AU2009200960B2 - Tapered joint for vehicle suspension components - Google Patents

Abstract

- 32 A non-torque reactive air suspension exhibiting excellent roll stability characteristics is shown to include frame hangers mounted to frame rails extending longitudinally on opposite sides of a vehicle. Longitudinally extending beams are 5 connected to the frame hangers at one end and extend parallel to the frame rails. At their other ends, the beams are joined by a crossbrace extending laterally across the vehicle centerline. In a central portion thereof, the beams have an axle pivot bore to which an axle clamp assembly is connected, the axle clamp assembly clamping a drive axle housing for the vehicle. The axle pivot bore is generally aligned with the 10 drive axle. A control rod assembly is connected to suspension or frame components. Together with the beams, the control rod assembly forms a parallelogram configuration wherein the beams form the lower linkages of that configuration and the control rods included within the control rod assembly form the upper linkages of that configuration. 04/03/09,wa 17824 speci.32 1lof 6 410 4-v/52 24-1,2 FIG.IA 25-3 0 A *

Description

P/00/0 Il Regulation 3.2 AUSTRALIA Patents Act 1990 COMPLETE SPECIFICATION FOR A DIVISIONAL PATENT ORIGINAL Name of Applicant: THE BOLER COMPANY. Actual Inventors: ASHLEY THOMAS DUDDING CHRISTOPHER WAYNE FORREST JOHN WAYNE STUART JASON STEBY THOMAS PEDRO RAMSES BANDA MARQUEZ MARK WILLIAM DANKOW ROGER D. JABLE Address for Service: CALLINANS LAWRIE, 1193 Toorak Road, Camberwell, Victoria 3124, Australia Invention Title: TAPERED JOINT FOR VEHICLE SUSPENSION COMPONENTS The following statement is a full description of this invention, including the best method of performing it known to us:- -2 TAPERED JOINT FOR VEHICLE SUSPENSION COMPONENTS BACKGROUND OF THE INVENTION The present invention relates generally to innovations and improvements in 5 vehicle suspensions. More particularly, the present invention relates to a new and improved vehicle suspension that does not react significantly to torsional forces produced by high-torque drivetrain such as those utilized in heavy-duty trucks and the like, yet exhibits excellent ride and handling characteristics. 10 For several reasons, including use of higher horsepower engines and advances in engine technology, there have been increases in the torque output of heavy-duty truck engines. Such increases have magnified the problems of driveline vibration associated with trailing arm air suspensions, which are inherently torque reactive. When increased torque is applied to the axle of a truck equipped with such a 15 torque reactive suspension, such as during acceleration, the frame of the truck rises up and away from the drive axle. This condition is known and referred to in the art as "frame rise". It has been found that driveline vibration in vehicles, particularly heavy-duty 20 trucks, is generally proportional to the severity of frame rise and wheel hop, and vice versa. Further, it has been found according to this invention that means for and methods of preventing or minimizing frame rise will result in suppressing driveline vibration and wheel hop. 0 4 /03/0 9 .va 17824 speci,2 -3 Various non-reactive drive axle suspensions are known in the art. The term "non-reactive" means that the suspension does not react appreciatively to torque applied to a drive axle, particularly during acceleration and deceleration (braking). 5 Various roll stable suspensions are also known in the art. The term "roll stable" means that a suspension adequately resists the tendency of a vehicle to roll when negotiating sharp turns. A suspension exhibiting that feature is said to have roll stability. 10 Various air suspensions are also known. The term "air suspension" refers to a suspension equipped with air springs or bellows for supporting a vehicle on an axle. Before the present invention, the various known air suspensions have not adequately managed the mobility versus stability tradeoff. Most air suspensions that 15 are adequately roll stable do not provide adequate mobility. Conversely, most air suspensions that provide mobility do not provide sufficient roll stability. Further, such suspensions have reduced the comfort and ride characteristics of the suspension. It is also desirable for a suspension to maintain the axle inclination angle or 20 "pinion" angle throughout the full range of axle travel. By doing this, the axle pinion angle will more closely match the drive shaft angle and by so doing minimizes driveline vibration. The parallelogram geometry created by the beam and control rod maintains the pinion angle where a trailing arm suspension does not. 04/03/09,va 17824 speci.3 -4 These prior art non-torque reactive suspensions are also generally heavy, translating into reduced payload capacity in commercial vehicle applications. Such suspensions are also generally expensive to manufacture in terms of increased component parts and they require lengthy installation and assembly time, which 5 further increases their manufacturing expense. The prior art non-torque reactive suspensions also have generally low roll stability, thereby limiting use of the vehicle to certain, limited applications. In light of the foregoing, it is desirable to design a vehicle suspension that 10 will overcome one or more of the above identified deficiencies of conventional non torque reactive suspensions. It is further desirable to design a vehicle suspension that is non-torque reactive. 15 It is further desirable to design a vehicle suspension that is a non-torque reactive air suspension. It is further desirable to design a vehicle suspension that minimizes loads into 20 the vehicle frame and its associated cross member. It is further desirable to design a non-torque reactive suspension that exhibits excellent roll stability characteristics. 04/03/09,va 17824 speci,4 -5 It is further desirable to design a non-torque reactive suspension that does not compromise ride and/or articulation characteristics, while providing excellent roll stability. 5 It is further desirable to design a vehicle suspension that minimizes the number of components required to achieve its objectives. It is further desirable to design a vehicle suspension that can be assembled and installed in a relatively short amount of time. 10 It is further desirable to design a vehicle suspension that is relatively light in weight, thereby translating into increased payload capacity when used in commercial vehicle applications. 15 It is further desirable to provide a rear drive axle air suspension suitable for applications requiring partial off highway operation. It is further desirable to design a vehicle suspension that is rated from 20,000 lb. to 23,000 lb. ground load per axle. 20 It is further desirable to design a vehicle suspension that can be used in connection with a variety of axle configurations, including single, tandem, or tridem axle configurations. 04/03/09.va 17824 speci,5 -6 It is further desirable to design a vehicle suspension that is a non-reactive suspension developed for heavy-duty vehicles with high torque engines. It is further desirable to design a vehicle suspension that minimizes vibration. 5 It is further desirable to design a vehicle suspension that improves ride quality. It is further desirable to design a vehicle suspension that eliminates torque 10 reactivity. It is further desirable to design a vehicle suspension that includes various unique torque rod design configurations. 15 It is further desirable to provide a vehicle suspension that has an optimized parallelogram geometry. It is further desirable to design a vehicle suspension that does not induce roll generated torque into the drive axle of a vehicle. 20 It is further desirable to design a vehicle suspension that includes a machine tapered joint for the connection between the longitudinally extending main beam sections and the laterally extending crossbrace. 04/03109,va 17824 speci,6 -7 It is further desirable to design a vehicle suspension that utilizes a D-shaped bar pin bushing for attachment to a single leg of the lower axle bracket used to connect various suspension components to the clamped drive axle housing. 5 It is further desirable to design a vehicle suspension that includes an axle clamp assembly bottom pad having shock and main beam bushing mounting structure for adjustment of the axle pinion angle. 10 It is further desirable to design a vehicle suspension that utilizes frame hanger components with integrated main beam and control rod mounting features. It is further desirable to design a vehicle suspension that utilizes an axle clamp assembly top pad having integrated control mounting and bump stop features. 15 It is further desirable to design a vehicle suspension that includes roll stiffness tuning capability. It is further desirable to design a vehicle suspension having features that aid 20 in the assembly of the bushing interface. It is further desirable to design a vehicle suspension having a geometry that eliminates axle pinion angle change throughout the range of vertical axle travel. 04/03/09,va 17824 speci,7 It is further desirable to design a vehicle suspension having a geometry with links connected both above and below the axle to resist axle torsional displacements that are generated by braking and acceleration. 5 It is further desirable to design a vehicle suspension having a parallel geometry that reduces driveline vibration relative to typical trailing beam style suspensions common in the industry. It is further desirable to design a vehicle suspension that incorporates one 10 lateral control rod per axle to support lateral loads. It is further desirable to design a vehicle suspension that has an alternative geometry replacing two longitudinal and one lateral control rod with a single V-rod configuration that forms the upper linkage in the parallelogram geometry of the 15 suspension and supports lateral loads. It is further desirable to design a vehicle suspension that has pivotal connections at the axle rather than rigid connections such that no torsional loads are transmitted into the axle, making the axle interface more robust than the typical rigid 20 connection. It is further desirable to design a vehicle suspension that eliminates the axle as an auxiliary roll-stabilizing component, yet obtains roll stability through various components of the suspension. 04/03/09.va 17824 speci,8 -9 It is further desirable to design a vehicle suspension that prevents vehicle frame rise. 5 It is further desirable to design a vehicle suspension wherein the pivot for connecting other suspension components to the frame hanger is approximately aligned with the axle pivot. These and other benefits of the preferred forms of the invention will become 10 apparent from the following description. It will be understood, however, that an apparatus could still appropriate the invention claimed herein without accomplishing each and every one of these benefits, including those gleaned from the following description. The appended claims, not the benefits, define the subject matter of this invention. Any and all benefits are derived from the preferred forms of the invention, 15 not necessarily the invention in general. BRIEF SUMMARY OF THE INVENTION The present invention is directed to a non-torque reactive air suspension exhibiting excellent ride and handling characteristics. The suspension includes frame 20 hangers mounted to frame rails extending longitudinally on opposite sides of a vehicle. Longitudinally extending beams are connected to the frame hangers at one end and extend parallel to the frame rails. At their other ends, the beams are joined by a crossbrace extending laterally across the vehicle centerline. In a central portion thereof, the beams have an axle pivot bore to which an axle clamp assembly is 04103/09.va 17824 speci,9 -10 connected, the axle clamp assembly clamping a drive axle housing for the vehicle. The axle pivot bore is generally aligned with the drive axle. A control rod assembly is connected to suspension or frame components. Together with the beams, the control rod assembly forms a parallelogram configuration wherein the beams form 5 the lower linkages of that configuration and the control rods included within the control rod assembly form the upper linkages of that configuration. In a preferred aspect, the frame hangers include control rod mounting features. These features permit the incorporation of longitudinally extending control 10 rods outboard of the vehicle frame rails. The frame hangers also preferably include features that facilitate installation and assembly of the suspension components, specifically the beams. In another preferred aspect, the top pad for the axle clamp assembly includes 15 control rod mounting features. These features also permit the incorporation of longitudinally extending control rods outboard of the vehicle frame rails. The top pad also preferably includes a bump stop. In still another preferred aspect, the bottom pad for the axle clamp assembly 20 includes a single leg having a curved surface to accommodate the curved portion of a D-shaped bar pin bushing that connects the axle clamp assembly to the beam through its axle pivot bore. This construction facilitates adjustment of axle pinion angle, as desired. The bottom pad also preferably includes shock damper mounting features. In yet another preferred aspect, the connection assembly that joins the 04/03/09,va 17824 speci,10 - 11 crossbrace at corresponding beam ends includes a machine taper joint and a square like geometry, exhibiting excellent roll stability characteristic during vehicle operation. 5 In alternative embodiments, the suspension can include various control rod configurations, including a first having two longitudinally extending control rods mounted on the frame hanger and axle clamp assembly outboard of the vehicle frame rails and one laterally extending control rod mounted between the drive axle housing and one of the vehicle frame rails, a second having a V-rod configuration mounted at 10 an apex to the drive axle housing and at each end to opposite ones of the vehicle frame rails, and a third having a single longitudinally extending control rod mounted between the drive axle housing and a frame cross member extending laterally and mounted to both vehicle frame rails and a single laterally extending control rod mounted to the drive axle housing and one of the vehicle frame rails. 15 BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING In the following detailed description, reference will frequently made to the following figures, in which like reference numerals refer to like components, and in which: 20 FIG. I is a rear perspective view of a drive axle suspension for a heavy duty truck or the like constructed in accordance with the principles of the present invention; 04/03/09,va 17824 speci. I I - 12 FIG. 1 A is a perspective view of a bushing used in the suspension shown in FIG. 1; FIG. 2 is a side elevational view of the suspension shown in 5 FIG. 1; FIG. 3 is a side elevational view of one of the main beams used in the suspension shown in FIG. 1; 10 FIG. 4 is an exploded perspective view illustrating the connection between the main beam shown in FIG. 3 and the crossbrace used in the suspension shown in FIG. 1; FIG. 4A is a rear perspective view of a retainer cup that can be used in the 15 connection assembly shown in FIG. 4; FIG. 4B is a side view of the retainer cup shown in FIG. 4A; FIG. 5 is a sectional view of the main beam shown in FIG. 3 taken along line 20 5-5; FIG. 6 is a side elevational view of a preferred form of the axle clamp assembly used in the suspension in FIG. 1; 04/03/09,va 17824 speci, 12 - 13 FIG. 6A is a perspective view of an alternative form of the axle clamp assembly shown in FIG. 6; FIG. 7 is a rear perspective view of the frame hanger assembly used in the 5 suspension shown in FIG. 1; FIG. 8 is a rear perspective view of the suspension shown in FIG. I having its axle clamp assembly top pad substituted for an alternative preferred form of that component; 10 FIG. 9 is a rear perspective view of the axle clamp assembly top pad included within the suspension shown in FIG. 8; FIG. 10 is a rear perspective view of the suspension shown in FIG. I having 15 an alternative control rod configuration; FIG. 11 is a top plan view of the alternative control rod configuration used in the suspension shown in FIG. 10; 20 FIG. 12 is a rear perspective view of the suspension shown in FIG. I having yet another alternative control rod configuration; and FIG. 13 is a rear view illustrating features of the suspension shown in FIG. 2. 04/03/09,va 17824 spcci.13 - 14 DETAILED DESCRIPTION OF THE INVENTION FIGS. 1 and 2 illustrate components used in association with a vehicle, such as a heavy-duty truck and the like (not shown) The vehicle includes longitudinally extending frame rails 20 positioned on opposite sides of the vehicle and having a 5 preferred C-shaped configuration. The vehicle further includes a drive axle having a housing illustrated in FIG. I by reference numeral 22. The drive axle for the vehicle extends laterally across the vehicle and is used to mount tires (not shown) driven by a vehicle engine (not shown). 10 In addition to the foregoing, the vehicle further includes a suspension generally designated by reference numeral 24, which connects the drive axle housing 22 to frame rails 20-20 positioned on opposite sides of the vehicle. As will be appreciated, with respect to suspension 24, the majority of the 15 components positioned on one side of the vehicle will have correspondingly similar components positioned on the other side. Accordingly, in this description, when reference is made to a particular suspension component, it will be understood that a similar component is present on the opposite side of the vehicle, unless otherwise apparent. 20 Suspension 24 includes a plurality of components including frame hangers 26 mounted on opposite sides of the vehicle to frame rails 20-20. Suspension 24 further includes longitudinally extending main beams 28-28 connected at one end to a frame hanger 26 through a bushing 30 (see FIG. IA) and an eccentric washer or member 0403109,va 17824 speci 4 - 15 31, which allows axle adjustment for the suspension. At the other end, beams 28-2 8 are connected to a laterally extending crossbrace 32 by way of a beam-to-brace connection assembly 34. As shown, a single crossbrace is utilized for each axle using the suspension 24 illustrated in FIG. 1. As such, crossbrace 32 extends laterally 5 across the vehicle to connect with the rearward ends of the beams 28-28 positioned on opposite sides of the vehicle. Crossbrace 32 forms a semi-torsion bar which lifts and rotates while resisting moments about all three axes of a Cartesian coordinate system. Crossbrace 32 is the 10 primary component contributing to roll stability for suspension 24. A secondary component for the roll stability of suspension 24 is the bushing 30 that is used to connect beam 2-8 with frame hanger 26. Bushing 30, illustrated in 15 FIG. IA, preferably is a sleeveless bushing and has an outer rim surface 33 on each end thereof trapped and compressed between the beam and the inner walls of the depending panels of the frame hanger when the bushing is installed within the bore positioned at the forward end of beam 28 and beam 28 is connected to frame hanger 26. As such, this outer surface 33 of bushing 30 reacts against vehicle roll as the 20 vehicle negotiates sharp turns and the trapped conical rate of the bushing provides additional roll stability. Between their ends, beams 28-28 include an axle pivot bore 36 (see FIG. 3), which permits an axle clamp assembly generally designated by reference numeral 38 25 to connect the drive axle housing 22 to each beam 28 for pivotal movement. The axle 04/03/09.va 1 7824 speci, 15 - 16 pivot bore 36 is positioned at the center of the drive axle. The combination of beam and control rod linkages to the axle make the suspension non-reactive. Details of the axle clamp assembly 38 are set forth in further detail in the description regarding other figures of the drawing. 5 Further shown in FIGS. 1 and 2 is a longitudinally extending control or torque rod 40 that is connected between frame hanger 26 and a component part of axle clamp assembly 38. As such, two longitudinal torque rods 40-40 are included within suspension 24, each positioned on an opposite side of the vehicle. Together, torque rods 40 and beams 28 form a parallelogram geometry that contributes to the 10 desired characteristics exhibited by suspension 24. The optimized geometry distributes loads between the torque rods 40 and beams 28 so that they are shared. The load distribution, handling characteristics and roll stability of suspension 24 can be tuned by varying the geometry thereof. 15 Similarly, a laterally extending control or torque rod 42 is included within suspension 24 and connected between drive axle housing 22 and frame rail 10 on one side of the vehicle. Laterally extending torque rod 42 extends in a direction generally transverse to the direction in which longitudinally extending torque rods 40-40 extend. Accordingly, laterally extending torque rod 42 can also be referred to as a 20 transverse torque rod. An axle housing control rod mounting bracket 44 is mounted to drive axle housing 22 in order to permit the laterally extending torque rod 42 to connect to the drive axle housing. Similarly, a frame rail control rod mounting bracket 46 is 04/03/09,va 17824 speci.16 - 17 mounted to frame rail 10 on one side of the vehicle to permit laterally extending torque rod 42 to connect to the frame rail on which it mounts. Suspension 24 further includes a shock damper 48 connected at its upper end 5 to an upper shock bracket 50 mounted to frame rail 20 and at its lower end to the axle clamp assembly 38, as discussed in further detail in the description regarding other figures of the drawing. Suspension 24 further includes air springs 52-52 connected at their respective top ends to an air spring mounting bracket 54 that is mounted to frame rail 20. Air springs 52 are positioned on crossbrace 32 in a manner known in 10 the art such as by being seated on a conventional, suitable air spring mounting pad (not shown). FIG. 2 and FIG. 13 also illustrate an outboard bump stop 55 mounted on frame rail 20. As will be understood by those skilled in the art, in certain 15 applications, air will be exhausted from the suspension to ride on bump stops. For instance, this is done to increase vehicle stability during events such as tipping a dump body to unload. The top pad 78 will strike bump stop 55 during jounce and the vertical load will pass through the top pad directly into the clamped drive axle. Top pad 178 of FIG. 9 could also be used for this purpose. 20 FIG. 3. illustrates one of the longitudinally extending beams 28 used in the suspension 24 depicted in the FIG. 1. As shown, beam 28 includes a bore 56 positioned at one end thereof in order to permit installation of bushing 30 (FIG. IA) and attachment of beam 28 to frame hanger 26 (FIG. 1). From that end, beam 28 04/03/09,va 17824 speci.17 - 18 extends downwardly at a relatively continuous angle towards a point 58 to define a section 60 of the beam. From point 58, beam 28 curves upwards towards a direction where it travels along a relatively straight and horizontally extending path to define a section 61 of the beam. Beam 28 obtains the horizontally extending path at or near 5 the axle pivot bore 36 located in a central, rearward portion of the beam. From axle pivot bore 36, beam 28 extends generally horizontally to an open, square-like end 62 designed to receive and permit connection with the crossbrace 32 depicted in FIG. 1. FIGS. 4 and 5 illustrate the connection assembly 34 used to connect the end of each longitudinally extending beam 28 with an associated end of crossbrace 32 to 10 establish a joint between same. During operation of suspension 24, it will be appreciated that this joint will be subjected to high bending moments about all three axes of a three dimensional Cartesian coordinate system. Connection assembly 34 preferably includes a plug component 64 having a 15 bore 66, a retainer plate 68 also having a bore 70, and a fastener 72. Plug component 64 is secured within the interior of hollow crossbrace 32. It will be appreciated that in an alternative arrangement plug component 64 could be integrally formed with crossbrace 32 during the manufacturing process. 20 Retainer plate 68 is brought into contact with the outboard, square-like surface of end 62 of beam 28 to axially align bores 66, 70. Once aligned, fastener 72 is inserted through bores 66, 70 and the joint is formed between beam 28 and crossbrace 32 by drawing the crossbrace end towards the beam end. It will be appreciated that bore 66 can be tapped in order to facilitate formation of the joint 04/03/09,va 17824 speci, 18 - 19 between beam 28 and crossbrace 32. Other fastening arrangements can also be used. Still referring to FIGS. 4 and 5, crossbrace 32 includes inwardly tapered surfaces 74 defining the walls at each end. Similarly, the square-like end 62 of beam 5 28 has a tapered surface 76 defining each of its inner walls. Preferably, the tapered surfaces 74, 76 form a six degree angle. Inwardly tapered surfaces 74 of crossbrace 32 and inwardly tapered surfaces 76 of beam 28 are designed to allow corresponding ones of the surfaces to mate and cause frictional contact during vehicle operation. This frictional contact and squared geometry of the joint resists the torsional loads 10 about the lateral axis of crossbrace 32. This characteristic provides exceptional roll stability for suspension 24. FIG. 5 does not illustrate the air spring mounts positioned in close proximity to the ends of crossbrace 32. However, it will be appreciated that such mounts are positioned at those locations. 15 FIGS. 4A and 4B illustrate a retainer cap 400 used in lieu of the retainer plate 68 shown in FIGS. 4 and 5. Retainer cap 400 is a casting having a cavity 402 that allows the fastener bolt head to be recessed, which provides increased tire clearance. Additionally, the retainer cap 400 includes bumps 404 positioned on the inboard side in each of its four corners to engage the corresponding corner of beam 28 and 20 properly index the cap, while preventing it from rotating. FIG. 6 illustrates axle clamp assembly 38 having a top pad 78 and a bottom pad 80. Top pad 78 includes two projecting ears 04/03/09.va 17824 speci.19 - 20 82 having bores 84 extending through them. As shown in FIG. 1, longitudinally extending torque rod 40 can connect to axle clamp assembly 38, and particularly to top pad 78, by use of this structure. In that regard, a through bolt or the like can be inserted through axially aligned bores 84 to permit connection with longitudinally 5 extending torque rod 40. In a conventional arrangement, top pad 78 includes grooved surfaces (not shown) designed to receive U-bolts 85 and permit clamping of the drive axle housing. U-bolts 85 are preferably three-quarter inch. 10 FIG. 6A illustrates an axle clamp assembly having a top pad 278 that includes the control rod mounting feature, described above. Top pad 278 also includes a bump stop 500 positioned inboard that will hit the underside of the frame rail during jounce and pass vertical load directly into the drive axle housing. As shown, bump stop 500 is integrated with top pad 278, which desirably reduces the 15 number of suspension component parts. Referring back to FIG. 6, bottom pad 80 includes a lower shock bracket 86 integrally formed therewith. Lower shock bracket 86 permits attachment of the lower end of a shock damper such as shock damper 48 illustrated in FIG. 1. As such, the 20 shock damper can be connected between axle clamp assembly 38 and the vehicle frame rail. As shown, bores 87 are machined or cast into bottom pad 80 to allow U bolts 85 to clamp the vehicle drive axle housing. Fasteners 88 are threaded onto the ends of U-bolts 85 to clamp the axle housing between the top pad 78 and bottom pad 80 of axle clamp assembly 38. 04/03/09,va 17824 speci.20 -21 Bottom pad 80 is pivotally connected to longitudinally extending beam 28 by a D-shaped bar pin bushing 90, which is received within axle pivot bore 36. Bottom pad 80 includes a lower portion 92 defining a single leg and having a curved surface 5 94 that receives the curved portion of D-shaped bar pin bushing 90. Lower portion 92 also has a bore machined through it that is brought into registration with the bore machined into D-shaped bar pin bushing 90. Fastener assembly 96 includes a rod like element that extends through the bore machined through lower portion 92 of bottom pad 80 and the bore machined through D-shaped bar pin bushing 90. Fastener 10 assembly 96 is then fastened to connect the clamped drive axle housing to longitudinally extending beam 28, and bear against the flat surface of fl-shaped bar pin bushing 90. Through this arrangement, the axle pinion angle can be readily adjusted. 15 FIG. 7 illustrates a frame hanger 26 preferably used in the suspension 24 illustrated in FIG. 1. As shown, frame hanger 26 preferably includes mounting bores 98, which permit the frame hanger to be mounted to a vehicle frame rail. Frame hanger 26 further includes a control rod mounting flange 100 having bores 102 machined through it to permit connection with a longitudinally extending torque rod 20 40 by use of a bar pin or the like. Accordingly, frame hanger 26 includes control rod mounting features integrated therewith, which provides a natural path for longitudinal loads from the axle to the frame. Referring still to FIG. 7, another unique aspect of frame hanger 26 is 04103/09,va 17824 speci.21 - 22 structure that facilitates installation and connection of the bushing 30 (FIG. lA) used to connect an end of longitudinally extending beam 28 to the frame hanger. In that regard, frame hanger 26 includes two depending panels 104, 106 each having a bore 108, 110 machined through it. An inwardly projecting surface 112 is disposed around 5 the perimeter of bore 110 of depending panel 106. In similar fashion, an inwardly projecting surface (not shown) is disposed around the perimeter of bore 108 of depending panel 104. An inwardly tapering surface 114 extends from the inner wall of depending panel 106 to inwardly projecting surface 112. Similarly, an inwardly tapering surface (not shown) extends from the inner wall of depending panel 104 to 10 the inwardly projecting surface that is disposed about the perimeter of bore 108. As will be appreciated by those skilled in the art, this construction greatly facilitates assembly of the longitudinally extending beam 28 to frame hanger 26 by allowing the bushing to be positioned in registration with bores 108, 110 more readily. 15 Ideally, bores 108, 110 are aligned vertically with axle 22 to provide optimum performance of suspension 24. As hanger 26 hangs lower, however, it is greater in weight, provides less clearance, and requires more expense to manufacture. In any event, the characteristics of suspension 24 can be tuned by varying the position of the main beam pivot vis-A-vis the axle pivot. 20 To assemble the components illustrated in FIGS. 1 and 2, frame hangers 26, frame rail control rod mounting brackets 46 and upper shock damper mounting brackets 50 are mounted to frame rails 20 to form a frame subassembly. The axle clamp assembly 38 is then clamped to drive axle housing 22, while beams 28 are 04/03/09.va 17824 speci.22 - 23 connected to crossbrace 32 and connected to the axle clamp assembly by fl-shaped bar pin bushing 90. The longitudinally extending control rods 40 are connected to the top pads 78 for each axle clamp assembly 38, and the laterally extending control rod 42 is connected to the axle housing control rod mounting bracket 44 mounted on 5 drive axle housing 22 to form an axle subassembly. Thereafter, the axle subassembly is installed into the frame subassembly. Finally, the eccentric washer or member 31 is rotated clockwise or counter-clockwise to move the drive axle forward or rearward, as desired. Further, drop in shims (not shown) can be added at the longitudinal torque rod and frame hanger interface, as desired. 10 FIG. 8 also illustrates a vehicle suspension having a geometry identical to that shown in FIG. 1. In the suspension shown in FIG. 8, the axle clamp assembly includes a top pad 178 having a different construction from that depicted in FIGS. 1, 2 and 6. 15 Referring to FIG. 9, top pad 178 includes an axle clamp base portion 180 and a control rod mounting portion generally designated by reference numeral 182. Control rod mounting portion 182 includes two ear-like sidewalls 184, 186 and a curved top wall or dome surface 188, which can serve as a bearing surface that 20 strikes a bump stop mounted on the vehicle frame rail. Openings exist between sidewalls 184, 186 at opposite ends of the top pad to permit entry of a control rod. Sidewall 184 includes a bore 190 machined or cast through it. Similarly, sidewall 186 includes a bore 192 machined or cast through it. Bores 190, 192 are in 04/03/09,va 17824 spcci.23 - 24 registration such that a pin can extend between them and through a bore positioned at one end of a longitudinally extending control rod such as control rod 40 depicted in FIG. 8. Accordingly, similar to the top pad 78 shown in FIG. 6, top pad 178 has control rod mounting features integrated therewith. As will be appreciated, top pad 5 178 might be more structurally sound, but top pad 78 is lighter in weight because it ordinarily would require less material. FIG. 10 illustrates a suspension generally designated 200 that utilizes a V shaped control rod configuration defined by a V-shaped control rod assembly 10 generally designated 202. In that regard, frame hanger 226 and top pad 278 can be conventional in design, and need not have control rod mounting features associated and integrated therewith. V-shaped control rod assembly 202 connects to frame rails 220 by way of frame brackets 204 mounted thereon, and further connects with drive axle housing 15 222 by way of a bracket 206 mounted on the housing. It will be appreciated by those skilled in the art that V-shaped control rod assembly 202 reacts to both lateral and longitudinal forces produced during vehicle operation, and that it provides the upper links for the preferred parallelogram geometry used for the roll stable, non-torque reactive vehicle suspension of the present invention. 20 FIG. I 1 illustrates V-shaped control rod assembly 202. Assembly 202 includes an apex component 208 having a bushing 210 for connection with bracket 206 on the drive axle housing 222. Assembly 202 further includes control rods 212, 214 fastened to apex component 208 by fasteners 216. Control rods 212, 214 include 04/03/09,va 17824 speci,24 - 25 bushings 218 for attachment to frame brackets 204 mounted on opposing frame rails 222 that extend longitudinally along opposite sides of the vehicle. Apex component 208 includes two recessed portions 224 defining channels that permit connection with control rods 212, 214 and direct them along their desired path, orientating them 5 towards frame rails 220. FIG. 12 illustrates a suspension generally designated 300 that utilizes a two rod control rod configuration. In that regard, a longitudinally extending control rod 302 connects to a cross member 304 of frame rails 306 by way of a frame bracket 10 308 mounted to the cross member, and further connects with drive axle housing 310 by way of bracket (not shown) mounted on the housing. This connection is not shown to facilitate illustration of this control rod configuration. Similarly, a laterally extending control rod 314 connects to one frame rail 306 by way of a frame bracket 316 mounted thereon, and further connects with drive axle housing 310 by way of a 15 bracket 318 mounted on the housing. It will be appreciated by those skilled in the art that control rod 302 reacts to longitudinal torque forces produced during vehicle operation, and control rod 314 reacts to lateral torque forces produced during vehicle operation. Together, control rods 302, 314 provide the upper links for the preferred parallelogram geometry used for the roll stable, non-torque reactive vehicle 20 suspension of the present invention. While this invention has been described with reference to certain illustrative embodiments, it will be understood that this description shall not be construed in a limiting sense. Rather, various changes and modifications can be made to the 04/03/09.va 17824 speci,25 - 26 illustrative embodiments without departing from the Erue spirit and scope of the invention, as defined by the following claims. Furthermore, it will be appreciated that any such changes and modifications will be recognized by those skilled in the art as an equivalent to one or more elements of the following claims, and shall be covered 5 by such claims to the fullest extent permitted by law. Throughout this specification and the claims which follow, unless the context requires otherwise, the word "comprise", and variations such as "comprises" and "comprising", will be understood to imply the inclusion of a stated integer or step or 10 group of integers or steps but not the exclusion of any other integer or step or group of integers or steps. The reference to any prior art in this specification is not, and should not be taken as, an acknowledgment or any form or suggestion that the prior art forms part 15 of the common general knowledge in Australia. 04/03/09,va 17824 speci.26

Claims (24)

1. A vehicle suspension sub-assembly, including: 5 a first suspension component extending in a first direction and having a first end and an open end, said open end defined by open end inner walls extending in a second direction generally normal to said first direction, said open end inner walls being tapered and arranged to have a generally square-like geometry; a second suspension component connected to said first suspension 10 component and extending in said second direction, said second component having a first end and a second end, said first end of said second suspension component defined by outer walls extending in said second direction, said outer walls arranged to have a generally square-like geometry, said outer walls being tapered and adapted to mate with said open end inner walls of said first suspension component; 15 said first and second suspension components being connected in a manner such that said tapered open end inner walls of said first suspension component are in frictional contact with said tapered outer walls of said second suspension component. 20

2. The vehicle suspension sub-assembly defined by claim I wherein said first suspension component includes a beam designed to extend longitudinally in a vehicle suspension.

3. The vehicle suspension sub-assembly defined by claim I wherein said second 25 suspension component includes a crossbrace designed to extend laterally in a vehicle suspension.

4. The vehicle suspension sub-assembly defined by claim 3 wherein said crossbrace is hollow. 30 04/03/09,va 17824 speci,27 - 28 5. The vehicle suspension sub-assembly defined by claim I wherein said manner of connection between said first and second suspension components defines a joint having a square-like geometry.

5

6. The vehicle suspension sub-assembly defined by claim 5 wherein said joint and said square-like geometry of said joint cause torsional loads about an axis defined in said second direction along said second suspension component to be resisted during operation of a vehicle incorporating a vehicle suspension having said vehicle suspension sub-assembly. 10

7. The vehicle suspension sub-assembly defined by claim 6 wherein said joint includes a machine taper joint.

8. The vehicle suspension sub-assembly defined by claim I wherein said outer 15 walls are inwardly tapered towards said first end of said second suspension component and said open end inner walls of said first suspension component are inwardly tapered in corresponding fashion.

9. The vehicle suspension sub-assembly defined by claim I wherein said outer 20 walls are machine tapered and said open end inner walls are machine tapered.

10. A vehicle suspension sub-assembly, including: a beam extending in a first direction and having a first end and an open end, said open end defined by open end inner walls extending in a second 25 direction generally normal to said first direction, said open end inner walls being tapered and arranged to have a generally square-like geometry; a crossbrace connected to said beam and extending in said second direction, said crossbrace having a first end and a second end, said first end of said crossbrace defined by outer walls extending in said second direction, said outer walls 30 arranged to have a generally square-like geometry, said outer walls being tapered and adapted to mate with said open end inner walls of said beam; 04/03/09,va 17824 speci.28 - 29 said beam and crossbrace being connected in a manner such that said tapered open end inner walls of said beam are in frictional contact with said tapered outer walls of said crossbrace. 5

11. The vehicle suspension sub-assembly defined by claim 10 wherein said beam is designed to extend longitudinally in a vehicle suspension.

12. The vehicle suspension sub-assembly defined by claim 10 wherein said crossbrace is designed to extend laterally in a vehicle suspension. 10

13. The vehicle suspension sub-assembly defined by claim 10 wherein said crossbrace is hollow.

14. The vehicle suspension sub-assembly defined by claim 10 wherein said 15 manner of connection between said beam and said crossbrace defines a joint having a square-like geometry.

15. The vehicle suspension sub-assembly defined by claim 14 wherein said joint and said square-like geometry of said joint cause torsional loads about an axis 20 defined in said second direction along said crossbrace to be resisted during operation of a vehicle incorporating a vehicle suspension having said vehicle suspension sub assembly.

16. The vehicle suspension sub-assembly defined by claim 15 wherein said joint 25 includes a machine taper joint.

17. The vehicle suspension sub-assembly defined by claim 10 wherein said outer walls are inwardly tapered towards said first end of said crossbrace and said open end inner walls of said beam are inwardly tapered in corresponding fashion. 30

18. The vehicle suspension sub-assembly defined by claim 10 wherein said outer walls are machine tapered and said open end inner walls are machine tapered. 04/03/09.va 17824 speci.29 - 30

19. A vehicle suspension connecting a vehicle drive axle housing to first and second vehicle frame rails extending longitudinally on opposite sides of a vehicle, including: 5 a first frame hanger mounted to said first frame rail; a second frame hanger mounted to said second frame rail; a first longitudinally extending beam having a first beam first end connected to said first frame hanger and a first beam open end opposite said first beam first end, said first beam open end defined by laterally extending first beam 10 open end inner walls, said first beam open end inner walls being tapered and arranged to have a generally square-like geometry, said first beam connected to said vehicle drive axle housing; a second longitudinally extending beam having a second beam first end connected to said second frame hanger and a second beam open end opposite 15 said second beam first end, said second beam open end defined bilaterally extending second beam open end inner walls, said second beam open end inner walls being tapered and arranged to have a generally square-like geometry, said second beam connected to said vehicle drive axle housing; a laterally extending crossbrace connected to said first and second 20 beams, said crossbrace having a first end and a second end; said first end of said crossbrace defined by laterally extending first end outer walls, said first end outer walls arranged to have a generally square-like geometry, said first end outer walls being tapered and adapted to mate with said first beam open end inner walls, said first beam and said crossbrace being connected in a 25 manner such that said tapered first beam open end inner walls are in frictional contact with said tapered first end outer walls of said crossbrace; and said second end of said crossbrace defined by laterally extending second end outer walls, said second end outer walls arranged to have a generally square-like geometry, said second end outer walls being tapered and adapted to mate 30 with said second beam open end inner walls, said second beam and said crossbrace being connected in a manner such that said tapered second beam open end inner 04/03/09.va 17824 speci.30 -31 walls are in frictional contact with said tapered second end outer walls of said crossbrace.

20. The vehicle suspension defined by claim 19 wherein said crossbrace is 5 hollow.

21. The vehicle suspension defined by claim 19 wherein said manner of connection between said first beam and said crossbrace defines a first joint having a square-like geometry and said manner of connection between said second beam and 10 said crossbrace defines a second joint having a square-like geometry.

22. The vehicle suspension defined by claim 21 wherein said first and second joints and said square-like geometries of said first and second joints cause torsional loads about a lateral axis of said crossbrace to be resisted during operation of a 15 vehicle incorporating said vehicle suspension.

23. The vehicle suspension defined by claim 22, wherein said first joint includes a machine taper joint and said second joint includes a machine taper joint. 20

24. The vehicle suspension defined by claim 19 wherein said first end outer walls are inwardly tapered towards said first end of said crossbrace, said first beam open end inner walls are inwardly tapered towards said first end of said crossbrace, said second end outer walls are inwardly tapered towards said second end of said crossbrace, and said second beam open end inner walls are inwardly tapered towards 25 said second end of said crossbrace. 04/03/09,va 17824 speci,31