WO2000034058A1

WO2000034058A1 - Fabricated axle housing and associated process of assembly

Info

Publication number: WO2000034058A1
Application number: PCT/US1999/026361
Authority: WO
Inventors: Eric H. Mortensen; Charles F. Sieck; Brian R. Janes; Robert E. Klimko
Original assignee: Caterpillar Inc.
Priority date: 1998-12-04
Filing date: 1999-11-09
Publication date: 2000-06-15

Abstract

A fabricated axle housing (10, 110, 210, 310) and associated process of assembly that includes a ring (12) having a first portion (14) and a second portion (16) having a first leg member (36) attached between the first portion (14) of the ring (12) and a first end member (26) and a second leg member (52) attached between the second portion (16) of the ring (12) and a second end member (42). A first tube (34) is substantially enclosed by the first leg member (36) and the first tube (34) forms a fluid conduit between the inside of the ring (12) and the first end member (26) and there is a second tube (50) that is substantially enclosed by the first leg member (36) and the second tube (50) forms a fluid conduit between the inside of the ring (12) and the second end member (42).

Description

FABRICATED AXLE HOUSING AND ASSOCIATED PROCESS OF ASSEMBLY

Technical Field

This invention relates generally to a fabricated axle housing and, more particularly, a fabricated axle housing having a ring, having a first portion and a second portion, with a first leg member that is attached between the first portion of the ring and a first end member and a second leg member that is attached between the second portion of the ring and a second end member.

Background Art

Typically, most axle housings are constructed of cast material in one or more pieces and then heavily machined in order to accommodate the attachment of other components. The process of casting and machining is costly and time consuming. The construction of the molds or patterns requires a significant period of time. Once a rough casting is received, it must be machined to accept a differential, final drives, and mounting surfaces.

The size of these cast axle housings requires the use of large, expensive machining centers or transfer lines. This will add to the cost and severely hamper flexibility. In addition, with cast axle housings, oil must flow through the entire leg member. This can lead to significant oil volume within an axle. Furthermore, a new mold must be developed for each and every permutation of cast axle housing that is varied by means of having the ring positioned off-center with respect to the legs of an axle housing.

The present invention is directed to overcoming one or more of the problems set forth above .

Disclosure of the Invention

In one aspect of this invention, a fabricated axle housing is disclosed. The fabricated axle housing includes a ring having a first portion, a second portion, an inner surface, an outer surface and a first aperture forming a conduit between the inner surface and the outer surface of the first portion and ■ a second aperture forming a conduit between the inner surface and the outer surface of the second portion. There is a first end member having a top portion, a bottom portion and an aperture forming a conduit between the top portion and the bottom portion of the first end member and a first tube connected between the first portion of the ring and the bottom portion of the first end member forming a conduit between the inner surface of the ring and the top portion of the first end member through the first aperture of the ring and the aperture of the first end member. There is also a first leg member having a first end portion, a second end portion wherein the first end portion of the first leg member is attached to the first portion of the ring and the second end portion of the first leg member is attached to the bottom portion of the first end member wherein the first leg member substantially encloses the first tube. The fabricated axle housing also includes a second end member having a top portion, a bottom portion and an aperture forming a conduit between the top portion and the bottom portion of the second end member and a second tube connected between the second portion of the ring and the bottom portion of the second end member forming a conduit between the inner surface of the second portion of the ring and the top portion of the second end member through the second aperture of the ring and the aperture of the second end member. There is a second leg member having a first end portion and a second end portion wherein the first end portion of the second leg member is attached to the second portion of the ring and the second end portion of the second leg member is attached to the bottom portion of the second end member wherein the second leg member substantially encloses the second tube. In another aspect of the present invention, a process for assembling a fabricated axle housing is disclosed. The process includes the following steps. Attaching a first tube between a first portion of a ring and a first end member and then attaching a second tube between a second portion of the ring and a second end member. Substantially enclosing the first tube member with a first leg member and substantially enclosing the second tube member with a second leg member . Brief Description of the Drawings

For a better understanding of the present invention, reference may be made to the accompanying drawings in which: FIG. 1 is a front view of a preferred embodiment of a fabricated axle housing of this present invention with spindle flanges as end members;

FIG. 2 is a top elevational view of the fabricated axle housing shown in FIG. 1 with spindle flanges as end members;

FIG. 3 is a side elevational view of the fabricated axle housing shown in FIG. 1 with spindle flanges as end members;

FIG. 4 is a perspective view of the fabricated axle housing shown in FIG. 1 with spindle flanges as end members;

FIG. 5 is a front view of an alternative embodiment of a fabricated axle housing of this present invention with spindle flanges as end members; FIG. 6 is a top elevational view of the fabricated axle housing shown in FIG. 5 with spindle flanges as end members;

FIG. 7 is a side elevational view of the fabricated axle housing shown in FIG. 5 with spindle flanges as end members;

FIG. 8 is a perspective view of the fabricated axle housing shown in FIG. 5 with spindle flanges as end members;

FIG. 9 is a front view of a preferred embodiment of a fabricated axle housing of this present invention with weld-in spindles as end members ; FIG. 10 is a top elevational view of the fabricated axle housing shown in FIG. 9 with weld-in spindles as end members;

FIG. 11 is a side elevational view of the fabricated axle housing shown in FIG. 9 with weld-in spindles as end members;

FIG. 12 is a front view of a preferred embodiment of a fabricated axle housing of this present invention with steering knuckles as end members;

FIG. 13 is a top elevational view of the fabricated axle housing shown in FIG. 12 with steering knuckles as end members;

FIG. 14 is a side elevational view of the fabricated axle housing shown in FIG. 12 with steering knuckles as end members;

FIG. 15 is a front view of a preferred embodiment of a fabricated axle housing of this present invention with a trunnion attached to a plate covering the opening of the ring;

FIG. 16 is a top elevational view of the fabricated axle housing shown in FIG. 15 with a trunnion attached to a plate covering the opening of the ring ; and FIG. 17 is a side elevational view of the fabricated axle housing shown in FIG. 15 with a trunnion attached to a plate covering the opening of the ring.

Best Mode for Carrying Out the Invention

Referring now to FIGS. 1, 2, 3, and 4, a fabricated axle housing is generally indicated by numeral 10. The central component of the fabricated axle housing 10 is a ring 12 divided into a first portion 14 and a second portion 16. The preferred embodiment of ring 12 is where the first portion 14 and the second portion 16 are two discrete half-circle segments. These half-circle segments can be formed from either a rolled ring forging or drawn tubing. However, any of a wide variety of shapes and sizes of ring 12 will suffice. This can include both unitary shapes as well as a combination of adjacent discrete components. This can include a steel casting.

Ring 12 also has an inner surface 20 and an outer surface 18. There is a first aperture 22 forming a conduit between the inner surface 20 and the outer surface 18 of the first portion 14 of the ring

12. Likewise, there is a second aperture 24 forming a conduit between the inner surface 20 and the outer surface 18 of the second portion 16 of the ring 12.

There is a first end member 26 having a top portion 28 and a bottom portion 30 with an aperture 32 forming a conduit between the top portion 28 and the bottom portion 30 of the first end member 26. Between the first end member 26 and the ring 12 is a first tube 34 connected between the first portion 14 of ring 12 and the bottom portion 30 of the first end member 26 forming a conduit between the inner surface 20 of the ring 12 and the top portion 28 of the first end member 26 through the first aperture 22 of the ring 12 and the aperture 32 of the first end member 26. There is a first leg member 36 having a first end portion 38 and the second end portion 40. The first end portion 38 is attached to the first portion 14 of the ring 12 and the second end portion 40 of the first leg member 36 is attached to the bottom portion 30 of the first end member 26. The first leg member 36 preferably, but not necessarily, encloses the first tube 34.

In the same manner, there is a second end member 42 having a top portion 44 and a bottom portion 46 with an aperture 48 forming a conduit between the top portion 44 and the bottom portion 46 of the second end member 42. Between the second end member 42 and the ring 12 is a second tube 50 connected between the second portion 16 of ring 12 and the bottom portion 46 of the second end member 42 forming a conduit between the inner surface 20 of the second portion 16 of ring 12 and the top portion 44 of the second end member 42 through the second aperture 24 of ring 12 and the aperture 48 of the second end member 42.

There is a second leg member 52 having a first end portion 54 and a second end portion 56. The first end portion 54 of the second end leg member 52 is attached to the second portion 16 of ring 12 and the second end portion 56 of the second leg member 52 is attached to the bottom portion 46 of the second end member 42. Like the first leg member 36, the second leg member 42, preferably, but not necessarily encloses the second tube 50.

Referring now to FIGS. 1 and 4, the preferred first leg member 36 includes a first reshaped channel member 78 that is attached to an opposing second c-shaped channel member 80. The preferred second leg member 52 includes a third c- shaped channel member 82 that is attached to an opposing fourth c-shaped channel member 84. The first c-shaped channel member 78 is preferably attached to the second C-shaped member 80 by welding, however, any of a wide variety of attachment methods would suffice, e.g., adhesives. However, the first leg member 36 and second leg member 52 can each be of unitary construction .

As shown in FIG. 4, the first weld seam 62 attaches the first c-shaped member 78 to the second c- shaped member 80. Likewise, there is a second weld seam 64 between the third C-shaped channel member 82 and the fourth C-shaped channel member 84.

The preferred welding process is an open gap root pass welding in which the current is precisely controlled and is independent of the wire feed speed. This would reduce weld puddle agitation, smoke, and splatter and provides the operator with increased control of the puddle and penetration. It utilizes pulsing techniques supplied to the arc for better puddle control. High current is applied for a fixed amount of time which establishes the arc length and heats the base material . The current is then switched to a lower level where the overall heating of the puddle is controlled. The exact welding parameters vary and are totally dependent on the dimensions and material associated with the fabricated axle housing 10. These welding parameters could be easily ascertained by an individual skilled in the art of welding. A weld fixture is used to locate the pre- machined parts during welding. This fixture ensures proper alignment of all parts in the assembly. The fixture is designed to accept parts from an entire axle family.

As shown in FIGS. 3 and 4, the first end member 26 and the second end member 42 are preferably spindle flanges. First end member number 26 has the plurality of through holes 74. The exact number of through holes will depend on the specific machine and application. The first end member 26 includes the bottom portion 30 that connects between the first leg member 36 and the first end member 26. The bottom portion 30 of the first end member 26 is preferably, but not necessarily, of a smaller diameter that comports with the diameter of the first leg member 36. In the same manner, as shown in FIG. 4, the second end member 42 has the plurality of through holes 76. The exact number of through holes will depend on the specific machine and application. The second end member 42 includes the bottom portion 46 that connects between the second leg member 52 and the second end member 42. The bottom portion 46 of the second end member 42 is preferably, but not necessarily, of a smaller diameter that comports with the diameter of the second leg member 52.

As shown in FIG. 1, the first tube 34 and the second tube 50 can function as an axle shaft tube that significantly reduces the amount of oil volume when contrasted to cast axle housings. In situations where more oil volume is desired, e.g., brake cooling, the tubes 34 and 50 can be left out of the assembly. The preferred method of cutting either the first c-shaped channel member 78, the second c-shaped channel member 80, the third c-shaped channel member 82, or the fourth c-shaped channel member 84 is with a laser and then bending to form a channel .

There is a cover 60, shown on FIG. 1, which is welded to the bottom of ring 12. On the top of ring 12 is the plurality of through holes 70 for attachment of the fabricated axle housing 10 to the rest of a machine .

The preferred method for assembling a fabricated axle housing 10 is to attach the first tube 34 between the first portion 14 of the ring 12 and the first end member 26 and to attach the second tube 50 between the second portion 16 of the ring 12 and the second end member 42. The first tube 34 is substantially enclosed by a first leg member 36. The first leg member 36 is preferably formed of a first c- shaped member 78 and a second c-shaped member 80 attached together in opposing relationship. The second tube 50 is substantially enclosed by a second leg member 52. The second leg member 52 is preferably formed of a third c-shaped member 82 and a fourth c- shaped member 84 attached together in opposing relationship. This sequence may be altered, however, as proper alignment of all pieces of the fabricated axle housing 10 requires attention to weld sequencing and assembly order.

Referring now to FIGS. 5, 6, 7 and 8 which represents an alternative embodiment of the present invention. The only difference between this embodiment and the preferred embodiment presented in FIGS. 1 through 4 is that the first leg member 136 includes two u-shaped members 178 and 180 respectively, in contrast to the first leg member 36 that includes two c-shaped members 78 and 80, respectively. In the same manner, in the second leg member 152 includes two u-shaped members 182 and 184 respectively, in contrast to the second leg member 52 that includes two c-shaped members 82 and 84, respectively. In all other aspects, including the method of assembly, fabricated axle housing 10 as shown in FIGS. 1 through 4 is identical to fabricated axle housing 110 with identical reference numerals to comport with this fact.

Referring now to FIGS. 9, 10 and 11, fabricated axle housing 210 is identical to the preferred fabricated axle housing 10 shown in FIGS. 1, 2 and 3 with the exception that the first end member 26 and second end member 42 are no longer spindle flanges but weld-in spindles 220 and 240, respectively .

Referring now to FIGS. 12, 13 and 14, fabricated axle housing 310 is identical to the preferred fabricated axle housing 10 shown in FIGS. 1,

2 and 3 with the exception that the first end member 26 and second end member 42 are no longer spindle flanges but steering knuckles 320 and 340, respectively. Referring now to FIGS. 15, 16 and 17, fabricated axle housing 10 is identical to the preferred fabricated axle housing 10 shown in FIGS. 1, 2 and 3 with the exception that a trunnion 410 is attached to the cover 60 to create an oscillating axle housing and provide sealing. Industrial Applicability

This invention is advantageously applicable in a wide variety of machines, typically, but not limited to, construction machines such as motor graders, off-highway trucks, wheel loaders, bulldozers, and the like. The following description is only for the purposes of illustration and is not intended to limit the present invention as such. It will be recognizable, by those skilled in the art, that the present invention is suitable for a plurality of other applications.

The present invention finds a number of advantages by allowing the finish machining of a ring 12 and a first end member 26 or second end member 42 prior to welding to eliminate the need for machine operations on the entire fabricated axle housing 10. By utilizing a common center ring 12 and end members 26 and 42 respectively, various channel members 78, 80, 82, and 84 can be added to form different product types, steerable axles, fixed or trunnion mounts, and so forth.

There is a significant advantage of having tubes 34 and 50 connected between the ring 12 and the end members 26 and 42 to reduce oil and sump volume within the fabricated axle housing 10. Also, the requirement to clean up welds within the fabricated axle housing 10 is reduced.

The trunnion 410 can attach to or replace cover 60 to provide oscillation and sealing. A pilot bore in ring 12 keeps the differential carrier (not shown) and trunnion 410 concentric or a weld fixture may also be used to locate the trunnion 410 with respect to the differential carrier.

In addition, mounting pads (not shown) can be placed at any location along first and second leg members 36 and 52, respectively depending on the type of machine and associated application.

Fabrication allows for a wide variety of rings 12, first and second leg members 36 and 52, and first and second end members 26 and 42, thereby allowing the creation of an entire family of axle housings .

Other advantages of fabricated axle housings 10 include the fact that the ring 10 may be positioned off-center from the leg members 36 and 52 so that four-wheel drive applications, among others, may be utilized. This can be accomplished with cast housings, however, it would require completely different patterns with no common components.

In addition, the c-shaped channel members 78, 80, 82, and 84 as shown in FIGS. 1 through 4 and the u-shaped channel members 178, 180, 182, and 184, as shown in FIGS. 5 through 9 provide taper in the vertical plane that increases stiffness along a longitudinal axis of the fabricated axle housing 10. In addition, weld seams 62 and 64 are along the neutral longitudinal axis where stresses are the lowest .

In addition, a wide variety of interchangeable end members 26, 42 may be utilized including, but not limited to spindle flanges 26, 42, weld-in spindles 220, 240 and steering knuckles 320, 340. In addition, the fabricated axle housing 10 can be directly attached to a machine by welding or adhesive and thereby replace redundant structural members . In view of the foregoing, it is readily apparent that the subject fabricated axle housing provides considerable improvements over a one-piece molded axle housing.

Other aspects, objects and advantages of the present invention can be obtained from a study of the drawings, disclosure and the appended claims.

Claims

1. A fabricated axle housing (10,110,210,310) comprising: a ring (12) having a first portion (14) , a second portion (16) , an inner surface (20) , an outer surface (18), and a first aperture (22) forming a conduit between said inner surface (20) and said outer surface (18) of said first portion (14) and a second aperture (24) forming a conduit between said inner surface (20) and said outer surface (18) of said second portion (16) ; a first end member (26) having a top portion (28) , a bottom portion (30) and an aperture (32) forming a conduit between said top portion (28) and said bottom portion (30) of said first end member (26) ; a first tube (34) connected between said first portion (14) of said ring (12) and said bottom portion (30) of said first end member (26) forming a conduit between said inner surface (20) of said ring (12) and said top portion (28) of said first end member (26) through said first aperture (22) of said ring (12) and said aperture (22) of said first end member (26) ; a first leg member (36) having a first end portion (38) , a second end portion (40) wherein said first end portion (38) of said first leg member (36) is attached to said first portion (14) of said ring (12) and said second end portion (40) of said first leg member (36) is attached to said bottom portion (30) of said first end member (26) wherein said first leg member (36) substantially encloses said first tube ; a second end member (42) having a top portion (44) , a bottom portion (46) and an aperture (48) forming a conduit between said top portion (44) and said bottom portion (46) of said second end member (42) ; a second tube (50) connected between said second portion (16) of said ring (12) and said bottom portion (46) of said second end member (42) forming a conduit between said inner surface (20) of said second portion (16) of said ring (12) and said top portion (44) of said second end member (42) through said second aperture (48) of said ring (12) and said aperture (48) of said second end member (42); and a second leg member (52) having a first end portion (54) and a second end portion (56) wherein said first end portion (54) of said second leg member (52) is attached to said second portion (16) of said ring (12) and said second end portion (56) of said second leg member (52) is attached to said bottom portion (46) of said second end member (42) wherein said second leg member (52) substantially encloses said second tube (50) .

2. The fabricated axle housing (10,110,210,310) as defined in claim 1, wherein said first leg member (36) includes a first channel member (78) attached to an opposing second channel member (80) and said second leg member (52) includes a third channel member (82) attached to an opposing fourth channel member (84) .

3. The fabricated axle housing (10,110,210,310) as defined in claim 1, wherein said first leg member (36) is of a different length than said second leg member (52) .

4. The fabricated axle housing (10,110,210,310) as defined in claim 2, wherein said first channel member (78) , said second channel member (80), said third channel member (82) and said fourth channel member (84) are c-shaped.

5. The fabricated axle housing (110) as defined in claim 2, wherein said first channel member (178), said second channel member (180), said third channel member (182) and said fourth channel member (184) are u-shaped.

6. The fabricated axle housing (10,110,210,310) as defined in claim 1, wherein said first portion (14) of said ring (12) includes a first c-shaped member (78) that is attached to said second portion (16) of said ring (12) that includes an opposing second c-shaped member (80) .

7. The fabricated axle housing (10,110,210,310) as defined in claim 1, further comprising a plate (60) attached to said ring (12) and substantially covering said opening.

8. The fabricated axle housing (10) as defined in claim 1, wherein said first end member (26) is a spindle flange and said second end member (42) is a spindle flange.

9. The fabricated axle housing (210) as defined in claim 1, wherein said first end member (26) is a weld-in spindle (220) and said second end member (42) is a weld-in spindle (240) .

10. The fabricated axle housing (310) as defined in claim 1, wherein said first end member (26) is a steering knuckle (320) and said second end member (42) is a steering knuckle (320) .

11. The fabricated axle housing (10,110,210,310) as defined in claim 7, further comprising a trunnion (410) attached to said plate (60) .

12. A method for assembling a fabricated axle housing (10,110,210,310) comprising the steps of: attaching a first tube (34) between a first portion (14) of a ring (12) and a first end member (26) ; attaching a second tube (50) between a second portion (16) of said ring (12) and a second end member (42) ; substantially enclosing said first tube (34) with a first leg member (36) ; and substantially enclosing said second tube (50) with a second leg member (52) .

13. A method for assembling a fabricated axle housing (10,110,210,310) comprising the steps of: attaching a first tube (34) between a first portion (14) of a ring (12) and a first end member (26) ; attaching a second tube (50) between a second portion (16) of said ring (12) and a second end member (42) ; attaching a first channel member (78) to a second channel member (80) in opposing relationship and substantially enclosing said first tube member (34) ; and attaching a third channel member (82) to a fourth channel member (84) in opposing relationship and substantially enclosing said second tube (50) .

14. A method of claim 12, where said ring (12) is formed of a plurality of components attached together.

15. A method of claim 13, wherein prior to said step of attaching a first channel member (78) to a second channel member (80) includes a step of bending said first channel member (78) and second channel member (80) and wherein prior to said step of attaching a third channel member (82) to a fourth channel member (84) includes a step of bending said third channel member (82) and fourth channel member (84) .

16. A method of claim 15, wherein said step of bending said first channel member (78) and said second channel member (80) includes bending said first channel member (78) and said second channel member (80) in a c- shape and said step of bending said third channel member (82) and said fourth channel member (84) includes bending said third channel member (82) and said fourth channel member (84) in a c-shape.

17. A method of claim 15, wherein said step of bending said first channel member (178) and said second channel member (180) includes bending said first channel member (178) and said second channel member (180) in a u-shape and said step of bending said third channel member (182) and said fourth channel member (184) includes bending said third channel member (182) and said fourth channel member (184) in a u-shape.

18. A method of claim 12, wherein said first end member (26) includes a spindle flange and said second end member (42) includes a spindle flange.

19. A method of claim 12, wherein said first end member (26) includes a weld-in spindle (220) and said second end member (42) includes a weld- in spindle (240) .

20. A method of claim 12, wherein said first end member (26) includes a steering knuckle (320) and said second end member (42) includes a steering knuckle (340) .

21. A method of claim 13, wherein said first end member (26) includes a spindle flange and said second end member (42) includes a spindle flange.

22. A method of claim 13, wherein said first end member (26) includes a weld-in spindle (220) and said second end member (42) includes a weld-in spindle (240) .

23. A method of claim 13, wherein said first end member (26) includes a steering knuckle (320) and said second end member (42) includes a steering knuckle (340) .

24. A method of claim 12, wherein said first leg member (36) is of a different length than said second leg member (52) .

25. A method of claim 13, wherein said first channel member (78) is of a different length than said third channel member (82) and said second channel member (80) is of a different length than said fourth channel member (84) .