Patent ID: 12220941

DETAILED DESCRIPTION

As required, detailed embodiments of the present invention are disclosed herein. It is to be understood that the disclosed embodiments are merely exemplary and that various and alternative forms are possible. The figures are not necessarily to scale; some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ embodiments according to the disclosure.

It will also be understood that, although the terms first, second, etc. are, in some instances, used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, a first element could be termed a second element, and similarly a second element could be termed a first element without departing from the scope of the various described embodiments. The first element and the second element are both elements, but they are not the same element.

The terminology used in the description of the various described embodiments is for the purpose of describing particular embodiments only and is not intended to be limiting. As used in the description of the various described embodiments and the appended claims, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will also be understood that the term “and/or” as used herein refers to and encompasses any and all possible combinations of one or more of the associated listed items. It will be further understood that the terms “includes,” “including,” “comprises,” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.

Referring toFIG.1, an example of a portion of an axle assembly10is shown. The axle assembly10may be provided with a vehicle like a truck, bus, farm equipment, mining equipment, military transport or weaponry vehicle, or cargo loading equipment for land, air, or marine vessels. The vehicle may include a trailer for transporting cargo in one or more embodiments. In at least one configuration and as is best shown with reference toFIG.2, the axle assembly10includes a spindle20, an axle shaft22, and a wheel end assembly24.

Referring toFIGS.2and3, the spindle20extends along or around an axis30and is configured to support components of the wheel end assembly24. The spindle20may be fixedly mounted to a structural component32of the axle assembly. For instance, in a steerable configuration, the wheel end assembly24may be mounted to a steerable structural component, such as a steering knuckle. In a non-steerable configuration, the wheel end assembly24may be mounted to a non-steerable structural component, such as a non-rotatable knuckle or an axle housing. The term axle assembly is used herein to generically reference both steerable and non-steerable configurations; however, the axle assembly10will primarily be described in the context of a non-steerable configuration in which the spindle20is mounted to a structural component32that is an axle housing. The spindle20may be integrally formed with the structural component32or may be a separate part that is attached to the structural component. In at least one configuration, the spindle20may include a tubular portion40and may define a spindle hole42.

Referring primarily toFIG.3, the tubular portion40may encircle the axis30. In at least one configuration, the tubular portion40may have an end portion50.

The end portion50may be disposed at a distal end of the tubular portion40. The end portion50may be configured to support the gear reduction unit74. In at least one configuration, the end portion50may include a mounting feature52and a threaded portion54.

The mounting feature52may facilitate mounting of a second side gear102of the gear reduction unit74to the spindle20. The mounting feature52may have any suitable configuration. For instance, the mounting feature52may be a fastener, weld, a plurality of splines that may be arranged around the axis30and that may engage and may inhibit rotation of the second side gear102, or the like.

The threaded portion54may be axially positioned or positioned along the axis30between a distal end of the end portion50and the mounting feature52. The threaded portion54may face away from the axis30and may engage or mate with a thread of a nut60. The nut60may be threaded onto the threaded portion54and may inhibit axial movement of the second side gear102toward the distal end. In addition, the nut60may exert a preload force on a wheel bearing72.

The spindle hole42may be a through hole that may extend through the spindle20. The spindle hole42extends along the axis30and may be encircled by the tubular portion40.

Referring toFIG.2, the axle shaft22is rotatable about the axis30. The axle shaft22may provide torque to the wheel end assembly24. For instance, the axle shaft22may be operatively connected at a first end to a vehicle drivetrain component, such as a differential or vehicle power source, and may be coupled to or operatively connected to the wheel end assembly24at a second end. For example, the axle shaft22may extend through the spindle hole42to a gear reduction unit74of the wheel end assembly24as will be discussed in more detail below. It is also contemplated that the axle shaft22may be configured for use with an independent suspension system and may have multiple shaft segments and/or joints that may facilitate relative movement between the first end and the wheel end assembly24.

The wheel end assembly24is configured to support a vehicle wheel. In at least one configuration and as is best shown with reference toFIG.2, the wheel end assembly24includes a hub70, at least one wheel bearing72, and a gear reduction unit74. The wheel end assembly24may also include a hub cap76and a brake component78.

Referring toFIGS.1and2, the hub70is rotatable about the axis30with respect to the spindle20. In addition, the hub70is configured to facilitate mounting of a wheel. The hub70may be operatively connected to an axle shaft22. In at least one configuration, the hub70may include a hub cavity80and a hub mounting flange82.

Referring primarily toFIGS.2and3, the hub cavity80may extend around the axis30. The hub cavity80may receive at least a portion of various components of the wheel end assembly24, such as the spindle20, wheel bearings72, and optionally a portion of the gear reduction unit74.

The hub mounting flange82may facilitate mounting of the wheel. For example, the hub mounting flange82may extend away from the axis30and may include a set of holes that may each receive a lug bolt84. A lug bolt84may extend through a corresponding hole in the wheel. A lug nut may be threaded onto a lug bolt84to secure the wheel to the hub70.

Referring primarily toFIG.2, one or more wheel bearings72may be disposed on the spindle20. A wheel bearing rotatably supports the hub70. In the configuration shown, two wheel bearings72are depicted. A wheel bearing72may have any suitable configuration. For instance, the wheel bearing72may include a plurality of rolling elements, such as balls or rollers, that may be disposed between an inner race and an outer race. The inner race may encircle the spindle20. The outer race may engage the hub70and may encircle the inner race and the rolling elements.

The gear reduction unit74operatively connects the axle shaft22to the hub70. The gear reduction unit74transmits torque from the axle shaft22to the hub70. It is contemplated that the gear reduction unit74or a portion thereof may be disposed inside the hub70. In at least one configuration and as is best shown inFIGS.3and4, the gear reduction unit74includes a first side gear100, a second side gear102, and a gear nest104. As is best shown inFIG.5, the gear nest104may include a case110, at least one pinion pin112, and at least one pinion gear114. Additionally, one or more retainer pins120, inner washers122, bearing elements124, thrust bearings126, outer washers128, or combinations thereof may be provided with the gear nest104.

Referring toFIGS.2-4and7, the first side gear100is shown. The first side gear100is disposed inside the wheel end assembly24and is disposed between the hub cap76and the case110. As such, a portion of the first side gear100may be received inside the hub cap76or may be encircled by the hub cap76. In addition, the first side gear100may be disposed further outboard or closer to the hub cap76than the second side gear102. The first side gear100may be fixedly disposed on the axle shaft22. For instance, the first side gear100may have a hole that may receive the axle shaft22such that the first side gear100is rotatable with the axle shaft22. For example, the first side gear100may be fastened to the axle shaft22or may have a spline that mates with a corresponding spline on the axle shaft22such that the first side gear100may not rotate with respect to the axle shaft22. The first side gear100may also have a set of teeth that may face toward and may be spaced apart from the case110. The set of teeth that may be arranged around the axis30and that may mate or mesh with teeth on one or more pinion gears114. The set of teeth may be at least partially disposed outside the case110.

The second side gear102is fixedly disposed on the spindle20or fixedly positioned with respect to the spindle20. The second side gear102may be disposed inside the wheel end assembly24. For example, the second side gear102may be disposed on an opposite side of the case110with respect to the first side gear100. The second side gear102may be disposed between the case110and the wheel bearing72. The second side gear102may be fixedly disposed on the spindle20in any suitable manner. For instance, the second side gear102may be attached with a fastener or weld or may have a hole that receive the spindle20such that the second side gear102may be fixed to the spindle20. For example, the second side gear102may have a spline that mates with a corresponding spline on the spindle20such that the second side gear102does not rotate with respect to the spindle20. The second side gear102may also have a set of teeth that may face toward and may be spaced apart from the case110. The set of teeth may be arranged around the axis30and may mate or mesh with teeth on one or more pinion gears114.

Referring primarily toFIGS.2and5-7, the case110may receive components of the gear nest104of the gear reduction unit74. For instance, the case110may receive and support the pinion pins112, pinion gears114, retainer pins120, inner washers122, bearing elements124, thrust bearings126, outer washers128, or combinations thereof. It is contemplated that the case110may be a single unitary one-piece component rather than an assembly of multiple parts. The case110may be fixedly positioned with respect to the hub70and may be rotatable about the axis30with the hub70. In at least one configuration and as is best shown with reference toFIG.6, the case110may include an inner ring130, an outer ring132, and one or more ribs134. In addition, the case110may define a plurality of cavities136.

Referring primarily toFIGS.2,5, and6, the inner ring130may extend around or encircle the axle shaft22and the axis30. In addition, the inner ring130may be spaced apart from and may not contact the axle shaft22. In at least one configuration and as is best shown inFIG.6, the inner ring130may have a first inner ring end140and a second inner ring end142and may define an inner ring hole144, and at least one socket146.

The first inner ring end140may face toward the first side gear100or to the left from the perspective shown inFIG.7. The first inner ring end140may extend around or encircle the axis30.

The second inner ring end142may be disposed at an opposite end of the inner ring130from the first inner ring end140. As such, the second inner ring end142may face away from the first side gear100and may face toward the second side gear102or to the right from the perspective shown inFIG.7. The second inner ring end142may extend around or encircle the axis30.

Referring primarily toFIG.6, the inner ring hole144may extend along or around the axis30. The inner ring hole144may extend between the first inner ring end140and the second inner ring end142. For instance, the inner ring hole144may extend from the first inner ring end140to the second inner ring end142. The axle shaft22, which is best shown inFIG.2, may be received inside and may extend through the inner ring hole144.

Referring primarily toFIG.6, a set of one or more sockets146may be provided with the inner ring130. A socket146may be disposed opposite the inner ring hole144and may face away from the axis30. The socket146may be configured to receive a corresponding pinion pin112as will be discussed in more detail below. In at least one configuration and as is best shown with reference toFIGS.6and7, the socket146may be at least partially defined by a socket bottom surface150, a socket side surface152, and a socket top surface154.

The socket bottom surface150may be disposed at the bottom of the socket146. As such, the socket bottom surface150may be disposed closer to the axis30than the socket side surface152, the socket top surface154, or both. The socket bottom surface150may be spaced apart from the first inner ring end140, the second inner ring end142, and the inner ring hole144. The socket bottom surface150may be disposed further from the axis30than the inner ring hole144is disposed from the axis30and may extend substantially parallel to the axis30in one or more configurations. The term “substantially parallel” as used herein means the same as or very close to parallel and includes features or axes that are within ±3° of being parallel each other. The socket bottom surface150may engage or contact the pinion pin112to limit or inhibit movement of a pinion pin112toward the axis30.

The socket side surface152may extend from the socket bottom surface150in a direction that extends away from the axis30. For instance, the socket side surface152may extend from the socket bottom surface150to the socket top surface154. The socket side surface152may encircle the socket bottom surface150and may encircle a portion of a pinion pin112that is received in the socket146. In at least one configuration, the socket side surface152may be radially disposed with respect to an associated center axis160. The center axis160may be disposed substantially perpendicular to the axis30. The term “substantially perpendicular” is used herein to designate features or axes that are the same as or very close to perpendicular and includes features that are within ±3° of being perpendicular each other.

The socket top surface154may extend from the socket side surface152in a direction that extends away from the center axis160. The socket top surface154may be disposed further from the axis30than the socket bottom surface150is disposed from the axis30. The socket top surface154may encircle the socket side surface152. In at least one configuration, the socket top surface154may be spaced apart from and may not engage a corresponding pinion pin112.

The outer ring132may encircle the inner ring130. As such, the outer ring132may be disposed further from the axis30than the inner ring130is disposed from the axis30. In addition, the outer ring132may be spaced apart from the inner ring130and the axle shaft22. In at least one configuration, the outer ring132may define a first outer ring end170, a second outer ring end172, an outer side174, at least one support side176, at least one pinion pin hole178, at least one retainer hole180, at least one fastener hole182, or combinations thereof.

The first outer ring end170may face toward the first side gear100or to the left from the perspective shown inFIG.7. The first outer ring end170may extend around and may encircle the axis30. The first outer ring end170may be disposed further from the axis30than the first inner ring end140is disposed from the axis30.

The second outer ring end172may be disposed at an opposite end of the outer ring132from the first outer ring end170. As such, the second outer ring end172may face away from the first side gear100and may face toward the second side gear102, or to the right from the perspective shown inFIG.7. The second outer ring end172may extend around and may encircle the axis30. In at least one configuration, the second outer ring end172may be disposed further from the axis30than the second inner ring end142is disposed from the axis30. As such, the outer ring132may have a greater axial length or length in a direction that extends along or parallel to the axis30than the inner ring130.

Referring primarily toFIG.6, the outer side174may face away from the axis30and may extend around the axis30. In addition, the outer side174may extend between the first outer ring end170and the second outer ring end172. For instance, the outer side174may extend from the first outer ring end170to the second outer ring end172. The outer side174may be an exterior surface of the wheel end assembly24as is best shown inFIG.1.

Referring toFIGS.6and7, at least one support side176may be provided with the outer ring132. The support side176may face toward the axis30and the inner ring130. As such, the support side176may be disposed opposite the outer side174. In addition, the support side176may extend between the first outer ring end170and the second outer ring end172. For instance, the support side176may extend axially from the first outer ring end170to the second outer ring end172. A support side176may encircle a pinion pin hole178. In the configuration shown, four support sides176are illustrated; however, it is contemplated that a greater or lesser number of support sides176may be provided. The support sides176may be separated or partially separated from each other. For instance, a rib134may be disposed between adjacent support sides176and may help separate one support side176from an adjacent support side176. In at least one configuration, each support side176extends along an arc; however, it is contemplated that a planar or non-arcuate configuration may be provided.

A set of one or more pinion pin holes178may be defined by the outer ring132. A pinion pin hole178may receive a pinion pin112. The pinion pin hole178may extend from the support side176toward or to the outer side174. Each pinion pin hole178may extend along a corresponding center axis160and may be aligned with a corresponding socket146.

The retainer hole180may extend from a pinion pin hole178to the first outer ring end170, the second outer ring end172, or both. The retainer hole180may be positioned closer to the axis30than the outer side174is positioned to the axis30and may be positioned further from the axis30than the support side176is positioned from the axis30. In at least one configuration, the retainer hole180may be disposed substantially parallel to the axis30. The retainer hole180may receive a retainer pin120that may engage and may extend into the pinion pin112to inhibit movement of the pinion pin112with respect to the case110. The retainer pin120may have any suitable configuration. For instance, the retainer pin120may be configured as a shaft or pin like a roll pin.

One or more fastener holes182may extend from the first outer ring end170toward or to the second outer ring end172. A fastener hole182may be configured to receive a fastener190that may couple or secure the case to the hub70, the hub cap76, or both. Examples of fasteners190are best shown inFIGS.3and4. One or more fastener holes182may be unthreaded.

Referring primarily toFIG.6, a set of one or more ribs134may connect the inner ring130to the outer ring132. A rib134may extend in a direction that extends away from the axis30from the inner ring130to the outer ring132. In at least one configuration, each member of the set of ribs134may be disposed substantially perpendicular to the axis30. Optionally, a member of the set of ribs134may be aligned with or may be coaxially disposed with one other member of the set of ribs134that is disposed on an opposite side of the axis30and inner ring130. A rib134may be integrally formed with the inner ring130, the outer ring132, or both. In the configuration shown, four ribs134are illustrated; however, it is contemplated that a greater or lesser number of ribs may be provided. Each rib134may be spaced apart from the sockets146of the inner ring130, the support side176of the outer ring132, or both. A rib134may have a shorter axial length or length in a direction that extends along the axis30than the inner ring130, the outer ring132, or both. For instance, a rib134may be spaced apart from the first outer ring end170, the second outer ring end172, or both. In such a configuration, the outer ring132may have a greater axial length or length in a direction that extends along the axis30than the rib134.

In at least one configuration and as is best shown with reference toFIG.6, the case110may define a plurality of cavities136when two or more ribs134are provided. Each cavity136may be bounded by the inner ring130, the outer ring132, and two members of the set of ribs134. Each cavity136may receive at least one pinion pin112and at least one pinion gear114. In the configuration shown inFIG.7, each cavity136receives one pinion pin112and one pinion gear114. In such a configuration, members of the set of ribs134and the set of sockets146may be arranged in an alternating relationship such that each member of the set of sockets146is positioned between two adjacent members of the set of ribs134in a direction that extends around the axis30.

Referring primarily toFIGS.6and7, a set of one or more pinion pins112may the mounted to the case110. A pinion pin112may be a separate component from the case110and may extend between the inner ring130and the outer ring132. A pinion pin112may be partially received inside a corresponding socket146of the inner ring130and may be partially received inside a corresponding pinion pin hole178of the outer ring132. Moreover, a pinion pin112may be spaced apart from the axle shaft22and may not extend into the inner ring hole144. A pinion pin112may have any suitable configuration. In the configuration shown, each pinion pin112has a generally cylindrical configuration and extends along a corresponding center axis160. In at least one configuration, the pinion pin112may have a first end surface200, a second end surface202, an outer pin side204, a groove206, and a retainer pin hole208.

The first end surface200may engage the inner ring130. For instance, the first end surface200may be received inside the socket146and engage or contact the socket bottom surface150.

The second end surface202may be disposed opposite the first end surface200. In at least one configuration, the second end surface202may be received inside a pinion pin hole178in the outer ring132.

The outer pin side204may extend between the first end surface200and the second end surface202. The outer pin side204may face toward and may engage the socket side surface152, a bearing element124, a surface that defines the pinion pin hole178, or combinations thereof.

The groove206may extend from the outer pin side204toward a corresponding center axis160. The groove206may receive a seal210, such as an O-ring, and may be axially positioned such that the groove206and the seal210are received in a pinion pin hole178in the outer ring132. The seal210may inhibit water and other contaminants from passing through the pinion pin hole178and entering the wheel end assembly24.

The retainer pin hole208may extend from the outer pin side204. The retainer pin hole208may be aligned with the retainer hole180of the outer ring132. The retainer pin120may be received in the retainer hole180of the outer ring132and the retainer pin hole208of the pinion pin112to secure the pinion pin112and inhibit removal of the pinion pin112from the retainer hole180. As such, the pinion pin112may be mounted to the case110such that the pinion pin112is rotatable about the axis30with the case110.

Referring primarily toFIGS.5and7, a set of one or more pinion gears114are provided with the gear nest104. Each pinion gear114may be rotatable with respect to the case110and with respect to a corresponding pinion pin112. For instance, the pinion gear114may define a hole that may receive a corresponding pinion pin112in a manner that permits the pinion gear114to rotate about the pinion pin112and a corresponding center axis160. The pinion gear114may mesh with the first side gear100and the second side gear102. For instance, the pinion gear114may include teeth that may mesh or mate with the teeth of the first side gear100and may mesh or mate with teeth of the second side gear102.

An inner washer122may be provided between the inner ring130and a pinion pin112. For instance, the inner washer122may encircle the pinion pin112and may extend from the socket top surface154to or toward the pinion pin112. The inner washer122may also engage and limit axial movement of the bearing elements124.

One or more bearing elements124may rotatably support the pinion gear114on a pinion pin112. The bearing elements124may be received in the hole of the pinion gear114and may be arranged around the pinion pin112and a corresponding center axis160. The bearing elements124may have any suitable configuration. For instance, the bearing elements124may be configured as needle bearings.

A thrust bearing126may be provided between a pinion gear114and the outer ring132. For instance, a thrust bearing126may encircle the pinion pin112and may engage or contact the pinion gear114. The thrust bearing126may cooperate with the bearing elements124to facilitate rotation of the pinion gear114.

An outer washer128may be provided between a pinion gear114and the outer ring132. For instance, an outer washer128may encircle the pinion pin112and may extend from the thrust bearing126to a corresponding support side176of the outer ring132. The outer washer128may also include an outer washer flange220that may extend toward and may engage the bearing elements124. The outer washer flange220may be encircled by the thrust bearing126.

Referring toFIGS.1,2, and7, the hub cap76encloses an outboard end of the wheel end assembly24. The hub cap76may be mounted to the hub70and the gear reduction unit74. For example, the hub cap76may be attached to the case110of the gear reduction unit74and may be disposed opposite and may be spaced apart from the hub70. In at least one configuration, one or more fasteners190, such as bolts, may secure the hub cap76to the hub70, the gear reduction unit74, or both. As an example, a fastener190may extend through a hole in the hub cap76, through a fastener hole in the case110, and may be threaded into a corresponding fastener hole in the hub70.

Referring toFIGS.1and2, the brake component78is fastened to the hub70. The brake component78may have any suitable configuration. For instance, the brake component78may be configured as a brake rotor or a brake drum.

An axle assembly as described above allows a gear reduction unit to be provided without a spider, such as a spider that has a central ring that encircles an axis of rotation and has one or more shafts or pins that may be integrally formed with the central ring, extend away from the axis of rotation, and about which a pinion gear may rotate. Eliminating a spider with integrally-formed pins may prevent a pin from fracturing and/or separating from the central ring, the case of the gear reduction unit, or both, which in turn may improve the durability of the gear reduction unit. In addition, such a configuration may allow a gear reduction unit to be provided with fewer parts than gear reduction unit designs that have a spider, which may help reduce assembly time of the gear reduction unit.

While exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention. Additionally, the features of various implementing embodiments may be combined to form further embodiments of the invention.