly <NUM> and the second arm assembly <NUM>, and is configured to couple the arm assembly <NUM> and the second arm assembly <NUM> to the loader <NUM>. With reference to <FIG>, the vehicle mounting subassembly <NUM> is shown in greater detail. As the vehicle mounting subassembly <NUM> is the same for both the arm assembly <NUM> and the second arm assembly <NUM>, the vehicle mounting subassembly <NUM> will be shown in detail herein with regard to the first beam <NUM> of the arm assembly <NUM> for ease of description, with the understanding that the vehicle mounting subassembly <NUM> coupled to the second arm assembly <NUM> is the same.

A portion of the vehicle mounting subassembly <NUM> passes through the first end 510a of the first beam <NUM> for coupling the respective one of the arm assembly <NUM> and the second arm assembly <NUM> to the loader <NUM>. With reference to <FIG>, in one example, the vehicle mounting subassembly <NUM> includes a pair of lock plates <NUM>, a sleeve <NUM> and a pair of intermediate plates <NUM>. Each of the pair of lock plates <NUM> is composed of a metal or metal alloy, including, but not limited to, steel, and is cast, forged, stamped, etc. Each of the pair of lock plates <NUM> is square or rectangular; however, each of the pair of lock plates <NUM> may have any desired shape. Each of the pair of lock plates <NUM> defines a central bore <NUM> and a plurality of coupling bores <NUM>. In one example, the central bore <NUM> includes a flat or keyed area 546a. The keyed area 546a cooperates with a respective flat or keyed area 542a on the sleeve <NUM> to inhibit relative rotation between the sleeve <NUM> and the pair of lock plates <NUM>. In one example, each coupling bore <NUM> of the plurality of coupling bores <NUM> is spaced apart about a perimeter of the respective one of the pair of lock plates <NUM> to receive a respective mechanical fastener <NUM> (<FIG>) for coupling the respective lock plate <NUM> to the first beam <NUM>. The pair of lock plates <NUM> are generally coupled to the first beam <NUM> so as to be on opposed surfaces of the first beam <NUM>.

The sleeve <NUM> is received through a central through bore 532a of the first through bores <NUM>. In this example, the sleeve <NUM> is a hollow cylinder, and includes a first end <NUM> opposite a second end <NUM> and a midsection <NUM> that extends between the first end <NUM> and the second end <NUM>. The sleeve <NUM> is composed of a metal or metal alloy, including, but not limited to, steel, and is cast, forged, stamped, etc. The first end <NUM> and the second end <NUM> each include the keyed area 546a. The keyed area 546a cooperates with the keyed area 546a of a respective one of the pair of lock plates <NUM> to inhibit rotation of the sleeve <NUM>. The sleeve <NUM> defines a sleeve bore <NUM> that extends from the first end <NUM> to the second end <NUM>. The sleeve bore <NUM> enables the pin <NUM> (<FIG>) to pass through the vehicle mounting subassembly <NUM> to couple the respective one of the arm assembly <NUM> and the second arm assembly <NUM> to the loader <NUM>.

Each of the intermediate plates <NUM> is composed of a metal or metal alloy, including, but not limited to, steel, and is cast, forged, stamped, etc. Each of the pair of intermediate plates <NUM> is substantially an elongated U-shape; however, each of the pair of intermediate plates <NUM> may have any desired shape. Each of the pair of intermediate plates <NUM> is received wholly within the first beam <NUM> at the first end 510a to couple the pair of lock plates <NUM> to the first beam <NUM>. Each of the pair of intermediate plates <NUM> includes a base <NUM> and a pair of flanges <NUM>, which extend outwardly from the base <NUM> on opposed sides of the base <NUM>. Each of the pair of flanges <NUM> defines a plurality of bores <NUM>. In one example, each bore <NUM> is spaced apart along the respective one of the pair of flanges <NUM> to receive a respective one of the mechanical fasteners <NUM> for coupling the respective lock plate <NUM> to the first beam <NUM>.

In this regard, with reference to <FIG>, generally, one of the intermediate plates <NUM> is disposed within the first chamber <NUM> and the other one of the intermediate plates <NUM> is disposed within the second chamber <NUM>. The sleeve <NUM> is inserted the through bore 532a. With the intermediate plates <NUM> disposed within the first end 510a, the bores <NUM> are coaxially aligned with remaining through bores 532b of the first plurality of through bores <NUM> defined through the first end 510a. With additional reference to <FIG>, the mechanical fasteners <NUM> are inserted into each of the through bores 532b and the bores <NUM> to couple the lock plates <NUM> and the intermediate plates <NUM> to the first end 510a of the first beam <NUM>. In this example, the mechanical fasteners <NUM> are blind oversized mechanical (BOM) fasteners, and one of the mechanical fasteners <NUM> is associated with each of the bores <NUM> and the through bores 532b. It should be noted that the use of BOM fasteners is merely exemplary, as rivets, bolts, etc. may be used to couple the lock plates <NUM> to the intermediate plates <NUM>, and thus, to the first beam <NUM>, if desired. Further, it should be noted that the number of bores <NUM> and the corresponding through bores 532b is merely exemplary, as any number of bores <NUM> and through bores 532b may be defined for the receipt of the mechanical fasteners <NUM>.

With reference back to <FIG>, the bucket mount bracket subassembly <NUM>, <NUM> couples the bucket <NUM> (<FIG> or <FIG>) to the HLBAA <NUM>. With reference to <FIG>, the bucket mount bracket subassembly <NUM> is shown in greater detail. As the bucket mount bracket subassembly <NUM> is a mirror image of the bucket mount bracket subassembly <NUM>, for ease of description, the bucket mount bracket subassembly <NUM> will be discussed herein with the understanding that the bucket mount bracket subassembly <NUM> is substantially the same. The bucket mount bracket subassembly <NUM> includes a first outer jacket assembly <NUM>, a second outer jacket <NUM>, a plurality of supports <NUM>, a bushing <NUM>, a plurality of pairs of the intermediate plates <NUM> (<FIG>) and a plurality of the mechanical fasteners <NUM>.

The first outer jacket assembly <NUM> is sized and configured to enclose the fourth end 512b of the second beam <NUM>. In one example, with reference to <FIG>, the first outer jacket assembly <NUM> includes a jacket <NUM> and a pair of reinforcing flanges <NUM>. The jacket <NUM> and the reinforcing flanges <NUM> are each composed of a metal or metal alloy, including, but not limited to, steel, and is cast, forged, stamped, etc. The jacket <NUM> is tubular in shape, and defines a channel 576a, which receives the third end 512a of the second beam <NUM>. The jacket <NUM> also defines a first plurality of bores <NUM>, a second plurality of bores <NUM> and a pair of retaining flanges <NUM>. The first plurality of bores <NUM> receives a respective one of the mechanical fasteners <NUM> to couple the jacket <NUM> to the second beam <NUM> via one pair of the intermediate plates <NUM> (<FIG>). The second plurality of bores <NUM> receives a respective one of the mechanical fasteners <NUM> to couple the jacket <NUM> to the second beam <NUM> via one pair of the intermediate plates <NUM> (<FIG>). With reference to <FIG>, the pair of retaining flanges <NUM> extends outwardly from an end 576b of the jacket <NUM>. The pair of retaining flanges <NUM> are spaced apart at the end 576b, and each define a bore <NUM> and a pair of opposed notches <NUM>. The bore <NUM> is sized and configured to receive the bushing <NUM> therethrough. The bushing <NUM> may be coupled to each of the retaining flanges <NUM> via welding, for example. The notches <NUM> are defined in the retaining flanges <NUM> so as to be on opposed sides of the bore <NUM>. The notches <NUM> receive a portion of the reinforcing flanges <NUM> to couple the reinforcing flanges <NUM> to the jacket <NUM>.

The pair of reinforcing flanges <NUM> provides additional rigidity to the retaining flanges <NUM>. In one example, the reinforcing flanges <NUM> are substantially H-shaped, and include a plurality of tabs <NUM> and a plurality of legs <NUM>. Each tab <NUM> is coupled to a respective one of the notches <NUM> associated with the retaining flanges <NUM>, and each leg <NUM> is coupled along an edge of the respective retaining flange <NUM>. In one example, the reinforcing flanges <NUM> are each composed of a metal or metal alloy, including, but not limited to, steel, and is cast, forged, stamped, etc. In this example, the reinforcing flanges <NUM> are coupled to the retaining flanges <NUM> via welding.

With reference to <FIG>, the second outer jacket <NUM> is sized and configured to enclose a second tube end 506b of the torque transfer tube <NUM>. In one example, the second outer jacket <NUM> is composed of a metal or metal alloy, including, but not limited to, steel, and is cast, forged, stamped, etc. The second outer jacket <NUM> is tubular in shape, and defines a channel 572a, which receives the second tube end 506b of the torque transfer tube <NUM>. With reference to <FIG>, the second outer jacket <NUM> also defines a plurality of bores <NUM>. The plurality of bores <NUM> receives a respective one of the mechanical fasteners <NUM> to couple the second outer jacket <NUM> to the torque transfer tube <NUM> via one pair of the intermediate plates <NUM> (<FIG>). In one example, the second outer jacket <NUM> is coupled to the jacket <NUM> via welding.

The plurality of supports <NUM> imparts stiffness to the connection of the jacket <NUM> and the second outer jacket <NUM>. In this example, the supports <NUM> are each triangular in shape, however, the supports <NUM> may have any desired shape. Each of the supports <NUM> is composed of a metal or metal alloy, including, but not limited to, steel, and is cast, forged, stamped, etc. The supports <NUM> are coupled to each of the jacket <NUM> and the second outer jacket <NUM> via welding, for example. Generally, a first surface 574a of each of the supports <NUM> is coupled to the jacket <NUM>, and a second surface 574b of each of the supports <NUM> is coupled to the second outer jacket <NUM>.

The bushing <NUM> comprises a hollow cylinder. The bushing <NUM> is composed of metal or metal alloy, including, but not limited to, steel, and is cast, forged, stamped, extruded, etc. The bushing <NUM> is coupled to the respective one of the pair of retaining flanges <NUM>. Generally, the bushing <NUM> is received through the bores <NUM> and is coupled to the respective one of the pair of retaining flanges <NUM>, via welding, for example. A midsection of the bushing <NUM> is positioned between the pair of retaining flanges <NUM>, and is configured to receive a portion of a hook 52a (<FIG>) of the bucket <NUM> to couple the bucket <NUM> to the second beam <NUM>.

The plurality of pairs of the intermediate plates <NUM> (<FIG>) and the plurality of the mechanical fasteners <NUM> interconnect the torque transfer tube <NUM> with the second outer jacket <NUM>, and interconnect the first outer jacket assembly <NUM> with the second beam <NUM>. In one example, with reference to <FIG>, two of the intermediate plates <NUM> cooperate with a first sub-plurality 538a of the plurality of bores <NUM> of the second beam <NUM> and with the plurality of bores <NUM> to couple the first outer jacket assembly <NUM> to the second beam <NUM>; and two of the intermediate plates <NUM> cooperate with a second sub-plurality 538b of the plurality of bores <NUM> of the second beam <NUM> and with the plurality of bores <NUM> to couple the first outer jacket assembly <NUM> to the second beam <NUM>.

In this example, two of the intermediate plates <NUM> are positioned in the first chamber <NUM> and the second chamber <NUM>, respectively, such that the bores <NUM> of the intermediate plates <NUM> are coaxially aligned with the first sub-plurality 538a of the plurality of bores <NUM>. With reference to <FIG>, two of the intermediate plates <NUM> are also positioned in the first chamber <NUM> and the second chamber <NUM>, respectively, and such that the bores <NUM> of the intermediate plates <NUM> are coaxially aligned with the second sub-plurality 538b of the plurality of bores <NUM>. With the first outer jacket assembly <NUM> disposed over the fourth end 512b, the mechanical fasteners <NUM> are inserted through the plurality of bores <NUM>, the first sub-plurality 538a of the plurality of bores <NUM> and into the bores <NUM> of the intermediate plates <NUM> to couple the first outer jacket assembly <NUM> to the second beam <NUM> (<FIG>). The mechanical fasteners <NUM> are also inserted through the plurality of bores <NUM>, the second sub-plurality 538b of the plurality of bores <NUM> and into the bores <NUM> of the intermediate plates <NUM> to couple the first outer jacket assembly <NUM> to the second beam <NUM> (<FIG>).

In one example, with reference to <FIG>, two of the intermediate plates <NUM> cooperate with a plurality of bores <NUM> of the torque transfer tube <NUM> and with the plurality of bores <NUM> to couple the second outer jacket <NUM> to the torque transfer tube <NUM>. With reference to <FIG>, two of the intermediate plates <NUM> are positioned in the first chamber <NUM> and the second chamber <NUM>, respectively, of the torque transfer tube <NUM> such that the bores <NUM> of the intermediate plates <NUM> are coaxially aligned with the plurality of bores <NUM>. With the second outer jacket <NUM> disposed over the second tube end 506b, the mechanical fasteners <NUM> are inserted through the plurality of bores <NUM>, the plurality of bores <NUM> and into the bores <NUM> of the intermediate plates <NUM> to couple the second outer jacket <NUM> to the torque transfer tube <NUM> (<FIG>).

With reference to <FIG> and <FIG>, the knee mounting subassembly <NUM> interconnects the first beam <NUM> with the second beam <NUM>. The knee mounting subassembly <NUM> comprises a connection assembly for the first beam <NUM> and the second beam <NUM>. The knee mounting subassembly <NUM> includes a pair of knee plates <NUM>, a pair of angled intermediate plates <NUM> (<FIG>) and a pair of coupling pins <NUM>. Each of the knee plates <NUM> is composed of metal or metal alloy, including, but not limited to, aluminum, and in this example, is die-cast. Each of the pair of knee plates <NUM> includes a first plate end <NUM> opposite a second plate end <NUM>, and a first plate side <NUM> opposite a second plate side <NUM>. Each knee plate <NUM> includes a plurality of knee coupling bores <NUM>, a pair of pin coupling bores <NUM>, a pair of locating pins <NUM>, a channel <NUM>, a first plurality of bores <NUM> and a second plurality of bores <NUM>.

The plurality of knee coupling bores <NUM> receives a respective knee mechanical fastener <NUM>, such as a knee bolt, to couple the knee plates <NUM> together. In one example, the knee plates <NUM> define four knee coupling bores <NUM> that receive a respective one of four knee mechanical fasteners <NUM> (<FIG>). The knee coupling bores <NUM> of each of the knee plates <NUM> are coaxially aligned for receiving the respective knee mechanical fastener <NUM>. In one example, each of the knee mechanical fasteners <NUM> has a plurality of threads defined at opposed ends, which matingly engage with respective pairs of flange nuts <NUM>, for example, to secure each of the knee mechanical fasteners <NUM> to the knee plates <NUM>. In this example, one of the knee coupling bores <NUM> is defined at the first side <NUM> adjacent to the first plate end <NUM>, and one of the knee coupling bores <NUM> is defined at the first side <NUM> between the one of the knee coupling bores <NUM> and the second plate end <NUM>. Another one of the knee coupling bores <NUM> is defined at the second side <NUM> adjacent to the first plate end <NUM>, and a final one of the knee coupling bores <NUM> is defined at the second side <NUM> at the second plate end <NUM> (<FIG>).

The pair of pin coupling bores <NUM> receives a respective one of the coupling pins <NUM>. One of the pin coupling bores <NUM> is defined at the first side <NUM> at the second plate end <NUM>, and the other of the pin coupling bores <NUM> is defined at the second side <NUM> at the second plate end <NUM>. The pair of locating pins <NUM> is integrally formed or monolithic with the knee plates <NUM>. The locating pins <NUM> are formed to extend outwardly from the channel <NUM>. One of the locating pins <NUM> engages a bore 534a of the plurality of bores <NUM> of the first beam <NUM>, and the other of the locating pins <NUM> engages a bore 536a of the plurality of bores <NUM> of the second beam <NUM>. The locating pins <NUM> facilitate the coupling of the knee plates <NUM> to the first beam <NUM> and the second beam <NUM>.

The channel <NUM> is defined along each of the knee plates <NUM> from the first plate end <NUM> to the second plate end <NUM>. The channel <NUM> includes two grooves <NUM> that are separated by a rail <NUM>. The two grooves <NUM> and the rail <NUM> of the knee plates <NUM> cooperate to define a first channel portion <NUM> (<FIG>) that receives the first beam <NUM> and a second channel portion <NUM> that receives the second beam <NUM> (<FIG>). Stated another way, the two grooves <NUM> and the rail <NUM> of the knee plates <NUM> cooperate to define a cross-section that corresponds to the cross-section of each of the first beam <NUM> and the second beam <NUM> (<FIG>). Generally, each of the grooves <NUM> of the knee plates <NUM> cooperate to surround the portion of the first beam <NUM> and the second beam <NUM> defined by the first chamber <NUM> and the second chamber <NUM>, respectively, and the rails <NUM> of each of the knee plates <NUM> are received along either side of the channels <NUM> defined by the shape of the third chamber <NUM> of the first beam <NUM> and the second beam <NUM>.

The first plurality of bores <NUM> couple the knee plates <NUM> to the first beam <NUM>. A first sub-plurality 632a of the first plurality of bores <NUM> receive respective ones of the mechanical fasteners <NUM> to couple the knee plates <NUM> to the first beam <NUM> via the angled intermediate plates <NUM>. A second sub-plurality 632b of the first plurality of bores <NUM> receive respective ones of the mechanical fasteners <NUM> to couple the knee plate <NUM> to the first beam <NUM> via a sub-plurality 532b of the second plurality of bores <NUM> of the first beam <NUM> (<FIG>).

The second plurality of bores <NUM> couple the knee plates <NUM> to the second beam <NUM>. A first sub-plurality 634a of the second plurality of bores <NUM> receive respective ones of the mechanical fasteners <NUM> to couple the knee plates <NUM> to the second beam <NUM> via the angled intermediate plates <NUM>. A second sub-plurality 634b of the second plurality of bores <NUM> receive respective ones of the mechanical fasteners <NUM> to couple the knee plate <NUM> to the second beam <NUM> via a sub-plurality 534b of the second plurality of bores <NUM> of the second beam <NUM> (<FIG>).

The pair of angled intermediate plates <NUM> interconnect the knee plates <NUM> with the first beam <NUM> and the second beam <NUM>; and interconnect the first beam <NUM> with the second beam <NUM>. Each of the angled intermediate plates <NUM> is composed of a metal or metal alloy, including, but not limited to, steel, and is cast, forged, stamped, etc. Each of the pair of angled intermediate plates <NUM> is substantially an elongated U-shape; however, each of the pair of angled intermediate plates <NUM> may have any desired shape. Each of the pair of angled intermediate plates <NUM> is received wholly within the first beam <NUM> at the second end 510b and the second beam <NUM> at the third end 512a. In one example, each of the angled intermediate plates <NUM> includes a first plate portion <NUM> interconnected to a second plate portion <NUM>. In this example, the first plate portion <NUM> is integrally formed with the second plate portion <NUM>; however, the first plate portion <NUM> may be separate from the second plate portion <NUM> and coupled together via welding, for example. The second plate portion <NUM> is angled relative to the first plate portion <NUM>. Stated another way, the first plate portion <NUM> extends along an axis A8, and the second plate portion <NUM> extends along a second axis A9, and the second axis A9 is oblique to the axis A8.

Each of the first plate portion <NUM> and the second plate portion <NUM> includes the base <NUM> and the pair of flanges <NUM>, which extend outwardly from the base <NUM> on opposed sides of the base <NUM>. Each of the pair of flanges <NUM> defines the plurality of bores <NUM>. Generally, the first plate portion <NUM> of one of the angled intermediate plates <NUM> is disposed within the first chamber <NUM> of the first beam <NUM> such that the bores <NUM> are coaxially aligned with a sub-plurality 532c of the plurality of bores <NUM>, and the second plate portion <NUM> is disposed within the first chamber <NUM> of the second beam <NUM> such that the bores <NUM> are coaxially aligned with a sub-plurality 536c of the plurality of bores <NUM>. The first plate portion <NUM> of the other of the angled intermediate plates <NUM> is disposed within the second chamber <NUM> of the first beam <NUM> such that the bores <NUM> are coaxially aligned with a sub-plurality 532d of the plurality of bores <NUM>, and the second plate portion <NUM> is disposed within the second chamber <NUM> of the second beam <NUM> such that the bores <NUM> are coaxially aligned with a sub-plurality 536d of the plurality of bores <NUM>.

With additional reference to <FIG>, the mechanical fasteners <NUM> are inserted into each of the through bores 534c, the bores <NUM> and the bores 632a of the knee plates <NUM> to couple the knee plates <NUM> and the first plate portion <NUM> of one of the angled intermediate plates <NUM> to the first end 510a of the first beam <NUM>. The mechanical fasteners <NUM> are also inserted into each of the through bores 534d, the bores <NUM> and the bores 632a of the knee plates <NUM> to couple the knee plates <NUM> and the first plate portion <NUM> of the other of the angled intermediate plates <NUM> to the first end 510a of the first beam <NUM>. The mechanical fasteners <NUM> are inserted into each of the through bores 536c, the bores <NUM> and the bores 634a of the knee plates <NUM> to couple the knee plates <NUM> and the second plate portion <NUM> of one of the angled intermediate plates <NUM> to the third end 512a of the second beam <NUM>. The mechanical fasteners <NUM> are also inserted into each of the through bores 536d, the bores <NUM> and the bores 634a of the knee plates <NUM> to couple the knee plates <NUM> and the second plate portion <NUM> of the other of the angled intermediate plates <NUM> to the third end 512a of the second beam <NUM>. The mechanical fasteners <NUM> are inserted into the bores 632a of the knee plates <NUM> and the bores 532b of the first beam <NUM> to further couple the first beam <NUM> to the knee plates <NUM>. The mechanical fasteners <NUM> are inserted into the bores 634a of the knee plates <NUM> and the bores 534b of the second beam <NUM> to further couple the second beam <NUM> to the knee plates <NUM>.

The pair of coupling pins <NUM> couple the hydraulic cylinders <NUM>, <NUM>, <NUM> to the respective one of the arm assembly <NUM> and the second arm assembly <NUM>. Each of the coupling pins <NUM> includes a pair of collars <NUM>. The pair of collars <NUM> secures and retains the coupling pins <NUM> to the pair of knee plates <NUM>. Generally, one of the coupling pins <NUM> is received through one pair of the pin coupling bores <NUM> and the other one of the coupling pins <NUM> is received through one pair of the pin coupling bores <NUM>. A first one of the collars <NUM> is coupled to one end of one of the coupling pins <NUM>, and a second one of the pair of collars <NUM> is coupled to the other opposed end of the respective one of the coupling pins <NUM>. One of the pair of collars <NUM> is coupled to one end of the other one of the coupling pins <NUM>, and the second one of the pair of collars <NUM> is coupled to the opposed end of the other coupling pins <NUM>. Thus, each of the collars <NUM> includes a central collar bore 660a that receives the respective end of the coupling pin <NUM> therein (<FIG>). In one example, one end 614a of the coupling pins <NUM> includes a through bore <NUM> that cooperates with corresponding cross-bores 660b defined in each of the collars <NUM>. A pin is received within the cross-bores 660b and the cross-bores 660b to couple the end 614a of the coupling pins <NUM> to the knee plates <NUM>. An opposed end 614b of the coupling pins <NUM> includes a cross-pin <NUM> that cooperates with corresponding cross-bores 660b defined in the collars <NUM>. The cross-pin <NUM> is received within the cross-bores 660b to couple the end 614b of the coupling pins <NUM> to the knee plates <NUM>. Each of the coupling pins <NUM> may also include a bore <NUM>, which receives a pin, to couple the respective hydraulic cylinders <NUM>, <NUM>, <NUM> to the respective one of the arm assembly <NUM> and the second arm assembly <NUM>.

With reference back to <FIG>, the torque transfer tube <NUM> interconnects the arm assembly <NUM> and the second arm assembly <NUM>. The torque transfer tube <NUM> is coupled to each of the arm assembly <NUM> and the second arm assembly <NUM> at the fourth end 512b of the respective second beam <NUM>. With reference to <FIG>, the torque transfer tube <NUM> has a first tube end 506a and the opposite second tube end 506b. The first tube end 506a is coupled to the arm assembly <NUM>, and the second tube end 506b is coupled to the second arm assembly <NUM>. In one example, as discussed with regard to <FIG>, the first tube end 506a is received within and coupled to the second outer jacket <NUM> of the bucket mounting bracket subassembly <NUM>, and the second tube end 506b is received within and coupled to the second outer jacket <NUM> of the bucket mounting bracket subassembly <NUM> via the intermediate plates <NUM> (<FIG>) and the mechanical fasteners <NUM>.

With reference back to <FIG>, the first beams <NUM>, the second beams <NUM>, the vehicle mounting subassemblies <NUM>, the bucket mount bracket subassemblies <NUM>, <NUM>, the knee mounting subassemblies <NUM>, the torque transfer tube <NUM> and the mechanical fasteners <NUM> comprise a kit <NUM> for the HLBAA <NUM>. In one example, in order to assemble the arm assembly <NUM> and the second arm assembly <NUM>, with the first beams <NUM> and the second beams <NUM> formed, the first plate portion <NUM> of the angled intermediate plates <NUM> are inserted into the first chamber <NUM> and the second chamber <NUM> at the second end 510b of the first beams <NUM>. The second plate portion <NUM> of the angled intermediate plates <NUM> are inserted into the first chamber <NUM> and the second chamber <NUM> at the third end 512a of the second beams <NUM>. With reference to <FIG>, the knee plates <NUM> are coupled to the second end 510b of the first beam <NUM> and the third end 512a of the second beam <NUM> such that the locating pins <NUM> are received within the bores 534a, 536a. The mechanical fasteners <NUM> are inserted into each of the through bores 534c, the bores <NUM> and the bores 632a of the knee plates <NUM> to couple the knee plates <NUM> and the angled intermediate plates <NUM> to the first end 510a of the first beam <NUM>. The mechanical fasteners <NUM> are inserted into each of the through bores 536c, the bores <NUM> and the bores 634a of the knee plates <NUM> to couple the knee plates <NUM> and the angled intermediate plates <NUM> to the third end 512a of the second beam <NUM>. The mechanical fasteners <NUM> are inserted into the bores 632a, 634a of the knee plates <NUM> and the bores 532b, 534b of the first beam <NUM> and the second beam <NUM>, respectively, to further couple the first beam <NUM> and the second beam <NUM> to the knee plates <NUM>. The knee mechanical fasteners <NUM> are inserted through the respective knee coupling bores <NUM> and secured with a respective pair of the flange nuts <NUM> to couple the knee plates <NUM> together. Each of the coupling pins <NUM> are inserted into a respective one of the pin coupling bores <NUM>, and the collars <NUM> are positioned about the ends 614a, 614b of the coupling pins <NUM>. The cross-pin <NUM> retains the ends 614b within the respective collar <NUM>, and a pin is received through the bore <NUM> and the cross-bore 660b to retain the ends 614a within the respective collar <NUM>.

With reference to <FIG>, in order to couple the vehicle mounting subassembly <NUM> to the first beam <NUM> of the arm assembly <NUM>, two intermediate plates <NUM> are positioned within the first end 510a of the first beam <NUM>. The sleeve <NUM> is inserted through the bore 532a of the first end 510a of the first beam <NUM>. The lock plates <NUM> are positioned on opposed sides of the first beam <NUM> such that the keyed area 542a of the sleeve <NUM> contacts the keyed area 546a on the lock plates <NUM>. The mechanical fasteners <NUM> are inserted into each of the through bores 532b and the bores <NUM> to couple the lock plates <NUM> and the intermediate plates <NUM> to the first end 510a of the first beam <NUM>. This process is repeated to couple the vehicle mounting subassembly <NUM> to the first beam <NUM> of the second arm assembly <NUM> (<FIG>).

With reference to <FIG>, in order to couple the bucket mount bracket subassembly <NUM> to the second beam <NUM> of the second arm assembly <NUM>, with the jacket <NUM> formed, the bushing <NUM> is coupled to the retaining flanges <NUM>, via welding. The reinforcing flanges <NUM> are coupled to the retaining flanges <NUM>, via welding. The second outer jacket <NUM> is coupled to the jacket <NUM>, via welding, and the supports <NUM> are coupled between the second outer jacket <NUM> and the jacket <NUM>, via welding. The intermediate plates <NUM> are inserted into the fourth end 512b of the second beam <NUM>, and the first outer jacket assembly <NUM> is positioned over the fourth end 512b. The mechanical fasteners <NUM> are inserted through the plurality of bores <NUM>, the first sub-plurality 538a of the plurality of bores <NUM> and into the bores <NUM> of the intermediate plates <NUM> to couple the first outer jacket assembly <NUM> to the second beam <NUM> (<FIG>). The mechanical fasteners <NUM> are also inserted through the plurality of bores <NUM>, the second sub-plurality 538b of the plurality of bores <NUM> and into the bores <NUM> of the intermediate plates <NUM> to couple the first outer jacket assembly <NUM> to the second beam <NUM> (<FIG>). This process is repeated to couple the bucket mount bracket subassembly <NUM> to the second beam <NUM> of the arm assembly <NUM> (<FIG>).

With reference to <FIG>, with the torque transfer tube <NUM> formed, in one example, the intermediate plates <NUM> are inserted into the respective one of the first chamber <NUM> and the second chamber <NUM> at the second tube end 506b. The second tube end 506b is inserted into the second outer jacket <NUM>. The mechanical fasteners <NUM> are inserted through the plurality of bores <NUM>, the plurality of bores <NUM> and into the bores <NUM> of the intermediate plates <NUM> to couple the second outer jacket <NUM> to the torque transfer tube <NUM> (<FIG>). With reference to <FIG>, the intermediate plates <NUM> are inserted into the respective one of the first chamber <NUM> and the second chamber <NUM> at the first tube end 506a. The first tube end 506a is inserted into the second outer jacket <NUM> of the arm assembly <NUM>. The mechanical fasteners <NUM> are inserted through the plurality of bores <NUM>, the plurality of bores <NUM> and into the bores <NUM> of the intermediate plates <NUM> to couple the second outer jacket <NUM> to the torque transfer tube <NUM>.

Claim 1:
A loader boom arm assembly for a loader work vehicle, the loader boom arm comprising:
an arm assembly including:
a first hollow beam (<NUM>) formed from a material having a weight lighter than steel;
a second hollow beam (<NUM>) formed from the material; and
a connection assembly having a first angled intermediate plate (<NUM>) and a pair of knee plates (<NUM>) formed from the material, with a portion of the first angled intermediate plate (<NUM>) received within the first hollow beam (<NUM>) at a first end and a second portion of the first angled intermediate plate (<NUM>) received within the second hollow beam (<NUM>) at a second end, the pair of knee plates (<NUM>) cooperating to define a first channel that receives the end of the first hollow beam (<NUM>) and a second channel that receives the second end of the second hollow beam (<NUM>) such that the first end of the first hollow beam (<NUM>) and the second end of the second hollow beam (<NUM>) are between the pair of knee plates (<NUM>), wherein the first angled intermediate plate (<NUM>) and the pair of knee plates (<NUM>) are configured for interconnecting the first hollow beam (<NUM>) with the second hollow beam (<NUM>) at the first and second ends.