Suspension system having high strength arm to axle connection

Abstract

A suspension system having a high strength arm to axle connection. In a described example, a suspension system includes a laterally extending axle and an arm assembly welded to the axle. The arm assembly includes a longitudinally extending arm body having top and bottom surfaces, an axle connector welded to the axle and an end of the arm body, and a plate extending longitudinally over and welded to the arm body top surface, wrapped rearwardly about and welded to the axle connector, and extending longitudinally over and welded to the arm body bottom surface. In a method of constructing a suspension system, the method includes the steps of welding an axle connector to an axle; welding a plate to the axle connector, the plate being wrapped rearwardly about the axle connector; and welding an arm body to the axle connector and to the plate, the arm body having top and bottom surfaces, and the plate being welded to each of the top and bottom surfaces.

1 . A suspension system, comprising: 
 a laterally extending axle; and    an arm assembly welded to the axle, the arm assembly including: 
 a longitudinally extending arm body having first and second surfaces,  
 an axle connector welded to the axle and a first end of the arm body, and  
 a first plate extending longitudinally over and welded to the arm body first surface, wrapped rearwardly about and welded to the axle connector, and extending longitudinally over and welded to the arm body second surface.  
   
   
   
       2 . The system of  claim 1 , wherein the axle connector is welded to the axle at a position proximate a horizontal axis of the axle approximately midway between upper and lower extents of the axle.  
   
   
       3 . The system of  claim 2 , wherein the axle connector includes an opening at the position proximate the horizontal axis, wherein the axle connector is welded to the axle about the opening, and wherein the first plate overlies the opening when the first plate is welded to the axle connector.  
   
   
       4 . The system of  claim 2 , wherein the axle connector includes at least one seam extending completely laterally across the axle connector, and wherein the axle connector is welded along the seam proximate the horizontal axis of the axle.  
   
   
       5 . The system of  claim 4 , wherein the first plate overlies the seam when the first plate is welded to the axle connector.  
   
   
       6 . The system of  claim 2 , wherein the axle connector includes at least two seams extending completely laterally across the axle connector dividing the axle connector into at least two sections, and wherein the axle connector is welded along each of the seams proximate the horizontal axis of the axle.  
   
   
       7 . The system of  claim 1 , wherein a pivot connection sleeve is welded to a second end of the arm body opposite the first end.  
   
   
       8 . The system of  claim 7 , wherein a lever arm is welded to the sleeve.  
   
   
       9 . The system of  claim 8 , wherein an axle lift actuator is connected between the lever arm and a hanger bracket.  
   
   
       10 . The system of  claim 7 , wherein the first plate is welded to the sleeve.  
   
   
       11 . The system of  claim 1 , wherein the arm body has a generally U-shaped cross-sectional shape with at least two generally vertically extending legs and a base extending between the legs, and wherein the first plate is welded to the at least two legs and to the base.  
   
   
       12 . The system of  claim 1 , wherein the arm body has a box cross-sectional shape and includes at least two generally vertical legs, and a second plate joined to the legs, the first plate overlapping the second plate.  
   
   
       13 . The system of  claim 1 , wherein the arm body has a generally I-shaped cross-sectional shape with upper and lower generally horizontally extending flanges, and wherein the first plate is welded to the flanges.  
   
   
       14 . A method of constructing a suspension system, the method comprising the steps of: 
 welding an axle connector to an axle;    welding a plate to the axle connector, the plate being wrapped rearwardly about the axle connector; and    welding an arm body to the axle connector and to the plate, the arm body having first and second surfaces, and the plate being welded to each of the first and second surfaces.    
   
   
       15 . The method of  claim 14 , wherein the plate welding step is performed after the axle connector welding step.  
   
   
       16 . The method of  claim 14 , wherein the arm body welding step is performed after the plate welding step.  
   
   
       17 . The method of  claim 16 , wherein the plate welding step is performed after the axle connector welding step.  
   
   
       18 . The method of  claim 14 , wherein the axle connector welding step further comprises welding the axle connector to the axle at a position proximate a horizontal axis of the axle approximately midway between upper and lower extents of the axle.  
   
   
       19 . The method of  claim 18 , wherein the axle connector includes an opening at the position proximate the horizontal axis, wherein the axle connector welding step further comprises welding the axle connector to the axle about the opening, and wherein the plate welding step further comprises welding the plate with the plate overlying the opening.  
   
   
       20 . The method of  claim 18 , wherein the axle connector includes at least one seam extending completely laterally across the axle connector, and wherein the axle connector welding step further comprises welding along the seam proximate the horizontal axis of the axle.  
   
   
       21 . The method of  claim 20 , wherein the plate welding step further comprises welding the plate with the plate overlying the seam.  
   
   
       22 . The method of  claim 18 , wherein the axle connector includes at least two seams extending completely laterally across the axle connector dividing the axle connector into at least two sections, and wherein the axle connector welding step further comprises welding along each of the seams proximate the horizontal axis of the axle.  
   
   
       23 . The method of  claim 14 , further comprising the step of welding a pivot connection sleeve to the arm body.  
   
   
       24 . The method of  claim 23 , further comprising the step of welding a lever arm to the sleeve.  
   
   
       25 . The method of  claim 24 , further comprising the step of connecting an axle lift actuator between the lever arm and a hanger bracket.  
   
   
       26 . The method of  claim 23 , further comprising the step of welding the plate to the sleeve.  
   
   
       27 . The method of  claim 14 , wherein the arm body has a generally U-shaped cross-sectional shape with at least two generally vertically extending legs and a base extending between the legs, and wherein the plate welding step further comprises welding the plate to the legs and to the base.  
   
   
       28 . The method of  claim 14 , wherein the arm body has a box cross-sectional shape and includes at least two generally vertical legs, and a base joined to the legs, and wherein the plate welding step further comprises welding the plate to the legs and to the base.  
   
   
       29 . The method of  claim 14 , wherein the arm body has a generally I-shaped cross-sectional shape with upper and lower generally horizontally extending flanges, and wherein the plate welding step further comprises welding the plate to the flanges.