Patent Description:
Wheeled vehicles commonly have suspension systems that that utilize axles and clamp groups to attach an axle to a longitudinally extending suspension component, such as a leaf spring or trailing arm. The suspension component typically is connected at an end to a vehicle frame or directly to a body assembly. For ride quality and efficiency, it is desirable to reduce unsprung weight associated with an axle and the clamp group that mounts the axle to the suspension component.

Truck and other heavy vehicle suspension systems are subjected to substantial forces or loads induced by vehicle acceleration, braking, turning and encountering road obstructions, such as bumps and depressions or shallow holes. The forces are transmitted, for example, from the axle through left side and right side clamp groups, which connect respective leaf springs to the frame or body assembly. In driving under various conditions and over many different surfaces, an axle may encounter numerous inputs that seek to cause the axle to try to move relative to a clamp group, frame or body assembly. The forces typically are in a lateral direction along the axle, or in the radial direction, such as causing rotation of the clamp group about the axle. One key challenge is reacting to the loads generated in the clamp group from cross articulation or roll motion.

Trailing arm suspensions generate auxiliary roll by developing a moment about the axle. During cross articulation or roll motion of the axle, one side of the axle will move upward, while the other side will move downward. For example, in a trailing arm air suspension system, the suspension will pivot about a pivot point at the front of the suspension as it moves through vertical travel. In a cross articulation event, the end of the axle that moves upward will act to twist the axle in a counterclockwise direction, while the end of the axle that moves downward will be twisted in the clockwise direction. Thus, forces may cause the clamp groups to try to translate laterally or rotate about the axle. This presents a challenge to keep the clamp groups firmly mounted in place relative to the axle.

When dealing with a square axle, the flat surfaces provide an advantage of inherently resisting rotation about the axle. With round axles, many prior art installations seek to rigidly connect a spring to the axle by using a heavy welded wrap, with sensitive welded areas requiring high precision, or the use of bulky welded brackets. The tendency of forces to cause an axle coupling to rotate about a round axle can make it particularly difficult to maintain the intended mounted position of a clamp group which seeks to utilize a bolted connection. The bolted connection typically must rely on compression and friction to resist lateral movement along or rotation about the axle. The key challenge in a trailing arm air suspension claim group design is achieving a fixed attachment of the bolted components to the axle and being able to react to the various forces or loads that are transmitted from the axle through the clamp group and ultimately into the frame or body assembly.

The present disclosure addresses shortcomings found in prior art suspension systems that include clamp groups that mount a leaf spring to a round axle.

<CIT> suggests a connection between a vehicle axle and carrier arm, the connection comprising a support part and clamping means. <CIT> does not suggest the use of a locator element between a leaf spring and an upper surface of a spring seat above which the leaf spring is positioned.

This disclosure is directed to a clamp group mounting of a leaf spring to a round axle that includes alignment features. The subject matter includes a locator ring welded to the top of the axle, and a clamp group that is fitted to and benefits from the locator ring by resisting movement laterally and rotationally relative to the axle. The clamp group, leaf spring and round axle bearing the locator ring work together to provide an efficient, relatively light weight, securely mounted assembly, wherein alignment features assist in aligning components during assembly and assist the assembly in effectively handling the forces that otherwise seek to move the spring and clamp group relative to the round axle.

In a first aspect, disclosed herein is a clamp group mounting of a leaf spring to a round axle including alignment features, including a round axle, a leaf spring and a clamp group connecting the leaf spring to the axle. The axle extends laterally and has an arcuate upper surface and arcuate lower surface, while a locator ring having a fish-mouth tapered lower end has the lower end welded to the arcuate upper surface of the axle. The leaf spring extends longitudinally and at least forward or rearward relative to the axle, and has a vertical bore that receives a locator element that extends at least upward or downward from the leaf spring. The clamp group includes a spring seat, top pad and a plurality of fasteners that connect the top pad, leaf spring, and spring seat to the axle. The spring seat further includes a downward facing generally arcuate surface configured to receive the arcuate upper surface of the axle, a recess in the downward facing arcuate surface, wherein the recess receives the locator ring that is welded to the arcuate upper surface of the axle. The spring seat also includes a generally planar upper surface against which the leaf spring is positioned and a recess that receives the locator element extending downward from the leaf spring. The top pad further includes a generally planar lower surface above the leaf spring, and an upper surface that engages the fasteners.

It is to be understood that both the foregoing general description and the following detailed description are exemplary and are provided for purposes of explanation only and are not restrictive to the subject matter claimed. Further features and objects of the present disclosure will become more apparent in the following description of the example embodiments and from the appended claims.

In describing the preferred examples, reference is made to the accompanying drawing figures wherein like parts have like reference numerals, and wherein:.

It should be understood that the drawings are not to scale. While some mechanical details of a clamp group mounting of a leaf spring to a round axle including alignment features, and other plan and section views of the particular components, have been omitted, such details are considered within the comprehension of those skilled in the art in light of the present disclosure. It also should be understood that the present disclosure is not limited to the examples illustrated.

This disclosure presents examples of a clamp group mounting of a leaf spring to a round axle including alignment features, for use in vehicle suspension systems.

Referring to the drawings, a first example embodiment of the claimed subject matter is shown in <FIG>. The reference numeral <NUM> generally designates a first example clamp group mounting of a leaf spring to a round axle including alignment features, for use in vehicle suspension systems. For brevity, the assembly also may be referred to herein as clamp group mounting <NUM>. The figures illustrate the first example includes a round axle <NUM>, a leaf spring <NUM> and a clamp group <NUM> connecting the leaf spring <NUM> to the axle <NUM>. In the relative orientation for installation in a vehicle, the axle <NUM> extends laterally.

As may be seen in <FIG> and <FIG>, the axle <NUM> is round, and therefore, has an arcuate upper surface <NUM> and arcuate lower surface <NUM>. A locator ring <NUM> has a fish-mouth tapered lower end <NUM>, which is best seen in <FIG>, and results in the locator ring <NUM> following the contour of the upper arcuate surface <NUM>. The locator ring <NUM> has an upstanding side wall <NUM> and in this example, is cylindrical, but other shapes may be utilized. As best seen in <FIG>, the locator ring <NUM> is open from above, providing access to form a weld <NUM> between the locator ring <NUM> and the upper arcuate surface <NUM> of the axle <NUM>, which is located inside the locator ring <NUM>. This along with the fish-mouth tapered lower end <NUM> results in a strong weld <NUM> that extends around the inside of the locator ring <NUM>. The interior weld <NUM> yields a clean, unobstructed outer periphery of the locator ring <NUM> and axle <NUM> for consistent assembly to the clamp group <NUM>.

As may be seen in <FIG>, the first example leaf spring <NUM> is a half leaf spring that extends longitudinally and forward relative to the axle <NUM>. However, it will be appreciated that a leaf spring will extend from the axle at least forward or rearward, such as when using a half leaf spring, or may extend in both directions, as when using a full leaf spring. The example leaf spring <NUM> has a rear end <NUM> connected to the clamp group <NUM>. The leaf spring <NUM> extends forward to a front end <NUM> having an eye <NUM> that may be connected to a bracket that would be fixedly attached to the vehicle frame or body. In this example, a leaf spring retainer <NUM> is constructed as a band that is configured to wrap around and capture the leaf spring <NUM>, in the event the spring is fractured. The rear end <NUM> of the example leaf spring <NUM> also includes a vertical bore <NUM> therethrough. The bore <NUM> receives a locator element <NUM>. In this example, the locator element <NUM> is a pin that extends upward from an upper surface <NUM> of the leaf spring <NUM> and downward from a lower surface <NUM> of the leaf spring <NUM>. For ease of assembly, the pin <NUM> may be, for example, a roll pin.

In the first example, the clamp group <NUM> includes a lower clamp <NUM>, spring seat <NUM>, top pad <NUM> and a plurality of fasteners <NUM> that connect the top pad <NUM>, leaf spring <NUM>, spring seat <NUM> and lower clamp <NUM> to the axle <NUM>. The lower clamp <NUM> includes an upward facing generally arcuate surface <NUM> configured to receive the arcuate lower surface <NUM> of the axle <NUM>, at least one upward extending alignment locator <NUM> positioned forward of the upward facing generally arcuate surface <NUM> and at least one upward extending alignment locator <NUM> positioned rearward of the upward facing generally arcuate surface <NUM>, and a plurality of apertures <NUM> through the lower clamp <NUM>. In this example, the lower clamp <NUM> also has a rearward extension <NUM> that includes an air spring seat <NUM>.

The spring seat <NUM> of the first example clamp group <NUM> includes a downward facing generally arcuate surface <NUM> configured to receive the arcuate upper surface <NUM> of the axle <NUM> and having a recess <NUM>. The recess <NUM> receives the locator ring <NUM> that is welded to the arcuate upper surface <NUM> of the axle <NUM>. The spring seat <NUM> includes at least one downward extending alignment locator <NUM> positioned forward of the downward facing generally arcuate surface <NUM> and vertically aligned with the upward extending alignment locator <NUM> of the lower clamp <NUM> positioned forward of the upward facing generally arcuate surface <NUM>, and at least one downward extending alignment locator <NUM> positioned rearward of the downward facing generally arcuate surface <NUM> and vertically aligned with the upward extending alignment locator <NUM> of the lower clamp <NUM> positioned rearward of the of the upward facing generally arcuate surface <NUM>. The spring seat <NUM> further includes a generally planar upper surface <NUM> against which the leaf spring <NUM> is positioned and which further includes a recess <NUM> that receives the locator element <NUM> extending downward from the lower surface <NUM> the leaf spring <NUM>.

The recess <NUM> in the spring seat <NUM> that receives the locator ring <NUM> preferably is shaped and sized to provide a close fit relative to the locator ring <NUM>. In this example, the recess <NUM> is cylindrical and has a diameter slightly larger than the diameter of the locator ring <NUM>. The recess <NUM> is deeper than the height of the side wall <NUM> of the locator ring <NUM>. The shape and sizing of the recess <NUM> relative to the locator ring <NUM> facilitate quick location and assembly of the spring seat <NUM> to the axle <NUM>. The close fit also limits lateral and radial or rotational movement of the spring seat <NUM>, and therefore, the clamp group <NUM>, relative to the axle <NUM>.

In addition, the spring seat <NUM> of the first example preferably includes laterally spaced apart upward extensions <NUM>, between which is located the generally planar surface <NUM> against which the leaf sprint <NUM> is positioned. As may be seen in <FIG>, the upward extensions <NUM> further include inward extending projections <NUM>' that engage the leaf spring <NUM>. The inward extending projections <NUM>' of the spring seat <NUM> are deformed as the clamp group <NUM> is connected to the axle <NUM> and assist in locating and retaining the rear end <NUM> of the leaf spring <NUM>. Still further, the downward facing generally arcuate surface <NUM> of the spring seat <NUM> preferably includes lateral extensions <NUM>. The lateral extensions <NUM> provide a broader generally arcuate surface, which enhances stability of the spring seat <NUM> atop the axle <NUM>.

The top pad <NUM> of this example includes a generally planar lower surface <NUM>. The generally planar lower surface <NUM> includes a recess <NUM> that receives the locator element <NUM> extending upward from an upper surface <NUM> of the leaf spring <NUM>. The top pad <NUM> also includes an upper surface <NUM> that engages the fasteners <NUM>. In this example, each of the plurality of fasteners <NUM> includes a U-shaped bolt <NUM> having a head <NUM> and threaded legs <NUM>. The threaded legs <NUM> of the U-shaped bolts <NUM> are received by the plurality of apertures <NUM> through the lower clamp <NUM>, and receive respective threaded nuts <NUM>. In turn, the top pad upper surface <NUM> that engages the plurality of fasteners <NUM> includes contoured surfaces in the form of saddles that receive the heads <NUM> of the U-shaped bolts <NUM>. It will be appreciated that upon installing the nuts <NUM> on the threaded legs <NUM>, the U-shaped bolts <NUM> are used to draw together the clamp group <NUM>, leaf spring <NUM> and axle <NUM>.

The front and rear alignment locators of the lower clamp <NUM> and spring seat <NUM> provide particular benefits. The downward extending alignment locators <NUM>, <NUM> of the spring seat <NUM> are configured to block lateral movement of the spring seat <NUM> relative to the vertically aligned upward extending alignment locators <NUM>, <NUM> of the lower clamp <NUM>. In the present example, the downward extending alignment locators <NUM>, <NUM> of the spring seat <NUM> include respective channels <NUM>, <NUM> that receive the vertically aligned upward extending alignment locators <NUM>, <NUM> of the lower clamp <NUM>. It will be appreciated that the configurations of the alignment locators could be reversed or modified to otherwise resist relative lateral movement.

In the configuration shown, the downward extending alignment locators <NUM>, <NUM> of the spring seat <NUM> and the vertically aligned upward extending alignment locators <NUM>, <NUM> of the lower clamp <NUM> are shaped and sized to avoid simultaneous contact forward and rearward of the axle <NUM>. Thus, when assembling the clamp group <NUM> and leaf spring <NUM> to the axle <NUM>, as the fasteners <NUM> are installed and tightened, the spring seat <NUM> and lower clamp <NUM> move toward each other and apply compressive force to the axle <NUM>. The locator ring <NUM> holds the spring seat <NUM> in place laterally and with respect to not permitting any rotation of the spring seat <NUM> about the axle <NUM>. Therefore, as the nuts <NUM> are rotated about the threaded legs <NUM> of the U-shaped bolts <NUM> to install the clamp group <NUM>, depending on which nut is tightened first, the lower clamp <NUM> may tilt slightly until there is contact between the front vertically aligned upward extending alignment locator <NUM> of the lower clamp <NUM> and the downward extending alignment locator <NUM> of the spring seat <NUM>, while leaving a gap between rear vertically aligned upward extending alignment locator <NUM> of the lower clamp <NUM> and the downward extending alignment locator <NUM> of the spring seat <NUM>. Alternatively, the lower clamp <NUM> may tilt slightly until there is contact between the rear vertically aligned upward extending alignment locator <NUM> of the lower clamp <NUM> and the downward extending alignment locator <NUM> of the spring seat <NUM>, while leaving a gap between front vertically aligned upward extending alignment locator <NUM> of the lower clamp <NUM> and the downward extending alignment locator <NUM> of the spring seat <NUM>. Once all of the nuts <NUM> are tightened, the lower clamp <NUM> may reverse the initial tilting to contact the opposite vertically aligned locators or may stop in a location where there is a slight gap between both the front and rear vertically aligned locators.

Given that the recess <NUM> in the spring seat <NUM> receives the locator ring <NUM> welded to the axle <NUM>, the spring seat <NUM> effectively will not move laterally relative to the axle <NUM>. In turn, the vertically aligned locators collectively will provide resistance to lateral movement of the lower clamp <NUM> relative to the spring seat <NUM>, regardless of whether they transmit compressive force. In addition, the further combination of the locating features within the spring seat <NUM>, leaf spring <NUM> and top pad <NUM>, along with the fasteners <NUM>, provide resistance to lateral movement of the remainder of the clamp group <NUM> and leaf spring <NUM> relative to the axle <NUM>. The interactions also resist radial or rotational movement of the respective components relative to the axle <NUM>.

Within the clamp group <NUM>, it will be appreciated that the leaf spring retainer <NUM> is located between the top pad <NUM> and the leaf spring <NUM>. This occurs above and below the leaf spring <NUM>. As such, the lower rear end of the leaf spring retainer <NUM> includes an aperture <NUM> through which extends the locator element <NUM> in the form of the roll pin. The upper rear end of the leaf spring retainer <NUM> includes an aperture <NUM>. The generally planar lower surface <NUM> of the top pad <NUM> further includes a downward projection <NUM>, which is received by the aperture <NUM> through the leaf spring retainer <NUM>. In the event of a fractured leaf spring <NUM>, this assembly seeks to ensure that the clamp group <NUM> and leaf spring retainer <NUM> will retain the pieces of the leaf spring <NUM>.

Another advantage of the first example assembly includes that the spring seat <NUM> and top pad <NUM> are configured to be reversibly mounted with respect to forward and rearward directions. In this way, the two components may also be deemed even handed, because they may be installed in a right hand or left hand clamp group. This is intended to simplify installation and avoid installation errors that may be inherent with structures that are right or left handed, or that require a forward or rearward orientation. Thus, the top pad <NUM> of this example includes a second recess <NUM>' in the generally planar lower surface <NUM>, which is capable of receiving the locator element <NUM> extending upward from the upper surface <NUM> of the leaf spring <NUM>, if the top pad <NUM> is reversed during installation. In turn, the spring seat <NUM> further includes a second recess <NUM>' in the generally planar upper surface <NUM>, which is capable of receiving the locator element <NUM> extending downward from the lower surface <NUM> of the leaf spring <NUM>, if the spring seat <NUM> is reversed during installation. The downward projection <NUM> of the top pad is centered, as is the recess <NUM> in the spring seat <NUM> that receives the locator ring <NUM>, also permitting reversible installation.

In a further advantage of the assembly, the locator ring <NUM> is a relatively small, lightweight part that requires a smaller amount of welding and in a less sensitive area than with the prior art use of heavy welded wraps on axles. Use of the locator ring <NUM> also may replace a shimming or machining operation needed to adjust a clamp group for different pinion angles, such as for use on drive axles. Instead of shimming or machining both the top pad and the spring seat for a pinion angle change, the location of the locator ring could be moved about the circumference of the axle to change the established angle of the spring seat.

In the first example shown, as noted above, the recess <NUM> is deeper than the height of the side wall <NUM> of the locator ring <NUM>. By design, this causes the downward compressive load of the spring seat <NUM> generated by the clamp group fasteners <NUM> to be applied by the downward facing generally arcuate surface <NUM> on the arcuate upper surface <NUM> of the round axle <NUM>. Contrary to prior art assemblies that rely only on friction from the compressive load to resist rotation of a clamp group about a round axle, in the present example, the locator ring <NUM> plays an integral role in helping to resist rotation of the clamp group <NUM> about the round axle <NUM>. It will be appreciated in <FIG> that the locator ring <NUM> resists shear load applied by the spring seat <NUM> based both on the weld <NUM> and on the geometry of the interface between the fish-mouth tapered lower end <NUM> of the locator ring <NUM> and the round axle <NUM>. As is apparent in <FIG>, if a rearward load is applied to the locator ring <NUM>, the locator ring <NUM> would have to physically be forced to ride up and over the upper arcuate surface <NUM> of the round axle <NUM>. Thus, the weld <NUM> resists shear load directly, while also holding the locator ring <NUM> down to the axle <NUM>, thereby taking advantage of this further geometric interface to gain further resistance to shear. Still further, while the height of the locator ring <NUM> could be tall enough to cause vertical engagement with the top of the recess <NUM> and that downward force would be applied by the spring seat <NUM>, it is believed that such downward force is not needed and that the lack of such engagement facilitates ease of installation of the spring seat <NUM> as the recess <NUM> receives the locator ring <NUM> on the axle <NUM>.

With respect to materials, it will be appreciated that conventional materials may be used. For example, the lower clamp <NUM>, spring seat <NUM> and top pad <NUM> preferably are constructed of cast iron or steel. The locator ring <NUM> preferably is constructed of extruded steel tubing that is compatible for welding to the axle <NUM>. It will be appreciated that other suitable materials, configurations, methods of construction and fastening may be used for the clamp group mounting.

Stated more broadly, the first example <NUM> of a clamp group mounting of a leaf spring to a round axle including alignment features, includes a round axle <NUM>, a leaf spring <NUM> and a clamp group <NUM> connecting the leaf spring <NUM> to the axle <NUM>. The axle <NUM> extends laterally and has an arcuate upper surface <NUM> and arcuate lower surface <NUM>. A locator ring <NUM> has a fish-mouth tapered lower end <NUM>, and has the lower end <NUM> welded to the arcuate upper surface <NUM> of the axle <NUM>. The leaf spring <NUM> extends longitudinally and at least forward or rearward relative to the axle <NUM>, and further includes a bore <NUM> that receives a locator element <NUM> that extends at least upward or downward from the leaf spring <NUM>. The clamp group <NUM> further includes at least a spring seat <NUM>, top pad <NUM> and a plurality of fasteners <NUM> that connect the top pad <NUM>, leaf spring <NUM>, and spring seat <NUM> to the axle <NUM>. The spring seat <NUM> further includes a downward facing generally arcuate surface <NUM> configured to receive the arcuate upper surface <NUM> of the axle <NUM>, a recess <NUM> in the downward facing arcuate surface <NUM>, and the recess <NUM> receives the locator ring <NUM> that is welded to the arcuate upper surface <NUM> of the axle. The spring seat <NUM> also includes a generally planar upper surface <NUM> above which the leaf spring <NUM> is positioned. The top pad <NUM> further includes a generally planar lower surface <NUM> above the leaf spring <NUM> and an upper surface <NUM> that engages the fasteners <NUM>.

Turning to <FIG>, a second example <NUM> of a clamp group mounting of a leaf spring to a round axle including alignment features, includes a round axle <NUM>, a leaf spring <NUM> and a clamp group <NUM> connecting the leaf spring <NUM> to the axle <NUM>. While it will be appreciated that the clamp groups of the examples herein could be connected to other axle configurations, for convenience in this disclosure, the axle <NUM> is the same as previously described with respect to the first example. Thus, the axle <NUM> extends laterally and has an arcuate upper surface <NUM> and arcuate lower surface <NUM>. As seen in <FIG>, a locator ring <NUM> has a fish-mouth tapered lower end <NUM>, and has the lower end <NUM> welded to the arcuate upper surface <NUM> of the axle <NUM>. The leaf spring <NUM> extends longitudinally and at least forward or rearward relative to the axle <NUM>, and further includes a bore <NUM> that receives a locator element <NUM> that extends at least upward or downward from the leaf spring <NUM>. The clamp group <NUM> further includes at least a spring seat <NUM>, top pad <NUM> and a plurality of fasteners <NUM> that connect the top pad <NUM>, leaf spring <NUM>, and spring seat <NUM> to the axle <NUM>.

The spring seat <NUM> further includes a downward facing generally arcuate surface <NUM> configured to receive the arcuate upper surface <NUM> of the axle <NUM>, a recess <NUM> in the downward facing arcuate surface <NUM>, and the recess <NUM> receives the locator ring <NUM> that is welded to the arcuate upper surface <NUM> of the axle. The spring seat <NUM> also includes a generally planar upper surface <NUM> above which the leaf spring <NUM> is positioned and which further includes a recess <NUM> that receives the locator element <NUM> extending downward from the lower surface <NUM> of the leaf spring <NUM>. The top pad <NUM> further includes a generally planar lower surface <NUM> above the leaf spring <NUM> and an upper surface <NUM> that engages the fasteners <NUM>.

As may be seen in <FIG>, the second example leaf spring <NUM> extends longitudinally forward and rearward relative to the axle <NUM>. As noted previously, it will be appreciated that a leaf spring will extend from the axle <NUM> at least forward or rearward, such as when using a half leaf spring, or may extend in both directions, such as in this example where the rear end <NUM> of the leaf spring <NUM> may provide, for example, an air spring seat. The leaf spring <NUM> extends forward to a front end <NUM> having an eye <NUM> that may be connected to a bracket that would be fixedly attached to the vehicle frame or body. The second example does not show use of a leaf spring retainer, a liner beneath the leaf spring or a bushing within the eye <NUM>. It will be appreciated that any and all of these features are optional and may be used if desired. As shown in <FIG>, this particular example leaf spring <NUM> includes a vertical bore <NUM>, which extends all the way through the leaf spring <NUM>. As previously noted, the bore <NUM> receives a locator element <NUM> and in this example, the locator element <NUM> is a pin that extends upward and downward from the leaf spring <NUM>. As in the first example, for ease of assembly, the pin <NUM> may be, for example, a roll pin.

Similarly to the first example, the recess <NUM> in the spring seat <NUM> of the second example that receives the locator ring <NUM> preferably is shaped and sized to provide a close fit relative to the locator ring <NUM>. In this example, the recess <NUM> is cylindrical and has a diameter slightly larger than the diameter of the locator ring <NUM>. The recess <NUM> is deeper than the height of the side wall <NUM> of the locator ring <NUM>. The shape and sizing of the recess <NUM> relative to the locator ring <NUM> facilitate quick location and assembly of the spring seat <NUM> to the axle <NUM>. The close fit also limits lateral and radial or rotational movement of the spring seat <NUM>, and therefore, the clamp group <NUM>, relative to the axle <NUM>.

In addition, similarly to the first example and as seen in <FIG> and <FIG>, the spring seat <NUM> of the second example preferably includes laterally spaced apart upward extensions <NUM>, between which is located the generally planar surface <NUM> above and against which the leaf sprint <NUM> is positioned. As may be seen in <FIG>, the upward extensions <NUM> further include inward extending projections <NUM>' that engage the leaf spring <NUM>. The inward extending projections <NUM>' of the spring seat <NUM> are deformed as the clamp group <NUM> is connected to the axle <NUM> and assist in locating and retaining the leaf spring <NUM> within the spring seat <NUM>. Still further, the downward facing generally arcuate surface <NUM> of the spring seat <NUM> preferably includes lateral extensions <NUM>. The lateral extensions <NUM> provide a broader generally arcuate surface, which enhances stability of the spring seat <NUM> atop the axle <NUM>.

The top pad <NUM> of the second example includes a generally planar lower surface <NUM>. The generally planar lower surface <NUM> includes a recess <NUM> that receives the locator element <NUM> extending upward from the upper surface <NUM> of the leaf spring <NUM>. The top pad <NUM> includes a plurality of apertures <NUM> through which the threaded legs <NUM> of the fasteners <NUM> extend and an upper surface <NUM> that engages the nuts <NUM> of the fasteners <NUM>. In this example, each of the plurality of fasteners <NUM> includes a U-shaped bolt <NUM> having a head <NUM> and threaded legs <NUM> that receive threaded nuts <NUM>. It will be appreciated that the lower arcuate surface <NUM> of the axle <NUM> receives the heads <NUM> of the inverted U-shaped bolts <NUM>, such that the threaded legs <NUM> extend upward to and through the plurality of apertures <NUM> through the top pad <NUM>. The contoured upper surface <NUM> in this example includes areas that engage the nuts <NUM>. It will be appreciated that upon installing the nuts <NUM> of the fasteners <NUM> on the threaded legs <NUM>, the U-shaped bolts <NUM> are used to draw together the clamp group <NUM>, leaf spring <NUM> and axle <NUM>.

In the second example configuration shown, when assembling the clamp group <NUM> and leaf spring <NUM> to the axle <NUM>, as the fasteners <NUM> are installed and tightened, the top pad <NUM>, leaf spring <NUM>, spring seat <NUM> and axle <NUM> move toward each other and apply compressive force to the axle <NUM>. The locator ring <NUM> holds the spring seat <NUM> in place laterally and with respect to not permitting any rotation of the spring seat <NUM> about the axle <NUM>. Therefore, as the nuts <NUM> are rotated about the threaded legs <NUM> of the U-shaped bolts <NUM> to install the clamp group <NUM>, the projections <NUM>' are deformed to more securely hold the leaf spring <NUM> in the spring seat <NUM>.

Given that the recess <NUM> in the spring seat <NUM> receives the locator ring <NUM> welded to the axle <NUM>, the spring seat <NUM> effectively will not move laterally relative to the axle <NUM>. In addition, the further combination of the locating features within the spring seat <NUM>, leaf spring <NUM> and top pad <NUM>, along with the fasteners <NUM>, provide resistance to lateral movement of the remainder of the clamp group <NUM> and leaf spring <NUM> relative to the axle <NUM>. The interactions also resist radial or rotational movement of the respective components relative to the axle <NUM>.

Similarly to the first example, another advantage of the second example assembly includes that the spring seat <NUM> and top pad <NUM> are configured to be reversibly mounted with respect to forward and rearward directions. In this way, the two components may also be deemed even handed, because they may be installed in a right hand or left hand clamp group. This is intended to simplify installation and avoid installation errors that may be inherent with structures that are right or left handed, or that require a forward or rearward orientation. Thus, the top pad <NUM> of this example includes a second recess <NUM>' in the generally planar lower surface <NUM>, which is capable of receiving the locator element <NUM> extending upward from the leaf spring <NUM>, if the top pad <NUM> is reversed during installation. In turn, the spring seat <NUM> further includes a second recess <NUM>' in the generally planar upper surface <NUM>, which is capable of receiving the locator element <NUM> extending downward from the leaf spring <NUM>, if the spring seat <NUM> is reversed during installation.

As noted with respect to the first example, there are further advantages in using the locator ring <NUM> on the axle <NUM> and with spring seats in the configurations shown in the first and second examples. As described previously, the locator ring <NUM> plays an integral role in helping to resist rotation of the clamp group <NUM> about the round axle <NUM>, while also resisting shear load applied by the spring seat <NUM> based both on the weld <NUM> and on the geometry of the interface between the fish-mouth tapered lower end <NUM> of the locator ring <NUM> and the round axle <NUM>.

Turning to <FIG>, a third example 110a of a clamp group mounting of a leaf spring to a round axle including alignment features, includes a round axle <NUM>, a leaf spring 114a and a clamp group 116a connecting the leaf spring 114a to the axle <NUM>. The third example 110a is essentially similar to the second example shown in <FIG>, except that the leaf spring 114a includes a bore 138a in its upper surface 139a that does not extend through the lower surface 141a of the leaf spring 114a. A locator element 140a is received in the bore 138a in the upper surface 139a of the leaf spring 114a and in this third example, the recess <NUM> in the lower surface <NUM> of the top pad <NUM> also receives the locator element 140a extending upward from the upper surface 139a of the leaf spring 114a. The construction of the locator element 140a of this example may be similar to that which was described for the locator elements <NUM>, <NUM> of the previous examples, but is shorter in length. The structure of the remainder of the third example is labeled with the same reference numbers and is the same as the second example <NUM> of <FIG>, so the previous description is incorporated herein and need not be repeated.

Turning to <FIG>, a fourth example 110b of a clamp group mounting of a leaf spring to a round axle including alignment features, includes a round axle <NUM>, a leaf spring 114b and a clamp group 116b connecting the leaf spring 114b to the axle <NUM>. The fourth example 110b is essentially similar to the second example shown in <FIG>, except that the leaf spring 114b includes a bore 138b in its lower surface 141b that does not extend through the leaf spring 114b. A locator element 140b is received in the bore 138b in the lower surface 141b of the leaf spring 144b and in this fourth example, the recess <NUM> in the upper surface <NUM> of the spring seat <NUM> receives the locator element 140b extending downward from the lower surface 141b of the leaf spring 114b. The construction of the locator element 140b of this example may be of similar to that which was described for the locator elements <NUM>, <NUM> of the first and second examples, but is shorter in length. The structure of the remainder of the fourth example is labeled with the same reference numbers and is the same as the second example <NUM> of <FIG>, so the previous description is incorporated herein and need not be repeated.

Claim 1:
A clamp group mounting (<NUM>, <NUM>) of a leaf spring (<NUM>, <NUM>) to a round axle (<NUM>) including alignment features, comprising:
a round axle (<NUM>), a leaf spring (<NUM>, <NUM>) and a clamp group (<NUM>, <NUM>) connecting the leaf spring (<NUM>, <NUM>) to the axle (<NUM>);
the axle (<NUM>) extending laterally and having an arcuate upper surface (<NUM>) and arcuate lower surface (<NUM>);
a locator ring (<NUM>) having a fish-mouth tapered lower end (<NUM>), and having the lower end welded to the arcuate upper surface (<NUM>) of the axle (<NUM>);
the leaf spring (<NUM>, <NUM>) extending longitudinally and at least forward or rearward relative to the axle (<NUM>), and further comprising a bore (<NUM>, <NUM>) that receives a locator element (<NUM>, <NUM>) that extends at least upward or downward from the leaf spring (<NUM>, <NUM>);
the clamp group (<NUM>, <NUM>) comprising a spring seat (<NUM>, <NUM>), top pad (<NUM>, <NUM>) and a plurality of fasteners (<NUM>, <NUM>) that connect the top pad (<NUM>, <NUM>), leaf spring (<NUM>, <NUM>), and spring seat (<NUM>, <NUM>) to the axle (<NUM>);
the spring seat (<NUM>, <NUM>) further comprising:
a downward facing generally arcuate surface (<NUM>, <NUM>) configured to receive the arcuate upper surface (<NUM>) of the axle (<NUM>);
a recess (<NUM>, <NUM>) in the downward facing arcuate surface (<NUM>, <NUM>), wherein the recess (<NUM>, <NUM>) receives the locator ring (<NUM>) that is welded to the arcuate upper surface (<NUM>) of the axle (<NUM>);
a generally planar upper surface (<NUM>, <NUM>) above which the leaf spring (<NUM>, <NUM>) is positioned and further comprising a recess (<NUM>) that receives the locator element (<NUM>, <NUM>) extending downward from the leaf spring (<NUM>, <NUM>);
the top pad (<NUM>, <NUM>) further comprising:
a generally planar lower surface (<NUM>, <NUM>) above the leaf spring (<NUM>, <NUM>);
an upper surface (<NUM>, <NUM>) that engages the fasteners (<NUM>, <NUM>).