Patent ID: 12251964

DETAILED DESCRIPTION

The present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Like numbers refer to like elements throughout, and prime notation is used to indicate similar elements in alternative embodiments.

Referring initially toFIGS.1-5, a wheel assembly30to be coupled to a hub21of a vehicle20includes an inner rim31to be coupled to the hub of the vehicle. The inner rim31may be coupled to the hub21of the vehicle20with fasteners through fastener receiving passageways24within an inwardly extending flange ring25. Illustratively, the flange ring25is centered laterally within the inner rim31, but may be positioned in another arrangement based upon a desired mounting arrangement with the hub21. Other coupling arrangements may be used to couple the inner rim31to the hub21.

The wheel assembly30also includes an outer rim33surrounding the inner rim31. The outer rim33may have a diameter of at least 3.5 feet, and more particularly, at least 4 feet. Those skilled in the art will appreciate that with a diameter of at least 3.5 feet, the wheel assembly30, and more particularly, the outer rim33may be particularly advantageous for relatively large or heavy machinery, such as, for example, earth excavation equipment and mining equipment. A typical overall outer diameter of such a wheel assembly may be 100 inches or greater. The outer rim33may have an increased thickness portion38along an inner circumference thereof. The increased thickness portion38may be provided by welding a separate reinforcing ring in position or it may be integrally formed with the outer rim33, for example.

Referring additionally toFIG.6, a disk40is coupled to the inner rim31and defines a closeable gap41with adjacent interior portions of the outer rim33. The disk40also includes weight-reduction openings43therein. The weight-reduction openings43each illustratively have a generally round or circular shape. The weight-reduction openings43may have another shape, such as oblong, hexagonal, and/or contoured for stress reduction, for example. Those skilled in the art will appreciate that having a reduced weight may increase the fuel efficiency of the vehicle20and/or may increase the lifespan of wheel assembly30.

The disk40also includes spaced apart thickened wall portions42. The spaced apart thickened wall portions42may be on both the inboard and outboard surfaces of the disk40. Each thickened wall portion42may provide increased strength or support as a coupling or attachment point, and/or to accept increased stresses thereat as will be described in further detail below. The thickened wall portions42may be provided by welding an additional metal body in position, for example, or they may be integrally formed with the disk40. Those skilled in the art will appreciate that the thickened wall portions42may be in the form of solid extensions (i.e., integrally formed with and/or a build-up of) of the disk40, and/or discrete bodies, for example, that function as mechanical stiffeners.

The inner rim31, outer rim33, and disk40may be formed of a high strength and rugged material, such as steel. As will be appreciated by those skilled in the art other materials may also be used.

Gas springs50are operatively coupled between the inner rim31and the outer rim33. Each gas spring50may be a double-acting gas spring, for example, and include a double-acting gas cylinder51and an associated piston52. Of course, in some embodiments, each gas spring50may be a single-acting gas spring. More than one type of gas spring may be used. The gas springs50may be air springs and/or nitrogen springs, for example. The gas springs50may include other gasses as well.

Illustratively, the gas springs50are arranged in pairs on opposite sides of the disk40. More particularly, the gas springs50diverge outwardly from the inner rim31to the outer rim33. A respective attachment bracket53afor each gas spring50is coupled to a respective thickened wall portion42of the disk40, for example, adjacent the inner rim31. Each attachment bracket53amay include a generally U-shaped or V-shaped base bracket that receives an end of the piston52therein (e.g., between the arm of the U- or V-shaped bracket). A fastener fastens the end of the piston52of the gas spring50to the base bracket and thus, each gas spring is coupled adjacent the respective thickened wall portion42of the disk40and adjacent the inner rim31. A similar attachment bracket53bis coupled to the outer rim33adjacent inboard and outboard surfaces. Accordingly, the gas springs50are pivotably coupled between the inner and outer rims31,33.

As will be appreciated by those skilled in the art, the gas springs50provide a gas suspension for relative movement between the inner rim31and the outer rim33. The gas springs50have an operating stroke the permits the disk40to define a mechanical stop. In other words, the gas springs50maintain the outer rim33spaced apart from the inner rim31. However, if pressure on any gas spring50causes the gas spring to reach its limit under load or the gas spring fails, the disk40may act as a mechanical stop to limit relative movement between the inner and outer rims31,33. In other words, the disk40and gas springs50may considered as providing a run-flat capability.

Initial charge pressures of the gas springs50, for example, when the gas springs are in the form of double-acting gas springs, will now be described, for example, with respect to initial pressures in the wheel assembly30when there are little or no external loads applied thereto (i.e., free-wheel). In particular, the chamber associated with the piston-side of the cylinder51is typically smaller (e.g., by about 10%) than the chamber associated with the full-bore side of the cylinder. Thus, when the piston52is centered within the cylinder51so that there is a relatively equal stroke in tension and compression, the piston-side chamber pressure is higher (e.g., by about 10%) than the full-bore side chamber pressure.

Thus, while equal pressure charging of the double-acting gas cylinder51may be convenient, it results in an offset piston52, which, in turn, results in an offset force to be applied to assemble the gas springs50within the wheel assembly30. To accomplish this, the inner and outer rims31,33may be temporarily fixed in a rigid jig. However, using a rigid jig may make replacement of the gas springs50in the field increasingly difficult. Thus, to address increased ease of in-field replacement of the gas springs50, weld-on rings may be coupled to the inner and outer rims31,33and to turn-buckles to temporarily lock the inner and outer rims in place. A similar arrangement may be used in-shop as well, as will be appreciated by those skilled in the art.

Accordingly, the result is a pre-stressed inner rim31suspension to the outer rim33. The pre-stressing may ensure that the lateral stops44,45(described below) are not active or under pressure. With different charge pressures, the suspension can be pre-compressed. While tension suspension and compression suspension may be considered equivalent, tension suspension may be particularly advantageous over compression suspension, as will be appreciated by those skilled in the art.

Another assembly technique may include applying a higher charge pressure (e.g., about 10% more) at the piston-side to center the piston52at about the half-stroke position. This results in there being no initial load on the gas spring50at the wheel assembly30and facilitates assembly without the temporary fixing within a jig. Thus, the wheel assembly30may be considered to be neither pre-stressed, nor pre-compressed, but neutral. For example, a higher full-bore side chamber pressure may be applied (e.g., about 10% higher) than the piston side chamber pressure. Gas may be released from the full-bore side chamber until the piston52becomes centered relative to full-stroke. Alternatively, a higher piston-side chamber pressure may be applied (e.g., about 10% higher) than the full-bore side chamber pressure. Releasing gas from the cylinder51may be considered easier than surcharging, however, this may use more gas (e.g., nitrogen) than other approaches resulting in an increased cost.

The wheel assembly30also includes inboard lateral stops44carried by an inboard surface of the outer rim33. More particularly, the inboard lateral stops44are positioned adjacent the thickened wall portion42. The wheel assembly30also includes outboard lateral stops45carried by an outboard surface of the outer rim33. Similarly to the inboard lateral stops44, the outboard lateral stops45are adjacent the thickened wall portion42. Each thickened wall portion42is positioned between a pair of inboard and outboard lateral stops44,45. The inboard and outboard lateral stops44,45together with the outer rim33may conceptually be considered to be in the form of an L-shaped bracket. Illustratively, the inboard and outboard lateral stops44,45each has a support plate61(e.g., having a rectangular shape) that is transverse to the outer rim33and has triangular side members62.

As will be appreciated by those skilled in the art, the inboard and outboard lateral stops44,45cooperate to limit relative lateral movement of the disk40and the outer rim33. In other words, turning, for example, of the vehicle20may cause lateral movement of the disk40relative to the outer rim33. The inboard and outboard lateral stops44,45may limit the amount of lateral movement of the disk40relative to the outer rim33to thereby maintain structural integrity of the wheel assembly30. Of course, the inboard and outboard lateral stops44,45include other and/or additional components or elements that cooperate to limit relative lateral movement of the disk40and the outer rim33.

Referring now additionally toFIGS.7-16, the wheel assembly30illustratively includes tread assemblies70carried by the outer rim33. Each tread assembly70includes a tread member support71. Each tread member support71may be in the form of an arcuate metal plate with openings69a,69btherein (FIG.10) and may couple to an outer circumference of the outer rim33. One or more of the tread member supports71may be a flat plate in other embodiments. A center one of the openings69bmay receive a pin83therein as will be described in further detail below. In some embodiments, the tread member support71may not be metal, such as steel. Those skilled in the art will appreciate that given the arcuate shape of the tread member support71, several tread assemblies70are coupled in end-to-end relation around the outer rim33.

A tread member72is coupled or bonded, for example, glued, fastened, etc., to the tread member support71, and a clamping arrangement73removably securing the tread member support to the outer rim33. There may be more than one tread member72bonded to the tread member support71. The tread member72includes a resilient body85that has tread pattern86defined in an outer surface thereof. The resilient body85may include rubber or other material, which may be selected based upon desired friction, traction, or other characteristics, for example, based upon the use of the vehicle20. The material of the tread member72may a metal such as steel, in other embodiments. The tread pattern86may similarly be selected based upon desired traction or other characteristics, for example, based upon the use of the vehicle20. Moreover, referring briefly toFIG.17, in another embodiment of a tread assembly70′, each tread member72′ and tread member support71′ may include a common material integrally formed as a monolithic unit, which may or may not be metal, such as steel. In other words, each tread member72′ and tread member support71′ define a single unit or body of the same material (e.g., an all-metal tread member support and tread member).

Further details of the clamping arrangement73will now be described. The clamping arrangement73illustratively includes inboard clamping members74coupled to the inboard side of the outer rim33. The inboard clamping members74each have a first slotted recess75receiving adjacent portions of the tread member support71. The inboard clamping members74are removably coupled to the inboard side of the outer rim33. The inboard clamping members74are illustratively arranged in an end-to-end relation and each coupled to adjacent respective portions of the outer rim33. In some embodiments, the inboard clamping members74may be fixed, for example, welded or fixedly coupled, to the inboard side of the outer rim33and/or a single inboard clamping member may be used.

The inboard clamping members74are coupled to the inboard side of the outer rim33by way of fasteners79a, for example, threaded fasteners to facilitate removal and replacement, for example, when tread members72wear or it is desirable to replace the tread members. The threaded fasteners79amay extend through openings89in the inboard clamping members74and engage corresponding threaded openings81ain the outer rim33.

The clamping arrangement73also illustratively includes outboard clamping members76coupled to the outboard side of the outer rim33. Similar to the inboard clamping member74, the outboard clamping members76each has a second slotted recess77therein receiving adjacent portions of the tread member support71. The outboard clamping members76are removably coupled to the outboard side of the outer rim33. The outboard clamping members76are illustratively arranged in an end-to-end relation and each coupled to adjacent respective portions of the outer rim33. In some embodiments, a single outboard clamping member76may be coupled to the outboard side of the outer rim33and extend the circumference of the outer rim.

The outboard clamping members76are coupled to the outboard side of the outer rim33by way of fasteners, for example, threaded fasteners to facilitate removal and replacement, for example, when tread members72wear, or it is desirable to replace the tread members. The threaded fasteners may extend through openings78in the outboard clamping members76and engage corresponding threaded openings81bin the outer rim33.

The tread member support71and adjacent portions of the outer rim33(e.g., along the outer circumference) define a retaining feature therebetween. The retaining feature is illustratively in the form of or includes a pin83carried by the outer rim33and a pin-receiving opening84in the tread member support71. The pin83and the pin-receiving opening84may advantageously prevent relative movement between the tread member support71and the outer rim33, and also facilitate replacement (e.g., easy alignment) of the tread members72, for example, thereby reducing downtime of the vehicle20.

Referring now briefly toFIGS.18and19, in another embodiment, the inboard and outboard lateral stops44″,45″ are biased toward the disk40″. More particularly, the inboard and outboard lateral stops44″,45″ each includes an arm46″ extending radially inward from the inboard and outboard interior surfaces of the outer rim33″. A transverse arm47″ is coupled to an end of each arm46″. Each transverse arm47″ carries a plug48″ that is biased toward the disk40″ by a biasing member49″, for example, a spring, such as a coil spring. Other biasing arrangements may be used. Elements labeled24″,25″,30″,31″,41″,43″,45″,50″,51″,52″,70″,76″,79a″,79b″,85″,86″, and98b″ are similar to those respectively numbered elements described above without double prime notation.

Referring now additionally toFIG.20, one or more of the gas springs50may have a controllable response. For example, the gas springs50may have either or both of a controllable gas pressure and a controllable gas volume. Any number of the gas springs50may have a controllable response. By having a controllable response, each of the gas springs50may be operated or controlled as will be explained in further detail below, for example, with respect to certain operating conditions and/or environments. More particularly, the wheel assembly30may include a local controller87(e.g., including a processor and/or circuitry) that is coupled to the gas springs50. The local controller87may be coupled to any number of gas springs50. The local controller87may be carried within the outer rim33, for example, inside the outer rim, or by the disk40. The local controller87may be carried by other elements of the wheel assembly30. The local controller87may also include respective actuators and/or valves to control the response of the gas springs50and cooperate with an accumulator91also coupled to the gas springs to act as a pressure and/or volume storage reservoir for gas springs.

The wheel assembly30may also include a local sensor88coupled to the local controller87. The local controller87may control (e.g., monitor and/or adjust) the operating response of the gas springs50based upon the local sensor88. For example, the local controller87may adjust the pressure or volume of the gas springs50without controlling the operation (e.g., extend/retract) of the gas springs. The local controller87may also adjust, for example, alternatively or additionally, the operation (e.g., extend/retract) of the gas springs50.

The local sensor88may be an acceleration sensor, for example, and cooperate with the local controller87to control the controllable response of the gas springs50based upon a sensed acceleration (e.g., braking, turning, etc.). The local sensor88may be another type of sensor, for example, a force sensor. There may be more than one local sensor88. In some embodiments, the local controller87may cooperate with the local sensor88to generate a notification, for example, when a sensed value exceeds a threshold. The notification may be communicate within the vehicle20(e.g., in the cab) or remotely from the vehicle. In other words, the local controller87may cooperate with the local sensor88independently from or without controlling the operating response of the gas springs50.

Referring now briefly toFIG.21, in another embodiment, a remote controller92′″ may be carried remote from the wheel assembly30, for example, within a wheel well of the vehicle20or within the truck cab. The remote controller92′″ may cooperate with the local sensor88′″ or other sensor, for example, remote from the wheel assembly30. The remote controller92′″ may also cooperate with the local controller87′″ to effectuate a change in the operating response of the gas springs50′″. Wiring from the remote controller92′″ may extend to the local controller87′″, and/or the remote controller may wirelessly communicate with the local controller. Elements labeled51′″,52′″, and91′″, are similar to those respectively numbered elements described above without triple prime notation.

Those skilled in the art will appreciate that the local controller87controls the operating response of the gas springs50while the wheel assembly30is rolling. For example, if the vehicle20, during motion thereof, makes a relatively sharp turn or applies the brakes, the local controller87may independently control the operating response of each or selected ones of the gas springs50based upon the turn or braking (e.g., increase pressures in the gas springs of front wheel assemblies). Other motion of the vehicle20may cause changes in the operating response, such as, for example, failure of any of the gas springs50, debris in the tread members72, and/or contact of the disk40with the outer rim33.

Referring now additionally toFIGS.22and23, the wheel assembly30may include inboard and outboard removable sidewalls93,94. The inboard and outboard removable sidewalls93,94are each illustratively in the form of a round or circular cover carried by the outer rim33. More particularly, the inboard and outboard removable sidewalls93,94each has an opening95,105therein to permit, for example, coupling of the wheel assembly30to the hub21. Respective flanges103,106extend inwardly within the openings95,105. The inboard and outboard removable sidewalls93,94may each be coupled to the inboard and outboard sides of the outer rim33by way of fasteners97a,97band to the inner rim31also by way of fasteners107a,107b. The fasteners97a,97bmay be received through fastener receiving passageways along the outer circumference of each of the inboard and outboard removable sidewalls93,94and fasten to corresponding respective aligned threaded passageways98a,98bin the outer rim33. The threaded passageways98a,98bin the outer rim33form a second, inner row of threaded passageways, with the outer row of threaded passageways81a,81bfor securing the clamping arrangement73to the outer rim with fasteners79a(FIG.7).

Referring now toFIG.24, in another embodiment, the outboard removable sidewall94″″ may have a removable inner panel101″″ that when removed, by way of respective fasteners102″″, permit access to inner interior of the wheel assembly30″″, for example, the inner rim. Similar to the outboard removable sidewall described above, the outboard sidewall94″″ couples by way of fasteners97b″″ to the outer rim inside of or adjacent the outboard clamping members76″″ (which are secured to the outer rim also by way of fasteners79b″″). Elements labeled51″″,52″″,91″″,70″″ and72″″ are similar to those respectively numbered elements described above without quadruple prime notation.

As will be appreciated by those skilled in the art, the inboard and outboard removable sidewalls93,94may be particularly advantageous for reducing the amount of dust and/or debris within the interior of the wheel assembly30, for example, between the inner and outer rims31,33. Accordingly, elements of the wheel assembly30, for example, the disk40and gas springs50, may have increased protection against damage, for example, from environmental elements (e.g., rocks, dust, dirt, water, etc.), and thus may have a longer service life. In some embodiments, the wheel assembly30may not include the inboard and outboard removable sidewalls93,94.

Referring now toFIG.25, in another embodiment, sensors188a,188bsense relative movement, such as by sensing a distance between the inner rim131and the outer rim133. More particularly, the sensors188a,188bmay be in the form of three-axis accelerometers. Of course, the sensors188a,188bmay be other types of sensors, for example, laser distance sensors, ultrasonic sensors, linear variable differential transformer (LVDT) sensors, and/or other contact or non-contact displacement sensors.

When the sensors188a,188bare in the form of three-axis accelerometers, one of the accelerometers is carried by the inner rim131defining an inner accelerometer, while another accelerometer is carried by the outer rim133defining an outer accelerometer. The inner and outer accelerometers188a,188bare aligned by way of their axes so that relative movement between the inner and outer rims131,133as a sensed acceleration can be translated, for example, by way of a distance measuring circuit187coupled to the accelerometers188a,188b(e.g., integrating each acceleration).

The sensors188a,188bmay each be different from one another. For example, an ultrasonic sensor may be used with the inner and outer accelerometers188a,188bto sense or measure displacement (e.g., tangential to the inner and outer accelerometers). Of course, a laser distance sensor may be used as an alternative to the ultrasonic sensor or in conjunction with the ultrasonic sensor and/or the inner and outer accelerometers188a,188b. The measuring circuit187may be carried by the wheel assembly, the vehicle, or remote from the vehicle.

A temperature sensor188cmay be carried by the outer rim133(e.g., within or on an inner surface of the outer rim) and coupled to the measuring circuit187to sense a temperature within the wheel assembly, for example, when a cover or inboard or outboard removable sidewalls are used. A humidity sensor188dmay alternatively or additionally be carried by the outer rim133(e.g., within or on an inner surface of the outer rim) and coupled to the measuring circuit187to sense humidity within the wheel assembly, for example, when a cover or inboard or outboard removable sidewalls are used. Data representing the humidity, acceleration or distance data (e.g., raw data or processed), and/or temperature may be remotely communicated from the wheel assembly or vehicle via a wireless transmitter190coupled to the measuring circuit187for downstream processing.

Referring now toFIGS.26-31, in another embodiment, the wheel assembly230includes a rigid inboard cover ring293coupled to an inboard side of the outer rim233, for example, by way of fasteners207a. The rigid inboard cover ring293extends radially inward toward the inner rim231. More particularly, the rigid inboard cover ring293defines a radially and axially extending inboard gap with the inner rim231. A flexible inboard seal209a, for example, in the form of an inboard bellows seal, is coupled between the rigid inboard cover ring293and the inner rim231, for example, by way of respective fasteners208ato couple to the inner rim (e.g., used with a clamping arrangement212a, such as, for example, metal banding or other material). The flexible inboard seal209acloses the radially and axially extending inboard gap and permits relative movement between the inner rim231and the outer rim233. Illustratively, the inboard bellows seal209ahas a Z-shaped cross-section. The flexible inboard seal209amay be a different kind of flexible seal, for example, and may have a different shaped cross-section. The flexible inboard seal209amay include rubber and/or an elastomeric material. The flexible inboard seal209amay include other and/or additional materials.

The wheel assembly230also includes a rigid outboard cover ring294coupled to an outboard side of the outer rim233, for example by way of fasteners207b. The rigid outboard cover ring294extends radially inward toward the inner rim231. More particularly, the rigid outboard cover ring294defines a radially and axially extending outboard gap with the inner rim231. A flexible outboard seal209b, for example, in the form of an outboard bellows seal, is coupled between the rigid outboard cover ring294and the inner rim231, for example, by way of respective fasteners208b(and respective clamping arrangement212b, for example). The flexible inboard seal209bcloses the radially and axially extending outboard gap and permits relative movement between the inner rim231and the outer rim233. Illustratively, the outboard bellows seal209ahas a Z-shaped cross-section. The flexible outboard seal209bmay be a different kind of flexible seal, for example, and may have a different shaped cross-section.

Still further, a respective pleated cover210(e.g., bellows), is coupled to each of the gas springs250. In particular, the pleated covers210cover the piston so that dust, dirt, and/or debris may be kept from the piston (FIG.26). A reduced amount of dust, dirt, and/or debris in contact with the piston may increase the operational lifespan of the gas springs250, as will be appreciated by those skilled in the art.

The flexible outboard seal209bmay include rubber and/or an elastomeric material. The flexible outboard seal209bmay include other and/or additional materials. A rigid outboard cover ring294and a flexible outboard seal209bmay not be used in some embodiments. Elements labeled224,225,240,241,242,243,244,245,262,281aand283are similar to respective elements labeled24,25,40,41,42,43,44,45,62,81aand83(i.e. decremented by 200) described above.

Referring now particularly toFIG.31, similar to the embodiments described above with respect toFIGS.22-24, a rigid removable inset panel or inner panel201may be carried within the rigid outboard cover ring294(e.g., secured to the wheel assembly by way of fasteners297b) so that when removed, by way of respective fasteners202, permits access to inner interior of the wheel assembly230, for example, the inner rim. Access ports or removable covers211aare spaced apart within the rigid outboard cover ring294. The removable covers211amay be clear acrylic, for example, to permit visual inspection within the wheel assembly without removing the rigid removable inset panel201and/or to permit ease of access to sensors, controller, and/or other circuitry, for example, as described above. A similar arrangement including the access ports or removable covers211bmay be used as the rigid inboard cover ring294, for example, as described above (FIGS.26-27). The access ports211a,211bmay be not used in all embodiments.

The embodiments of the wheel assembly30described herein may be particularly advantageous with respect to a conventional pneumatic tire, for example, particularly on a relatively large vehicle (e.g., heavy machinery). A conventional pneumatic tire, for example, for heavy machinery has a relatively high cost and, in some environments, may have a relatively short usage life. Moreover, particularly with heavy machinery, a failure of a conventional tire may cause be associated with an increased chance of damage to the heavy machinery. Even still further, a failure of a conventional tire may cause the vehicle20to be inoperable or out of service for a relatively long time period, thus resulting in a financial loss and loss of productivity, particularly for certain types of vehicles or heavy machinery that operate around the clock.

The wheel assembly30may address these shortcomings of a conventional tire. More particularly, the wheel assembly30may have a lower operational cost with increased performance (e.g., by way of the controllable operating response of the gas springs50). Additionally, the wheel assembly30may be field serviceable, meaning that tread members72may be replaced in the field. Repairs, for example, in the case of failed gas springs50, may also be repaired in the field.

A method aspect is directed to a method of making a wheel assembly30to be coupled to a hub21of a vehicle20. The method includes operatively coupling a plurality of gas springs50between an inner rim31to be coupled to the hub21of the vehicle20and an outer rim33surrounding the inner rim. The method also includes mounting a plurality of tread assemblies70to the outer rim33. Each tread assembly70may be mounted by bonding at least one tread member72to a tread member support71and positioning a clamping arrangement73to removably secure the tread member support to the outer rim33.

Another method aspect is directed to a method of making wheel assembly30to be coupled to a hub21of a vehicle20. The method includes operatively coupling a plurality of gas springs50between an inner rim31to be coupled to the hub21of the vehicle20and an outer rim33surrounding the inner rim31to provide a gas suspension for relative movement between the inner rim and the outer rim. The method also includes coupling a disk40to the inner rim31that defines a closeable gap41with adjacent interior portions of the outer rim33to define a mechanical stop to limit relative movement between the inner rim and outer rim.

Another method aspect is directed to a method of making a wheel assembly30to be coupled to a hub21of a vehicle20. The method includes operatively coupling a plurality of gas springs50operatively between an inner rim31to be coupled to the hub21of a vehicle20and an outer rim33surrounding the inner rim to provide a gas suspension for relative movement between the inner rim and the outer rim. The method also includes coupling a disk40coupled to the inner rim31and defining a closeable gap41with adjacent interior portions of the outer rim33. The method may further include positioning a plurality of inboard lateral stops44carried by an inboard interior surface of the outer rim33, and positioning plurality of outboard lateral stops45carried by outboard interior surface of the outer rim so that the plurality of inboard lateral stops and plurality of outboard lateral stops cooperate to limit relative lateral movement of the disk40and the outer rim.

Another method aspect is directed to a method of making a wheel assembly30to be coupled to a hub21of a vehicle20. The method includes operatively coupling a plurality of gas springs50between an inner rim31to be coupled to the hub21of the vehicle20and an outer rim33surrounding the inner rim. At least one gas spring50from among the plurality thereof has a controllable operating response. The method also includes coupling a local controller87to the at least one gas spring50to control the operating response of the at least one gas spring.

Another related method aspect is directed to a method of operating a wheel assembly30to be coupled to a hub21of a vehicle20. The wheel assembly30includes an inner rim31to be coupled to the hub21of the vehicle20, an outer rim33surrounding the inner rim, and a plurality of gas springs50operatively coupled between the inner rim and the outer rim. At least one gas spring50from among the plurality thereof has a controllable operating response. The method includes operating a local controller87coupled to the at least one gas spring50to control the operating response of the at least one gas spring.

Another method aspect is directed to a method of sensing relative movement, e.g. a distance, between an inner rim131of a wheel assembly30to be coupled to a hub21of a vehicle20and an outer rim133of the wheel assembly. The inner rim131is to be coupled to the hub21of a vehicle20and the outer rim133surrounding the inner rim. The wheel assembly30includes a plurality of gas springs50operatively coupled between the inner rim131and the outer rim133and permitting relative movement therebetween. The method includes using at least one sensor188a,188bto sense the relative movement between the inner and outer rims131,133during operation or rolling of the wheel assembly.

Another method aspect is directed to a method of making a wheel assembly30to be coupled to a hub21of a vehicle20. The method includes coupling an inner rim231to be to the hub21of the vehicle20and positioning an outer rim233surrounding the inner rim. The method also includes operatively coupling a plurality of gas springs50between the inner rim231and the outer rim233to permit relative movement therebetween. The method further includes coupling a rigid inboard cover ring293to an inboard side of the outer rim233and extending radially inward toward the inner rim231and coupling a flexible inboard seal209abetween the rigid inboard cover ring and the inner rim.

Referring now toFIG.32, in another embodiment of the wheel assembly330, an outer ring340or disk is coupled to the outer rim333. This is in contrast to embodiments described above where the ring or disk40is coupled to the inner rim331. In the present embodiments, the outer ring340being coupled to the outer rim333defines a closeable gap341with adjacent interior portions of the inner rim331to define a mechanical stop to limit relative movement between the inner and outer rims. Similarly to the embodiments described above, the outer rim333may have a diameter of at least 3.5 feet.

Similarly to the embodiments above, the outer ring340also includes weight-reduction openings343therein. The weight-reduction openings343each illustratively have a generally round or circular shape. The weight-reduction openings343may have another shape, such as oblong, hexagonal, and/or contoured for stress reduction, for example.

Gas springs350are operatively coupled between the inner rim331and the outer rim333. Each gas spring350may be a double-acting gas spring, for example, and include a double-acting gas cylinder351and an associated piston352. Of course, in some embodiments, each gas spring350may be a single-acting gas spring. More than one type of gas spring350may be used. The gas springs350may be air springs and/or nitrogen springs, for example. The gas springs350may include other gasses as well.

Illustratively, the gas springs350are arranged in pairs on opposite sides of the outer ring340. More particularly, the gas springs350diverge outwardly from the inner rim331to the outer rim333. A respective attachment bracket353for each gas spring350is coupled to the inner rim331. Each attachment bracket353may include a generally U-shaped or V-shaped base bracket that receives an end of the piston352therein (e.g., between the arm of the U- or V-shaped bracket). A fastener fastens the end of the piston352of the gas spring350to the base bracket353. A similar attachment bracket353is coupled to the outer rim333adjacent inboard and outboard surfaces. Accordingly, the gas springs350are pivotably coupled between the inner and outer rims331,333.

Similar to the embodiments described above, as will be appreciated by those skilled in the art, the gas springs350provide a gas suspension for relative movement between the inner rim331and the outer rim333. The gas springs350have an operating stroke the permits the outer ring340to define a mechanical stop. In other words, the gas springs350maintain the outer rim333spaced apart from the inner rim331. However, if pressure on any gas spring350causes the gas spring to reach its limit under load or the gas spring fails, the outer ring340may act as a mechanical stop to limit relative movement between the inner and outer rims331,333. In other words, the outer ring340and gas springs350may be considered as providing a run-flat capability. Since the gas springs350are similar to the gas springs described with respect to the embodiments above, further details of the gas springs need not be described.

Referring additionally toFIG.33, the wheel assembly330also includes inboard lateral stops344coupled between an inboard side of the outer rim333and an inboard side of the inner rim331. More particularly, the inboard lateral stops344are illustratively in the form of hinge retainers or scissor hinges. Each inboard lateral stop344includes inboard hinge brackets346a,346band inboard elastomeric bodies347, for example, urethane bodies, carried by the hinge bracket adjacent the outer rim333. More particularly, the inboard elastomeric bodies347couple to an outer lateral stop mounting bracket349athat is coupled to the outer rim333. The inboard hinge brackets346a,346bare coupled by way of a hinge pin348. In some embodiments, an outer lateral stop mounting bracket349amay not be used as the inboard elastomeric bodies347may couple, for example, directly, to the outer ring340, for example, by way of a hinge pin348. The hinge bracket346bis coupled to the inner rim331by way of an inner lateral stop mounting bracket349bcoupled to the inner rim by a hinge pin348coupled to the inner lateral stop mounting bracket. In some embodiments, the hinge bracket346bmay couple to the inner rim331without an inner lateral stop mounting bracket349b, for example, directly to the inner rim by way of a hinge pin348.

The wheel assembly330also includes outboard lateral stops345coupled between an outboard side of the outer rim333and an outboard side of the inner rim331. More particularly, the outboard lateral stops345are illustratively in the form of hinge retainers or scissor hinges that are similar to the inboard lateral stops344. That is, each outboard lateral stop345includes outboard hinge brackets346a,346band outboard elastomeric bodies347, for example, urethane bodies, carried by the hinge bracket adjacent the outer rim333. More particularly, the outboard elastomeric bodies347couple to an outer lateral stop mounting bracket349athat is coupled to the outer rim333. The hinge brackets346a,346bare coupled by way of a hinge pin348. In some embodiments, an outer lateral stop mounting bracket349amay not be used as the outboard elastomeric bodies347may couple, for example, directly, to the outer ring340, for example, by way of a hinge pin348. The hinge bracket346bis coupled to the inner rim331by way of an inner lateral stop mounting bracket349bcoupled to the inner rim by a hinge pin348coupled to the inner lateral stop mounting bracket. In some embodiments, the hinge bracket346bmay couple to the inner rim331without an inner lateral stop mounting bracket349b, for example, directly to the inner rim by way of a hinge pin348.

Those skilled in the art will appreciate that the inboard and outboard lateral stops344,345, similarly to the lateral stops described with respect to the embodiments above, limit relative movement between the outer rim333(and thus the outer ring340) and the inner rim331. In other words, turning, for example, of the vehicle may cause lateral movement of the outer ring340relative to the inner rim331. The inboard and outboard lateral stops344,345may limit the amount of lateral movement of the outer ring340relative to the inner rim331to thereby maintain structural integrity of the wheel assembly330. Of course, the inboard and outboard lateral stops344,345may include other and/or additional components or elements that cooperate to limit relative lateral movement of the outer ring340and the outer inner rim331.

Other elements illustrated, such as, for example, fastener receiving passageways324within inwardly extending flange ring325, the tread assemblies370, and the clamping arrangement373including the inboard clamping members374and fasteners379a, are similar to corresponding elements described with respect to the embodiments described above. Accordingly, these elements as they relate to the present embodiments need no further discussion.

A method aspect is directed to method of making a wheel assembly330to be coupled to a hub of a vehicle. The method includes operatively coupling a plurality of gas springs350between an inner rim331to be coupled to the hub of the vehicle and an outer rim333surrounding the hub to provide a gas suspension for relative movement between the inner rim and the outer rim. The method may also include coupling an outer ring340to the outer rim333that defines a closeable gap341with adjacent interior portions of the inner rim to define a mechanical stop to limit relative movement between the inner rim and outer rim.

Referring now toFIGS.34-35, in another embodiment of the wheel assembly330′, an outer ring340a′ is coupled to the outer rim333′ and an inner ring340b′ is coupled to the inner rim331′. The inner ring340b′ defines a closeable gap341′ with adjacent portions of the outer ring340a′ to define a mechanical stop to limit relative movement between the inner and outer rims331′,333′. Similarly to the embodiments described above, the outer rim333′ may have a diameter of at least 3.5 feet.

The outer ring340a′ has an outer ring body363a′ and an outer ring edge cap364a′ carried by an inner edge of the outer ring body. The inner ring340b′ also includes an inner ring body363b′ and an inner ring edge cap364b′ carried by an outer edge of the inner ring body. The inner and outer ring edge caps364a′,364b′ provide an increased surface area mechanical stop to limit the relative movement between the inner and outer rims331′,333′.

Similarly to the embodiments above, the outer ring340a′ also includes weight-reduction openings343a′ therein. The inner ring340b′ also includes weight-reduction openings343b′ therein. The weight-reduction openings343a′,343b′ each illustratively have a generally round or circular shape. The weight-reduction openings343a′,343b′ may have another shape, such as oblong, hexagonal, and/or contoured for stress reduction, for example.

Gas springs350′ are operatively coupled between the inner rim331′ and the outer rim333′. Each gas spring350′ may be a double-acting gas spring, for example, and include a double-acting gas cylinder351′ and an associated piston352′. Of course, in some embodiments, each gas spring350′ may be a single-acting gas spring. More than one type of gas spring350′ may be used. The gas springs350′ may be air springs and/or nitrogen springs, for example. The gas springs350′ may include other gasses as well.

Illustratively, the gas springs350′ are arranged in pairs on opposite sides of the outer ring340a′. More particularly, the gas springs350′ diverge outwardly from the inner rim331′ to the outer rim333′. A respective attachment bracket353′ for each gas spring350′ is coupled to the inner ring340b′, and more particularly, the inner ring body363b′. Each attachment bracket353′ may include a generally U-shaped or V-shaped base bracket that receives an end of the piston352′ therein (e.g., between the arm of the U- or V-shaped bracket). A fastener fastens the end of the piston352′ of the gas spring350′ to the base bracket. A similar attachment bracket353′ is coupled to the outer rim333′ adjacent inboard and outboard surfaces. Accordingly, the gas springs350′ are pivotably coupled between the inner and outer rims331′,333′.

Similar to the embodiments described above, as will be appreciated by those skilled in the art, the gas springs350′ provide a gas suspension for relative movement between the inner rim331′ and the outer rim333′. The gas springs350′ have an operating stroke the permits the outer ring340a′ to define a mechanical stop. In other words, the gas springs350′ maintain the outer rim333′ spaced apart from the inner rim331′. However, if pressure on any gas spring350′ causes the gas spring to reach its limit under load or the gas spring fails, the outer ring340a′ may act as a mechanical stop to limit relative movement between the inner and outer rims331′,333′. In other words, the outer ring340a′ and gas springs350′ may be considered as providing a run-flat capability. Since the gas springs350′ are similar to the gas springs described with respect to the embodiments above, further details of the gas springs need not be described.

Referring additionally toFIG.37, the wheel assembly330′ also includes inboard lateral stops344′ carried between an inboard side of the outer rim333′ and an inboard side of the inner rim331′. More particularly, the inboard lateral stops344′ are illustratively in the form of hinge retainers or scissor hinges. Each inboard lateral stop344′ includes inboard hinge brackets346a′,346b′ and an inboard elastomeric body347′, for example, a urethane body, carried by the hinge bracket adjacent an inboard side of the outer ring340a′. The inboard elastomeric body347′ couples to a wall portion of outer ring340a′ by way of a hinge pin348′. The hinge brackets346a′,346b′ are coupled together by way of a hinge pin348′. The hinge bracket346b′ is coupled to a wall portion of the inner ring340b′ by way of a hinge pin348′.

The wheel assembly330′ also includes outboard lateral stops345′ carried between an outboard side of the outer rim333′ and an outboard side of the inner rim331′. More particularly, the outboard lateral stops345′ are illustratively in the form of hinge retainers or scissor hinges. Each outboard lateral stop345′ includes outboard hinge brackets346a′,346b′ and an outboard elastomeric body347′, for example, a urethane body, carried by the hinge bracket adjacent an outboard side of the outer ring340a′. The outboard elastomeric body347′ couples to a wall portion of outer ring340a′ opposite a corresponding portion of the inboard lateral stop344′ by way of a hinge pin348′, which may be shared with the hinge pin of the inboard lateral stop. The hinge brackets346a′,346b′ are coupled by way of a hinge pin348′. The hinge bracket346b′ is coupled to a wall portion of the inner ring340b′ opposite the corresponding portion of the inboard lateral stop344′ by way of a hinge pin348′, which may be shared with the hinge pin of the inboard lateral stop. As will be appreciated by those skilled in the art, the inboard lateral stops344′ are structurally similar to the outboard lateral stops345′, just positioned opposite (i.e., on the inboard side) to the outboard lateral stops.

Those skilled in the art will appreciate that the inboard and outboard lateral stops344′,345′ limit relative movement between the outer ring340a′ and the inner ring340b′. In other words, turning, for example, of the vehicle may cause lateral movement of the outer ring340a′ relative to the inner ring340b′. The inboard and outboard lateral stops344′,345′ may limit the amount of lateral movement of the outer ring340a′ relative to the inner ring340b′ to thereby maintain structural integrity of the wheel assembly330′. Of course, the inboard and outboard lateral stops344′,345′ may include other and/or additional components or elements that cooperate to limit relative lateral movement between the outer ring340a′ and the outer inner rim331′.

Other elements illustrated, such as, for example, the tread assemblies370′ and the clamping arrangement373′ including the inboard clamping members374′ and fasteners379a′, are similar to corresponding elements described with respect to the embodiments described above. Accordingly, these elements as they relate to the present embodiments need no further discussion.

A method aspect is directed to a method of making a wheel assembly330′ to be coupled to a hub of a vehicle. The method includes operatively coupling a plurality of gas springs350′ between an inner rim331′ to be coupled to the hub of the vehicle and an outer rim333′ surrounding the hub to provide a gas suspension for relative movement between the inner rim and the outer rim. The method also includes coupling an outer ring340a′ to the outer rim333′ and coupling an inner ring340b′ to the inner rim331′ that defines a closeable gap341′ with adjacent interior portions of the outer ring to define a mechanical stop to limit relative movement between the inner rim and outer rim.

Referring now toFIGS.38-39, in another embodiment of the wheel assembly430, an outer ring440or disk is coupled to the outer rim433adjacent an inboard side of the outer rim. The outer ring440being coupled to an inboard side of the outer rim433defines a closable gap441with adjacent interior portions of an inboard side of the inner rim431to define a mechanical stop to limit relative movement between the inner and outer rims. Similarly to the embodiments described above, the outer rim433may have a diameter of at least 3.5 feet.

Gas springs450are operatively coupled between the inner rim431and the outer rim433. Each gas spring450may be a double-acting gas spring, for example, and include a double-acting gas cylinder451and an associated piston452. Of course, in some embodiments, each gas spring450may be a single-acting gas spring. More than one type of gas spring450may be used. The gas springs450may be air springs and/or nitrogen springs, for example. The gas springs450may include other gasses as well.

Illustratively, the gas springs450are arranged on an outboard side of the outer ring440. As will be appreciated by those skilled in the art, the position of the gas springs450on an outboard side of the outer ring440and the position of the outer ring adjacent in inboard side of the inner and outer rims431,433may advantageously permit relatively easy access to serviceable parts, such as, for example, the gas springs, hydraulic dampers460, and lateral stops444. In other words, the outer ring440may not inhibit or block access to the serviceable parts, when for example, an outboard cover of the wheel assembly430is removed for service.

A respective attachment bracket453for each gas spring450is coupled to the inner rim431. Each attachment bracket453may include a generally U-shaped or V-shaped base bracket that receives an end of the piston452therein (e.g., between the arm of the U- or V-shaped bracket). A fastener fastens the end of the piston452of the gas spring450to the attachment bracket453. A similar attachment bracket453is coupled to the outer rim433. Accordingly, the gas springs450are pivotably coupled between the inner and outer rims431,433.

Similar to the embodiments described above, as will be appreciated by those skilled in the art, the gas springs450provide a gas suspension for relative movement between the inner rim431and the outer rim433. The gas springs450have an operating stroke the permits the outer ring440to define a mechanical stop. In other words, the gas springs450maintain the outer rim433spaced apart from the inner rim431. However, if pressure on any gas spring450causes the gas spring to reach its limit under load or the gas spring fails, the outer ring440may act as a mechanical stop to limit relative movement between the inner and outer rims431,433. In other words, the outer ring440and gas springs450may be considered as providing a run-flat capability. Since the gas springs450are similar to the gas springs described with respect to the embodiments above, further details of the gas springs need not be described.

The wheel assembly430includes lateral stops444coupled between the inner and outer rims431,433to limit relative lateral movement between the inner and outer rims. The lateral stops444are illustratively coupled adjacent an inboard side of the outer rim433and an inboard side of the inner rim431. The lateral stops444are illustratively in the form of hinge retainers or scissor hinges. The lateral stops444may be similar to the lateral stops described above and include elastomeric bodies. Of course, the lateral stops444may include other components and/or may be coupled alternatively or additionally adjacent an outboard side of the inner and outer rims431,433.

Hydraulic dampers460are illustratively operatively coupled between the inner and outer rims431,433. The hydraulic dampers460may be in the form of oil dampers, for example. Of course, all or some of the dampers may include other, additional, or different fluids therein. Each hydraulic damper460includes a double-acting hydraulic cylinder461and an associated piston462.

A respective hydraulic damper460is coupled adjacent a corresponding gas spring450. In other words, each hydraulic damper460is aligned side-by-side (e.g., at about the same angle between the gas spring and the inner and outer rims431,433or the coupling location) with a corresponding gas spring450. Thus, for a wheel assembly430that includes six (6) gas springs450, there would be six (6) hydraulic dampers460. Similarly to the gas springs450, respective mounting brackets469couple each hydraulic damper460to the inner and outer rims431,433, respectively.

As will be appreciated by those skilled in the art, the hydraulic dampers460may dampen or reduce vibrations and movements caused by traversing the ground or by movement of the wheel assembly430over the ground. Moreover, as double-acting hydraulic dampers460, each hydraulic damper advantageously dampens on both extension and compression.

Cable ties480are coupled to opposing ends of the gas springs450. More particularly, each cable tie or safety cable480is coupled to a corresponding mounting bracket453of each gas spring450. When a given gas spring's450operating stroke is retracted (i.e., the piston452is retracted within the cylinder451), the corresponding safety cable480has slack. However, if a given gas spring450exceeds its operating stroke limitations (i.e., the piston452extends outwardly from the cylinder451beyond operational limits), for example, if the gas spring malfunctions, the safety cable480would become taught and may thus prevent the gas piston from separating from the cylinder as during a failure.

A method aspect is directed to a method of making a wheel assembly430to be coupled to a hub of a vehicle. The method includes operatively coupling a plurality of gas springs450between an inner rim431to be coupled to the hub of the vehicle and an outer rim433surrounding the hub to provide a gas suspension for relative movement between the inner rim and the outer rim. The method also includes coupling an outer ring440adjacent an inboard side of the outer rim433, the outer ring defining a closeable gap441with adjacent interior portions of an inboard side of the inner rim431to define a mechanical stop to limit relative movement between the inner rim and outer rim. The plurality of gas springs450are operatively coupled on an outboard side of the outer ring440.

Referring now additionally toFIGS.40-41, the wheel assembly430includes a tread assembly470that includes a tread body472and a clamping arrangement473. The tread body472is carried by the outer rim433and has an outer contact surface475, an inboard side, and an outboard side. The tread body472may include rubber, for example. Of course, the tread body472may include other and/or additional materials. The tread body472also has a first plurality of embedded passageways478below the outer contact surface475and extending between the inboard and outboard sides. More particularly, the first plurality of embedded passageways478, which illustratively have a circular shape, open outwardly to the inboard and outboard sides. In other words, the first plurality of embedded passageways478may conceptually be considered tunnels within the tread body472that extend between the inboard and outboard sides.

The tread body472also includes a second plurality of circumferential grooves476extending downward from the outer contact surface475and intersecting the first plurality of embedded passageways478. The second plurality of circumferential grooves476may have a v-shape with the wider opening of v-shape being in the outer contact surface475. Illustratively, there are five circumferential grooves476, but those skilled in the art will appreciate there may be any number of circumferential grooves, for example, based upon the type of contact surface and usage application.

The tread body472also includes a third plurality of frustoconical opening features477extending inwardly from the outer contact surface475. While frustoconical opening features477are illustrated, the opening features may have another shape, for example, cylindrical. The third plurality of frustoconical opening features477are illustratively aligned along the corresponding ones of the second plurality of circumferential grooves476. In some embodiments, the third plurality of frustoconical opening features477may not be aligned with the second plurality of circumferential grooves476. For example, the third plurality of frustoconical opening features477may be spaced about the outer contact surface475, and/or may extend downwardly from the outer contact surface to intersect the first plurality of embedded passageways478.

The tread assembly470may also include a tread body support471. The tread body support471may be in the form of a metal plate (e.g., an arcuate metal plate) that couples to an outer circumference of the outer rim433. The tread body472may be coupled or bonded, for example, glued, fastened, etc., to the tread body support471.

A clamping arrangement or clamping member473removably secures the tread body472to the outer rim. The clamping arrangement473couples to the inboard and outboard sides of the outer rim433, respectively, by way of fasteners479, for example, threaded fasteners to facilitate removal and replacement, for example, when the tread body472wears or it is desirable to replace the tread body. The threaded fasteners479may extend through openings in the clamping arrangement473and engage corresponding threaded openings in the outer rim433. Other types of clamping arrangements or members, for example, such as those described above with respect to other embodiments, may be used. Those skilled in the art will appreciate that while a single tread body support471, the tread body472, and clamping arrangement473have been described herein, there may be more than one tread body support, tread body, and clamping arrangement coupled in end-to-end relation around the outer rim433, for example, as illustrated.

A method aspect is directed to a method of making a wheel assembly430to be coupled to a hub of a vehicle. The method may include operatively coupling a plurality of gas springs450between an inner rim431to be coupled to the hub and an outer rim433surrounding the hub to provide a gas suspension permitting relative movement between the inner rim and the outer rim. The method may further include coupling a tread body472to be carried by the outer rim433and having an outer contact surface475, an inboard side, and an outboard side. The tread body472may also have a first plurality of embedded passageways478below the outer contact surface475and extending between the inboard and outboard sides, and a second plurality of circumferential grooves476extending downward from the outer contact surface and intersecting the first plurality of embedded passageways.

Other elements illustrated, such as, for example, fastener receiving passageways424within inwardly extending flange ring425, the clamping arrangement473, and the sidewall covers and cover assemblies401are similar to corresponding elements described with respect to the embodiments described above. Further details of sidewall cover assemblies401are described in U.S. patent application Ser. No. 16/886,065 the entire contents of which are hereby incorporated by reference. Accordingly, these elements as they relate to the present embodiments need no further discussion.

Referring now additionally toFIGS.42-43in another embodiment, the gas springs450′ each have a cylinder body451′ and an associated piston452′ movable within the cylinder body. The piston452′ divides the cylinder body451′ into first and second gas chambers454a′,454b′.

A respective hydraulic damper460′ is mounted on each gas spring450′ and operatively coupled between the first and second gas chambers454a′,454b′. Each hydraulic damper460′ includes a damper cylinder body461′, and first and second pistons462′ movable within the damper cylinder body. The first and second pistons462′ of each hydraulic damper460′ define first and second damper gas chambers463a′,463b′ and first and second hydraulic fluid chambers464a′,464b′.

The first and second damper gas chambers463a′,463b′ are coupled to respective ones of the first and second gas chambers454a′,454b′ of the gas springs450′, for example, by way of respective conduits455′,465′. More particularly, a gas spring conduit455′ and a hydraulic damper conduit465′ may be aligned and mateably coupled when the hydraulic damper460′ is mounted to the gas spring450′. A seal456′, for example, a sealing washer, may be between or at an interface between the gas spring conduit455′ and a hydraulic damper conduit465′. Of course, other mating arrangements to permit gas communication between the first and second gas chambers454a′,454b′ and the first and second damper gas chambers463a′,463b′. The hydraulic damper460′ illustratively has ports457′ at opposing ends.

A chamber wall466′ divides the damper cylinder body461′ into the first and second hydraulic fluid chambers464a′,464b′. The chamber wall466′ illustratively has an orifice467′ therein permitting hydraulic fluid to pass between the first and second hydraulic fluid chambers464a′,464b′.

Cylinder clamps458′ illustratively mount the respective hydraulic damper460′ to a corresponding gas spring450′ in a piggy-back configuration. Each cylinder clamp458′ has a figure eight shape. Each cylinder clamp458′ may conceptually be in the form of a double pipe clamp that permits the gas spring450′ and hydraulic damper460′ to be slidably received within the respective openings and tightened into place using respective fasteners459′. While a cylinder clamp458′ is illustrated, those skilled in the art will appreciate that other and/or additional types of cylinder clamps may be used.

A method aspect is directed to a method of making a wheel assembly430to be coupled to a hub of a vehicle. The method may include operatively coupling a plurality of gas springs450′ between an inner rim431to be coupled to the hub of the vehicle and an outer rim433surrounding the hub to provide a gas suspension for relative movement between the inner rim and the outer rim. Each of the plurality of gas springs450′ may include a cylinder body451′ and an associated piston452′ moveable therein and dividing the cylinder body into first and second gas chambers454a′,454b′. The method may also include mounting a respective hydraulic damper460′ on each gas spring450′ and operatively coupled between the first and second gas chambers454a′,454b′.

Referring now toFIGS.44-45, in another embodiment, a mine material processing apparatus510includes a rotatable drum511to process mine material. Wheel assemblies530a-530f, for example, as described herein, are illustratively configured for rotation of the rotatable drum511.

Similar to other wheel assemblies, each wheel assembly530a-530fincludes an inner rim531, an outer rim533surrounding the inner rim, and gas springs550operatively coupled between the inner and outer rims. An outer ring540is coupled to the outer rim533and, as described in embodiments above, defines a closable gap541with adjacent portions of the inner rim531to define a mechanical stop to limit movement between the inner and outer rims. Other elements of the wheel assembly530aillustrated but not specifically described, such as, for example, the dampers560, the tread body572, the lateral stops544, the gas spring and damper mounting brackets553,569, and the fastener receiving passageways524within inwardly extending flange ring525, for example, are similar to those described above.

A drive motor515is coupled to the inner rim531of wheel assemblies530a,530b. More particularly, the drive motor515may be coupled to the wheel assemblies via the fastener receiving passageways524within inwardly extending flange ring525. The drive motor515may include an electric motor coupled to a drivetrain, for example. In some embodiments, the drive motor515may directly drive the wheel assembly530a-530f. Other wheel assemblies530c-530fmay be considered idle wheel assemblies and may not be driven, but rather are permitted to rotate freely or independently of a drive motor515. In some embodiments, a respective drive motor515may be coupled to the inner rim531of each wheel assembly530a-530f.

Referring now toFIGS.46-48, in another embodiment, a tread body572′, for example, a rubber tread body, is carried by the outer rim533′. The tread body572′ has an outer contact surface575′, an inboard side, and an outboard side. Embedded passageways578′ are below the outer contact surface575′ and extend between the inboard and outboard sides. The embedded passageways578′ are illustratively circular. Of course, the embedded passageways578′ may be another shape.

Circumferential grooves576′, for example, having a U-shape, extend downward from outer contact surface575′ to expose the embedded passageways578′ at intersections579′ thereof. Opening features577′ extend inwardly from the outer contact surface575′. The opening features577′ are illustratively round or have a circular shape. The opening features577′ may have another shape.

As will be appreciated by those skilled in the art, the tread body572′ illustratively has a circular shape to permit changing of tread body by slidably removing the tread body from outer rim533′. Replacement of the tread body572′ is performed by sliding the tread body over the outer rim533′. In some embodiments, the tread body572′ may not be bonded to the outer rim533′, since as use in a mine material processing apparatus (i.e., to rotate the rotatable drum), forces that typically occur on vehicle, for example, from relatively hard braking, may be reduced. Elements illustrated but not specifically described, such as, for example, the outer ring540′ and the gas spring mounting brackets553′, are similar to those described above.

Referring now toFIG.49, in another embodiment of a wheel assembly530″ for mine material processing, each wheel assembly may be segmented, for example. More particularly, the inner rim531″ may include arcuate inner rim segments532a″-532d″ coupled together, for example, in end-to-end relation, to define a circular inner rim.

Each arcuate inner rim segment532a″-532d″ has end flanges518a″,518b″ at opposing ends. More particularly, a respective inner flange518a″,518b″ is at each end of an arcuate inner rim segment532a″-532d″ for coupling adjacent ones of the arcuate inner rim assemblies in end-to-end relation. Each inner flange518a″,518b″ has openings or inner flange fastener receiving passageways therein to receive inner flange fasteners therethrough when aligned with an adjacent end flange.

The wheel assembly530″ also includes an outer rim533″ having a circular shape. Similar to the circular inner rim531″ the circular outer rim533″ is segmented, or defined by coupled together arcuate outer rim segments539a″-539h″. While eight arcuate outer rim segments539a″-539h″ are illustrated, it will be appreciated by those skilled in the art that there may be any number of arcuate outer rim segments, for example, and, as illustrated, the number of arcuate outer rim segments need not match the number of arcuate inner rim segments532a″-532d″.

Each arcuate outer rim segment539a″-539h″ also has end flanges516a″,516b″ at opposing ends. More particularly, a respective outer flange516a″,516b″ is at each end of the arcuate outer rim segment539a″-539h″ for coupling adjacent ones of the arcuate outer rim segments. Each outer flange516a″,516b″ has openings or outer flange fastener receiving passageways517″ therein to receive outer flange fasteners therethrough when aligned with an adjacent outer flange. Elements illustrated, but not specifically described, for example, fastener receiving passageways524″ within inwardly extending flange ring525″, and further details of a segmented wheel assembly, are described in U.S. patent application Ser. No. 16/865,231, the entire on contents of which are herein incorporated by reference.

A method aspect is directed to a method of processing mine material. The method includes operating a plurality of wheel assemblies520a-520fto rotate a rotatable drum511to process the mine material. Each wheel assembly520a-520fincludes an inner rim531, an outer rim533surrounding the inner rim, and a plurality of gas springs550operatively coupled between the inner rim and the outer rim.

Another method aspect is directed to a method of making an apparatus510for processing mine material. The method includes arranging a plurality of wheel assemblies520a-520ffor rotation of a rotatable drum511to process the mine material. Each wheel assembly520a-520fincludes an inner rim531, an outer rim533surrounding the inner rim, and a plurality of gas springs550operatively coupled between the inner rim and the outer rim.

Referring now toFIG.50, in another embodiment, a wheel assembly630illustratively includes an inner rim631to be coupled to a hub of a vehicle. An outer rim633surrounds the hub, and more particularly, the inner rim631. An outer ring640or disk is coupled to the outer rim633adjacent an inboard side of the outer rim. The outer ring640being coupled to an inboard side of the outer rim633defines a closable gap641with adjacent interior portions of an inboard side of the inner rim631to define a mechanical stop to limit relative movement between the inner and outer rims.

Gas springs with associated integral hydraulic dampers650are operatively coupled between the inner rim631and the outer rim633to provide a suspension for relative movement between the inner and outer rims. The gas springs with associated integral hydraulic dampers650, similar to embodiments of the gas springs described above, have an operating stroke the permits the outer ring640to define a mechanical stop. As will be appreciated by those skilled in the art, the gas springs with associated integral hydraulic dampers650function similarly to the gas springs and hydraulic dampers described to provide the suspension and provide damping.

Referring now toFIGS.51-54, further details of the gas springs with associated integral hydraulic dampers650will now be described. Each gas spring with associated integral hydraulic damper650includes a first cylinder body651aand a second cylinder body651b. The second cylinder body651bis slidable within the first cylinder body651a. In other words, the second cylinder body651bmay conceptually be considered a piston movable within with the first cylinder body651a.

A first seal656is carried by an end of the of second cylinder body651b. The first seal656defines first and second gas chambers654a,654bwithin the first cylinder body651a. A shaft662is coupled to an end of the first cylinder body651and extends within the first cylinder body and into the second cylinder body651b. The shaft662defines a hydraulic fluid chamber663within the second cylinder body651b. Each gas spring with associated integral hydraulic damper650also includes an enlarged orifice body668coupled to the shaft662to define a hydraulic damper with the second cylinder body651b. The enlarged orifice body668has orifices669therein to permit the flow of hydraulic fluid therethrough. While three orifices669are illustrated, there may be any number of orifices.

A flow restrictor666is carried within the second cylinder body651b. The flow restrictor666illustratively includes an orifice667therein to permit hydraulic fluid to pass therethrough.

Gas ports657a,657bare respectively coupled to the first and second gas chambers654a,654bof each gas spring with associated integral hydraulic damper650. A hydraulic fluid port657cis coupled to the second cylinder body651b. While two gas ports and one hydraulic fluid port is illustrated, those skilled in the art will appreciate that there may be more any number of gas and hydraulic fluid ports657a-657c.

Each gas spring with associated integral hydraulic damper650also includes first and second mounting brackets653a,653bcoupled to the first and second cylinder bodies651a,651b, respectively. The first and second mounting brackets653a,653b, similar to the mounting brackets described above, are for mounting the gas springs with associated integral hydraulic dampers650between the inner and outer rims631,633.

Those skilled in the art will appreciate that the gas springs with associated integral hydraulic dampers650may advantageously provide a gas suspension and a damper function while saving space within the wheel assembly (i.e., between the inner and outer rims631,633). More particularly, the gas springs with associated integral hydraulic dampers650provide this functionality by way of a Kelvin coupling mechanism, as will be appreciated by those skilled in the art.

Referring briefly toFIG.55, in another embodiment, the shaft662′, the first seal656′, an end of the first cylinder body651a′, and the end of the second cylinder body651b′ opposite the first seal may be threaded. By provided threads on the shaft662′, the first seal656′, and the ends of the first and second cylinder bodies651a′,651b′, the gas springs with associated integral hydraulic dampers650′ may be adjusted for a desired response with respect to the spring and damper. A volume compensator (e.g., in the form of a reservoir and diaphragm, not illustrated) may be spring loaded, in which case, a charge post may not be desirable. Other elements illustrated but specifically described, for example, the first cylinder body651a′, the enlarged orifice body668′ and associated orifices669′, the first and second gas chambers654a′,654b′, the second cylinder wall666′ and associated orifice667′, the hydraulic fluid chamber663′, the ports657a′-657c′, and the first and second mounting brackets653a′,653b′ are similar to those described above.

A method aspect is directed to method of making a wheel assembly630to be coupled to a hub of a vehicle. The method includes operatively coupling a plurality of gas springs with associated integral hydraulic dampers650between an inner rim631to be coupled to the hub of the vehicle and an outer rim633surrounding the hub to provide a suspension for relative movement between the inner rim and the outer rim. Each of the plurality of gas springs and associated integral hydraulic dampers650includes a first cylinder body651aand a second cylinder body651bslidable therein, a first seal656carried by an end of the second cylinder body defining first and second gas chambers within the first cylinder body, and a shaft662extending within the first cylinder body and into the second cylinder defining a hydraulic fluid chamber. Each of the gas springs with associated integral hydraulic dampers650also includes an enlarged orifice body668coupled to the shaft662defining a hydraulic damper with the second cylinder body651b.

Referring now toFIG.56, in another embodiment, a wheel assembly730illustratively includes an inner rim731to be coupled to a hub of a vehicle. An outer rim733surrounds the hub, and more particularly, the inner rim731. A tread770is carried by the outer rim.

Gas springs750are operatively coupled between the inner rim731and the outer rim733to provide a suspension for relative movement between the inner and outer rims. As will be appreciated by those skilled in the art, the gas springs750may include elements described herein to implement the damping, and/or additional dampers (not shown) coupled between the inner and outer rims731,733may be used to provide damping.

An inboard flange771extends radially outward from an inboard side of the inner rim731to define an inboard mechanical stop. The inboard flange771includes a flange body772and flange lips773a,773bextending outwardly from the flange body. The radially inner flange lip773ais coupled to the inner rim by way of fasteners777.

An outboard flange774extends radially outward from an outboard side of the inner rim731to define an outboard mechanical stop. Similar to the inboard flange772, the outboard flange774includes a flange body775and flange lips776a,776bextending outwardly from the flange body. The radially inner flange lip776ais coupled to the inner rim731by way of fasteners777.

Inboard and outboard sidewalls781,782extend radially inward from the outer rim733. The inboard and outboard sidewalls781,782are removably coupled to the inboard and outboard sides of the outer rim733with fasteners783, for example. Of course, the inboard and outboard sidewalls781,782may be coupled to the outer rim733using other and/or coupling techniques. The inboard and/or outboard sidewalls781,782may be removed to provide access to the gas springs750and other hardware that may be positioned between the inner and outer rims731,733.

The inboard and outboard sidewalls781,782define an overlap area with the inboard and outboard flanges771,774, respectively. An elastomeric body784is in each overlap area. A fabric (e.g., felt-like) or other material body785may also be coupled to the elastomeric body784in the overlap area. The elastomeric bodies784and fabric bodies785may be in sliding contact with either of the flanges771,774or sidewalls781,782. The elastomeric bodies784and the fabric bodies785may provide a seal to help keep contaminants from the space between the inner and outer rims731,733while allowing the relative movement therebetween. The sidewalls781,782, for example, with the elastomeric and fabric bodies784,785may provide between 2% and 4% damping, for example, in the lateral direction.

Inboard and outboard elastomeric rings786,787are illustratively carried by an interior surface of the outer rim733. The inboard and outboard elastomeric rings786,787are aligned with the inboard and outboard flanges771,774respectively. During operation, as will be appreciated by those skilled in the art, as the wheel assembly730moves during motion of the vehicle, the gas springs750permit relative movement between the inner and outer rims731,733up to the mechanical stops. During operation of the mechanical stops, the elastomeric rings786,787contact the radially outward ones of the inner and outer flange lips773b,776b. The elastomeric rings786,787may permit up to 20,000 lbs of load for example.

The wheel assembly730may advantageously provide, for vehicles driven by combustion engines, increased fuel efficiency by providing less roadway resistance. For electric driven vehicles, the decreased roadway resistance may equate to a longer range on a given battery charge, for example. Additionally, the inboard and outboard mechanical stops may operate as a “run-flat” feature, so that a vehicle may not have to carry a spare tire, thus reducing vehicle weight and increasing operating efficiency.

Referring now toFIG.57, in another embodiment rather than inboard and outboard flanges, a medial flange778′ extends radially from a middle of the outer rim733′. The medial flange778′ includes a flange body779′ and a flange lip788′ extending from the flange body and outwardly toward an outer side of the wheel assembly730′. The outer rim733′ may include inboard and outboard rim segments734a′,734b′, for example, each having a U-shape and coupled together by fasteners735′. The medial flange778′ may be coupled between the inboard and outboard rim segments734a′,734b′ by way of the fasteners735′. In other words, the medial flange778′ is sandwiched between adjacent arms of the U-shaped inner and outer rim segments734a′,734b′. The flange lip788′ defines a mechanical stop with inner rim731′, and more particularly, the elastomeric ring786′ aligned with the flange lip.

Inner and outer inner rim sidewalls791′,792′ coupled to the inboard and outboard sides of the inner rim731′, for example, by fasteners793′ replace the inboard and outboard flanges and define the overlap areas with the inboard and outboard sidewalls781′,782′. Lateral stops745′, illustratively in the form of hinge retainers, are coupled between the inner and outer rims731′,733′ and limit relative lateral movement between the inner and outer rim, for example, as described above. Elements such as the tread770′, fasteners783′, elastomeric body784′, fabric body785′, and the gas springs750′ are similar to those described above.

Referring now toFIG.58, in another embodiment, the inner rim731″ and the outboard flange774″ are integrally formed as a monolithic unit. The outer rim733″ and the outer sidewall782″ are also integrally formed as a monolithic unit. Of course, the inner rim731″ and the inboard flange771″, and the outer rim733″ and the inboard sidewall781″ may be integrally formed as monolithic unit. This way, access to the inside of the wheel assembly730″ may be provided by one of the inboard and outboard sides of the wheel assembly. In some embodiments, both the inboard and outboard sidewalls781″,782″, and outer rim may be integrally formed as a monolithic unit, and/or the inboard and outboard flanges and outer rim may be integrally formed as a monolithic unit. Elements such as the tread770″, fasteners783″,777″, lateral stops745″, elastomeric rings786″,787″, flange bodies772″,775″, flange lips773a″,773b″ elastomeric and fabric bodies784″,785″, and the gas springs750″ are similar to those described above.

A method aspect is directed to a method of making a wheel assembly730to be coupled to a hub of a vehicle. The method includes operatively coupling a plurality of gas springs750between an inner rim731to be coupled to the hub of the vehicle and an outer rim733surrounding the inner rim to provide a gas suspension permitting relative movement between the inner rim and the outer rim. The method also includes positioning an inboard flange771to extend radially outward from an inboard side of the inner rim731to define an inboard mechanical stop with the outer rim733. The method also includes positioning an outboard flange774spaced from the inboard flange771and extending radially outward from an outboard side of the inner rim731to define an outboard mechanical stop with the outer rim733.

Referring now toFIGS.59-63in another embodiment, a wheel assembly830includes an inner rim831to be coupled to the hub of a vehicle. The wheel assembly830also includes an outer rim833surrounding the inner rim831. A disk or ring840may be between the inner and outer rims831,833to define a closeable gap841.

The wheel assembly830also includes gas springs850operatively coupled between the inner and outer rims831,833to provide a gas suspension permitting relative movement between the inner and outer rims. Each gas spring850includes a gas cylinder851and a piston852movable within the gas cylinder. The gas cylinder851includes a first metal.

The piston852illustratively includes a shaft853, and a piston head854coupled to the shaft. The piston head854includes a recess855therein, and more particularly, a circumferential recess.

The piston852also includes a biasing member856within the recess855. More particularly, the biasing member856is in the form of an elastomeric material body that surrounds the shaft853and operates as a spring to provide radially outward biasing. While a single biasing member856is illustrated, those skilled in the art will appreciate that there may be any number of biasing members, the biasing member may be another material, for example, metallic and/or the biasing member may be in the form of another shape or biasing member type.

The piston852also includes damping members857adjacent the biasing member856. The damping members857are within the recess between the biasing member856and adjacent portions of an inner surface of the gas cylinder851. The damping members857are arranged in side-by-side relation circumferentially around the shaft or, more particularly, around the biasing member856. The damping members857are illustratively in the form of rigid bodies, and each includes a second metal that is softer than the first metal, i.e., the metal of the gas cylinder851. The second metal may include bronze, for example. There may be any number of damping members857including one. The damping members857may be spaced apart or abutting. As will be appreciated by those skilled in the art, the biasing member856radially biases the damping members857outwardly so that the damping members frictionally engage the inner surface of the gas cylinder851.

The damping members857may provide increased damping for the wheel assembly830. For example, the added damping may be between 4-6%. Those skilled in the art will appreciate that an increased amount of damping provided by the damping members857may generate increased heat, while the adjustment to have less damping may be undesirable as it may not attenuate motion sufficiently.

A seal858is carried by the piston head854. The seal858is carried in a circumferential recess axially separated from the recess carrying the biasing member856and the damping members857. The seal858illustratively has a channel859therein to define a U-shape.

The piston head854also includes first pin-receiving passageways861. The damping members857have second pin-receiving passageways862therein. The second pin-receiving passageways862are aligned with the first pin-receiving passageways861to accommodate respective retaining pins (not shown) during assembly. As will be appreciated by those skilled in the art, the damping members857, when biased, extend outwardly to engage the inner surface of the gas cylinder851. During assembly of the gas springs850, it may be desirable to retract the damping members857so that the piston852can be inserted into the gas cylinder851.

Once seated within the gas cylinder851, the pins may be pulled or removed from the first and second pin-receiving passageways861,862permitting the damping members857to expand radially to contact the inner surface of the gas cylinder851. The contact with the inner surface of the gas cylinder851causes the damping members857to expand axially to be retained in the recess.

A related method aspect is directed to a method of making a wheel assembly830to be coupled to a hub of a vehicle. The method may include operatively coupling a plurality of gas springs850between an inner rim831to be coupled to the hub of the vehicle and an outer rim833surrounding the inner rim to provide a gas suspension permitting relative movement between the inner rim and the outer rim. Each of the plurality of gas springs850may include a gas cylinder851having an inner surface, and a piston852movable within the gas cylinder. The piston852may include a shaft853, a piston head854coupled to the shaft and having a recess855therein, at least one biasing member856within the recess, and at least one damping member857adjacent the at least one biasing member and within the recess to frictionally engage the inner surface of the gas cylinder.

While several embodiments have been described herein, those skilled in the art will appreciate that any one or more elements from any one or more embodiments may be used in conjunction with any one or more elements from any other embodiment or embodiments. Moreover, while reference is made herein to inner and outer, those skilled in the art will appreciate that in many embodiments, elements described with respect to inner may be used as outer and vice versa, and/or those elements described as being inner may be used with elements described as being outer and vice versa.

Many modifications and other embodiments of the invention will come to the mind of one skilled in the art having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is understood that the invention is not to be limited to the specific embodiments disclosed, and that modifications and embodiments are intended to be included within the scope of the appended claims.