阅读说明：本技术 例如用于车轴/悬挂系统的重载连接 (Heavy-duty connection, for example for axle/suspension systems ) 是由 S·马肯 S·巴布 N·威尔逊 于 2018-10-23 设计创作，主要内容包括：通过将连接器套筒(2)装配到车轴上,并使组件经受压接操作,将诸如车轴轴颈或悬挂梁(3)的车辆部件连接到管状车轴(1),在压接操作中,通过在连接区域(11、12)处在连接器套筒和车轴壁中的凹进形成多个凹陷(206、2018),以将连接器套筒固定在管状车轴上。在所描述的提议中,在压接之前,在连接区域处在连接器套筒(2)与车轴(1)之间施加固体润滑剂(4),例如二硫化钼。然后,另一个车辆部件(3)通过焊接而连接到连接器套筒(2)。(A vehicle component, such as an axle spindle or suspension beam (3), is connected to a tubular axle (1) by fitting a connector sleeve (2) onto the axle and subjecting the assembly to a crimping operation in which a plurality of recesses (206, 2018) are formed by recesses in the connector sleeve and the axle wall at connecting regions (11, 12) to secure the connector sleeve on the tubular axle. In the described proposal, a solid lubricant (4), for example molybdenum disulfide, is applied between the connector sleeve (2) and the axle (1) at the connection region before crimping. Then, the other vehicle component (3) is connected to the connector sleeve (2) by welding.)

1. A method of connecting a metallic inner component (1) to a metallic outer component (2), the inner component having a wall with an outer connecting surface, the outer component having a wall complementary to the outer connecting surface of the inner component, the method comprising:

-fitting together the inner part (1) and the outer part (2) with the walls complementary;

forming one or more recesses (206, 208) in both of said walls by recessing to provide mating engagement between said inner and outer components at their aligned recesses to connect them together by mechanical interlocking, and

it is characterized in that

-providing a lubricant (4) between the inner part and the outer part at connection areas (11, 12) forming the one or more depressions, such that the lubricant is present between recessed wall portions of the inner and outer parts.

2. The method according to claim 1, wherein the lubricant (4) is a solid lubricant, such as molybdenum disulphide, graphite, boron nitride (h-BN) or tungsten disulphide.

3. Method according to claim 1 or 2, wherein the lubricant is pre-applied to the connection area and to the outer surface of the inner part (1), or to the inner surface of the outer part (2) at the connection area (11, 12), or to both said surfaces, in the form of a fluid or a carrier, such as a paste, grease or spray.

4. A method according to claim 1, 2 or 3, wherein a plurality of said recesses (206, 208) are formed as an array distributed around said inner part (1) and said outer part (2).

5. The method according to any one of the preceding claims, wherein the one or more recesses (206, 208) are inwardly oriented such that an outer surface of the outer component (2) is recessed and an inner surface of the inner component (1) protrudes inwardly.

6. The method according to any of the preceding claims, wherein the inner member (1) is a tubular member.

7. The method according to any one of the preceding claims, wherein the interior component (1) is a vehicle axle.

8. The method according to any of the preceding claims, wherein the outer part (2) comprises or consists of a tube or a partial tube fitting on or around the outer connection surface of the inner part (1).

9. Method according to any of the preceding claims, comprising subsequently attaching a further component (3) to the outer component, preferably using welding.

10. A method according to any of the preceding claims, wherein the edge (22) of the outer part (2) overlying the outward surface of the inner part (1) has an inwardly directed edge surface portion (23) angled away from the outward surface of the inner part (1), e.g. as a chamfer or radius.

11. The method according to any one of the preceding claims, comprising providing a seal (6) along an edge of the outer part (2) forming a boundary to keep the lubricant (4) at the connection region (11, 12) and/or keep contaminants out of the connection region.

12. A connected assembly comprising an inner component (1) and an outer component (2) connected to the inner component (1), the assembly being obtained or obtainable by the method of any one of claims 1 to 11 and having the one or more recesses (206, 208) and lubricant (4) present at the one or more recesses (206, 208) at the interface between the inner component (1) and the outer component (2).

13. A method of connecting a vehicle component (2, 3) to a tubular axle (1), comprising:

fitting a connector sleeve (2) onto or around the axle shaft and providing a solid lubricant (4) interposed between the connector sleeve and the axle shaft at a connection region (11, 12),

the resulting assembly is crimped to form a plurality of recesses (206, 208) in the connector sleeve and in the wall of the axle at the connection region to secure the connector sleeve to the tubular axle.

14. The method according to claim 13, comprising attaching another vehicle component, such as a suspension component (3), a brake assembly or an axle spindle, to the connector sleeve (2) by means comprising welding.

15. An axle assembly obtainable by the method of claim 13 or 14, comprising the axle (1), the connector sleeve (2) in a crimped form, and optionally a suspension component (3), a brake assembly or an axle spindle attached to the connector sleeve, the lubricant (4) being present between the connector sleeve and the axle at the connection region (11, 12).

16. The axle assembly of claim 15, wherein the suspension component (3) is a suspension beam that is attached to the connector sleeve by welding.

17. A method or component according to any of claims 13 to 16, wherein the lubricant is a solid lubricant, preferably comprising molybdenum disulphide.

Technical Field

The present invention relates to a method for connecting heavy-duty metal components, in particular wherein a hollow inner component, such as a vehicle axle tube, is connected at its outer surface to another component (e.g. a suspension beam or other component), in particular by means of a sleeve-shaped outer component. A connection assembly manufactured using this method is one aspect of our proposal.

Background

In WO2012/044802 (corresponding to US8454040 and EP2621737, etc.) filed by Hendrickson USA, l.l.c., a method for connecting an axle tube to a suspension beam is described, which is not by direct welding, as in the conventional method, but by the intervention of a separate outer sleeve part fitted around the axle. For the connection, the sleeve member is slid over the axle tube in a close-fitting manner, and then the assembly is subjected to a crimping or swaging operation to simultaneously form a set of permanent recesses or depressions in both components, the sleeve member desirably undergoing greater plastic deformation than the axle wall. Desirably, a series or array of such depressions is formed around the axle tube. The formation of the depression creates a strong mechanical interlock, while the greater elastic recovery of the axle tube wall forces it to bias against the inside of the sleeve at the location of the depression, creating a permanent strong joint, resulting in a rigid joint without play. The associated outer suspension component is then welded to the sleeve rather than directly to the axle, allowing the use of relatively thin wall (and therefore light weight) axles, while the resulting connection is found to have good strength and rigidity. A similar approach is proposed for connecting the beam to the suspension cross-brace (see, for example, US9079467B) and mounting the brake assembly to the axle.

Disclosure of Invention

It is an object herein to provide a new and useful connection method of the type described, as well as heavily loaded connected assemblies, such as axle/suspension assemblies and subassemblies thereof, which may have improved fatigue strength and/or product life. Use in axle/suspension assemblies for heavy-duty vehicles (trucks, lorries, semitrailers, etc.) is a preferred field of application.

In a first aspect, the present invention provides a method for connecting an inner metal part to an outer metal part. The inner member has a wall which preferably defines a lumen, and in a preferred embodiment the inner member is a tubular member, in particular a cylindrical tubular member. It may be an axle/suspension component, such as an axle/suspension component for a heavy-duty vehicle. It may be an axle, a cross brace or the like. The outer part is formed with a wall complementary to the outer connection surface of the wall of the inner part and preferably comprises or consists of a tube or part of a tube fitting on and/or around the outer connection surface of the inner part. The outer component desirably constitutes an intermediate construction by which the inner component is connected to another component or structure. The other component or structure may be, for example, a suspension component in a vehicle suspension, such as a beam in a heavy-duty vehicle axle/suspension system, a spring beam, an axle seat, a braking system, an axle journal, or the like. However, the present invention may be used in other technical fields. In particular, it is contemplated that the connection of an outer component to an inner component by the present method may be substituted for the connection of another component or structure to the inner component by welding or by penetrating fasteners such as bolts or the like. Although the outer component may be included in such other components or structures, we prefer that the outer component be discrete, at least when it is connected to the inner component. This enables the use of a simple form of external component, such as a sleeve or part of a sleeve, which is easy to manipulate.

In this connection method, the inner and outer components are fitted together and one or more recesses are formed in the inner and outer components by recessing, desirably simultaneously, and desirably inwardly oriented (such that the outer surface of the outer component is recessed and the inner surface of the inner component projects inwardly), each respective recess having a mating engagement between the inner and outer components to connect them together by mechanical interlocking. It is desirable to form a plurality of such recesses/depressions, for example in an array distributed around the component, as described in the above-mentioned patent documents.

According to the invention, lubricant is provided between the inner part and the outer part at the connection region where the recess is formed, so that lubricant is present between the recessed wall portions of the two parts. Preferably, such a lubricant is provided for each or all recesses, e.g. all around the component. Depending on the shape of the components and the consistency and adhesion of the lubricant, the lubricant may be pre-applied to the outer surface of the inner component or the inner surface of the outer component at the connection area, or to both the outer surface of the inner component and the inner surface of the outer component.

At another stage of the process, another component or structure is typically attached to the external component, and preferably the attachment uses welding. The other components or structures may be of any of the types described above.

A second aspect of the invention is a connection assembly of an inner part and an outer part having said one or more recesses and a lubricant present at the one or more recesses at the interface between the inner part and the outer part, obtained or obtainable by the method described, and preferably also comprising said other structure or part connected to the outer part, e.g. by welding.

As mentioned above, it is generally preferred that the outer part has more plastic deformation than the inner part, so that the wall of the inner part is forced into contact with the wall of the outer part by the different elastic recovery at the recessed area. Ideally, the components are made of steel. The outer component may be made of a lower grade or lower carbon steel than the inner component.

Preferably, the lubricant is or includes a solid lubricating compound. Known solid lubricants, preferably inorganic compounds such as molybdenum disulfide, graphite, boron nitride (h-BN), tungsten disulfide or the like, may be used. A typical characteristic of solid lubricants is that they adhere relatively fixedly to one of the two metal surfaces and subsequently withstand high loads between them without displacement. A further feature that may be provided by appropriately selected solid lubricants is that they are able to withstand high operating temperatures, particularly in generally static conditions, such as in fixed connection joints. This is important for components that are welded in the vicinity of the connection joint because such welds are susceptible to degradation of conventional lubricants such as soap/oil-based greases. However, a grease or grease-type composition, paste or other fluid form may be conveniently used as a carrier for the application of the solid lubricant. The solid lubricant may remain in place and perform its function even after other components of the lubricant composition may have dispersed or degraded. Such compositions are also available in sprayable form and the compositions can be conveniently used. The method of application of the lubricant may be selected based on, for example, the type, consistency and adhesion of the lubricant (or type, consistency and adhesion of the carrier composition) and the material, size, shape, etc. of the surface of the component or components to which the lubricant is to be applied. Brushing and spraying are often suitable methods.

Molybdenum disulfide containing lubricant compositions are particularly preferred for the present invention. Lubricants that are capable of maintaining a film formation under static load conditions at a temperature of at least 700 ℃ or at least 800 ℃ are preferred. In fact, temperatures of 400 ℃ or higher may occur in the joining region and need to be withstood by the lubricant without the lubricant losing its resistance to fretting.

The basic idea of the present invention stems from the research made by the present inventors on heavy-duty connecting axle-beam joints produced as described in the above-mentioned prior art documents. These connections are generally found to have good performance and satisfactory durability, but we are always looking for possible improvements. When examining prior art types of sample connections, we accidentally found micro-motion marks between the inner and outer components at the recessed contact area. This is unexpected because the parts appear to be completely fixed, but research studies have revealed some areas of wear type associated with micromotion, that is to say repeated relative movements of the contact surfaces, albeit of small amplitude. Of course, in the actual recessing process (crimping or swaging), there is an initial forced frictional movement of the parts relative to each other. The proposed use of a lubricant has been found to reduce both the absolute level and the range of variation of this friction relative to known processes without a lubricant. It is also conceivable that during use of the connected components, for example in suspension systems of heavy-duty vehicles, they are subjected to forced vibrations, producing small but powerful repetitive movements, which may lead to fretting-type damage. Since micro-motion may ultimately be associated with corrosion and fracture initiation, by significantly reducing any such micro-motion, the reliable life and fatigue resistance of the components so connected may also be improved. By experimentation we have found that this is indeed achieved by introducing a lubricant between the components at the joint region.

Thus, in one preferred aspect of our proposal, a method of connecting a vehicle component to a tubular axle comprises: fitting the connector sleeve onto or around the axle with a solid lubricant interposed between the connector sleeve and the axle at the connection area, and subjecting the assembly to a crimping operation in which a plurality of recesses are formed by the recesses in the walls of the connector sleeve and the tubular axle at the connection area to secure the connector sleeve on the tubular axle. Another vehicle component, such as a suspension component, a brake assembly, or an axle spindle, is preferably connected to the connector sleeve after the connector sleeve is crimped onto the axle tube, and preferably by a means that includes or consists of welding. Alternatively, another vehicle component may be connected to the connector sleeve before the connector sleeve is crimped onto the axle tube, or may be integrally formed with the connector sleeve. The sleeve may be a complete sleeve or a partial sleeve that does not completely surround the axle.

Another aspect is an axle tube assembly that includes a crimp-style connector sleeve, wherein a lubricant is present between the connector sleeve and the axle tube at the connection region. Another aspect is an axle assembly that additionally includes another vehicle component, such as a suspension component, connected to the axle shaft, for example, through or by a connector sleeve, as mentioned above. Preferably, the mechanical connection between the connector sleeve and the axle tube is achieved solely by the interengagement of the recesses.

Ideally, in addition to forming the depressions, the crimping process generally swages or reduces the size of the outer member (sleeve) so that its inner surface is in substantially intimate contact against the outer surface of the inner member (axle tube). Generally, to facilitate pre-assembly, the components have a loose fit prior to crimping, especially in the presence of a lubricant. In contrast, the tight fit after crimping helps to keep water and other fluids out of the interface where the lubricant is located so that the lubricant can remain substantially in place without being contaminated or washed out even when liquid is present in the environment, such as during painting or under other wet conditions. In practice, the crimping of the sleeve itself is generally sufficient and effective to provide such watertightness between the outer and inner components.

If desired, a sealing element acting between the outer and inner components may be provided to form a boundary to retain lubricant at the joint region where its action is required and/or to retain contaminants or water outside the joint region. Such sealing may be provided by applying a sealant composition to the components after assembly of the components together, before or after formation of the recess, typically at/along the edge of an outer component or sleeve covering the inner component. This may help to keep lubricant present near the edge region where micro-motion may otherwise result from the edge contacting the internal components. Additionally or alternatively, one or both of the inner and outer components may have a retaining formation, such as a lip or bead formation, to inhibit escape of the lubricant composition from the joint area when the components are assembled together.

Another option is for the edge of the outer member or sleeve overlying the outward facing surface of the inner member (especially where the outward facing surface of the inner member extends beyond the edge) to have an inwardly directed edge surface portion that angles away from the outward facing surface, for example as a chamfer or enlarged radius of the inward edge of the outer member, to provide some clearance, for example radial clearance, between the inner member and the outer member surface in the secured or crimped condition. This reduces the likelihood that the normal square edge will joggle.

Such a gap may also constitute a covered groove extending along the edge, in which groove a seal or sealant may be conveniently positioned, for example as suggested above. The overhang of the outer component edge helps to locate the seal/sealant and protect the seal/sealant during subsequent use of the component (e.g., on a vehicle).

Other aspects we propose are set out in the claims.

Drawings

Examples of the invention will now be described with reference to the accompanying drawings, in which:

FIG. 1 is a perspective view of a heavy-duty vehicle axle (truck axle) fitted with a connector sleeve according to our proposal;

FIG. 2 shows the axle tube prior to assembly of the sleeve;

FIGS. 3 and 4 are end views of the axle shaft with the sleeve assembled before and after the crimping operation, respectively;

FIG. 5 is a perspective view showing a portion of a heavy-duty vehicle (truck) suspension assembly incorporating an axle embodying our proposal and showing a cross-section at the interface region;

FIG. 6 is an enlarged view of a similar cross-section at the area of the connection;

FIG. 7 is a longitudinal axial cross-sectional view at the connection area showing the edge shaping of the connector sleeve; and

figure 8 shows a detail of the seal at the edge of the connector sleeve.

Detailed Description

Fig. 1 shows a tubular steel truck axle 1 fitted with four connector sleeves 2. A connector sleeve 2 at the end of the axle tube 1 is used for connecting an axle spindle (not shown). Spaced from the ends of the axle tube are two further connector sleeves 2 for welded connection to respective suspension elements, such as arms, links, springs or beam members, by which the axle is connected to the vehicle frame, typically by a pivot at a frame hanger or the like, to constitute a suspension system. These general features of heavy duty suspension assemblies and suspension systems are well known.

In these embodiments, the axle tube 1 and the connector sleeve 2 constitute embodiments of the inner and outer components in general terms of the present disclosure.

Fig. 2 shows the axle tube 1 prior to fitting the sleeve and indicates the connection areas, in particular the first and second journal connection areas 12 at the ends of the tube and the first and second beam connection areas 11 spaced inwardly from the first and second journal connection areas 12. The longer central region 10 of the axle extends between them.

Fig. 2 shows (by shading) a lubricant composition 4 applied to the outer surface 101 of the axle tube at the connection regions 11, 12, in the form of an anti-fretting paste comprising a molybdenum disulphide solid lubricant. The outer tube surface can be prepared for cleaning and good adhesion, in particular for removing small particles which may be abrasive, for example by shot blasting, cleaning or the like. The lubricant paste may be applied by brushing, or the lubricant may be applied by spraying in a more fluid formulation. These lubricant types provide very low friction and have high pressure resistance and high temperature resistance up to about 800 ℃. Those skilled in the art will recognize other molybdenum disulfide containing compositions, and other types of solid lubricant compositions that may be used instead.

The connector sleeve 2 made of steel is fitted at the connection regions 11, 12 by a crimping process, as generally described in WO 2012/044802. The sleeve fits around the axle tube with a slight radial clearance so that the applied lubricant does not significantly displace. In a typical example, the outer diameter of the axle tube 1 may be 100-150 mm and the wall thickness may be 5-10 mm. The thickness of the connector sleeve 2 may be, for example, 5-10 mm. The initial fit clearance between the sleeve inner diameter and the tube outer diameter may be, for example, 1-5 mm radially (i.e., considered in the concentric case). The connector sleeve may be a continuous sleeve or a welded sleeve; the weld 21 is shown in figure 3.

As described in WO2012/044802, the preassembly is subjected to a crimping and swaging process in a suitable apparatus having a die set selected to recess the component walls and create a series of circumferentially and longitudinally localized recesses or depressions around the axle tube assembly at each sleeve, as shown in fig. 1. Fig. 4 shows by end view the significant recess of the walls of the two components and the elimination of the initial gap between the components by the swaging effect.

During such deformation, the anti-fretting paste 4 serves to reduce friction and possible fretting between the inner and outer parts during the crimping operation. The material of the connector sleeve 2 is a lower carbon steel than the axle tube 1 and undergoes more plastic deformation during the crimping operation so that after elastic recovery of the components, the concave outer surfaces of the axle tube indentations 208 are forced outwardly into contact with the convex inner surfaces of the respective sleeve indentations 206 (see fig. 6), thereby creating a completely rigid connection between the connector sleeve 2 and the axle tube 1. The embodiment shown has eight recesses distributed around the tube. The number is not strictly limited and may be, for example, 2 to 10, and may be selected according to the size and shape of the components to provide the necessary degree of safety.

Fig. 5 shows how the axle tube 1 assembled with the connector sleeve 2 is connected to a suspension member, in this example a beam 3 of a trailing arm, to form a suspension assembly 214 on one side of the suspension system. In this embodiment, the beam 3 constitutes "another component" in the generic term as used herein.

The illustrated beam 3 has a hollow manufactured form. The channel form members constitute the top and side walls 266 of the beam and the base plate 263 welded along the bottom edge of the side walls 266 completes the structure. The beam has a front end 220 with a sleeve 242 for pivotal connection to the frame and a rear end 226, the rear end 226 projecting rearwardly of the axle location where an air spring may be mounted. The two side walls 266 have aligned circular openings 209 sized and spaced to receive the single connector sleeve 2 of the axle assembly. The assembly is completed by forming a circular weld CW around the opening between the connector sleeve 2 and each side wall 266 of the beam 3. The convenience of only welding the connection is achieved, but not directly to the axle. By avoiding direct welding to the axle, localized stress risers can be avoided or reduced, and durability and longevity improved. Furthermore, the solid lubricant selected in the area of the connection between the sleeve and the axle shaft is able to withstand the environment at that location during a nearby weld, which may typically rise to about 500 ℃.

Since a film of lubricant is then held between the contact surfaces of the axle tube 1 and the connector sleeve 2, fretting and corrosion are suppressed in these regions even under use conditions including vibration, and an increase in the average life can be expected. The crimp contact is sufficiently tight and uniform over the fitting to protect the lubricated zone from water in normal operation.

Fig. 7 shows a preferred configuration at the edge 22 of the connector sleeve 2. Here, one sleeve edge 22 overlies the corresponding edge 10 of the end of the axle tube 1, and the other sleeve edge 22 overlies the outer surface 101 of the axle tube that extends beyond the connector sleeve 2. At each edge 22, the original "square" inner edge corner is machined back to an enlarged radius or chamfer, forming an inwardly directed edge surface portion 23 that is angled and spaced from the outer axle surface 101 and defines a converging groove 5 therebetween. The end of the connector sleeve 2, which may tend to frictionally or micro-engage the axle surface 101 during deformation under load, presents a rounded and gently angled surface to minimize the possibility of such frictional damage.

In addition, the groove 5 may be used to help form a preventative external seal around the lubricant-containing joint area. Fig. 8 shows in partial cross-section how a sealant, such as a polyurethane or silicone sealant, can be applied around the edge 22 in the groove 5 to form a sealing bead 6. The overhang of the sleeve edge 22 on the groove 5 helps to protect the sealing strip 6 from damage during subsequent use of the shaft.

It will be appreciated that not only the suspension beam, but also another component of another kind, such as a brake system element or an axle spindle, may be secured to the axle in a similar manner.