Wheel assemblies including gas spring piston biasing members and related methods

Abstract

A wheel assembly to be coupled to a vehicle hub includes an inner rim to be coupled to the vehicle hub, an outer rim surrounding the inner rim, and a gas suspension operatively coupled between the inner rim and the outer rim to provide relative movement between the inner rim and the outer rim. Each of the gas springs includes a cylinder having an inner surface and a piston movable within the cylinder. The piston includes a shaft, a piston head coupled to the shaft and having at least one recess therein, and at least one biasing member within the at least one recess. Each gas spring also includes at least one damping member adjacent to the at least one biasing member and located within the at least one recess to frictionally engage the inner surface of the cylinder.

Description

Technical Field

[0001] The present invention relates to the field of wheels, and more particularly, the present invention relates to wheel assemblies for vehicles and related methods. Background Art

[0002] A typical wheel may include a rim and a tire surrounding the rim. The tire transfers the load of the vehicle from the axle through the wheel to the ground. For example, the tires on most vehicles are pneumatic tires. In other words, a typical tire is pneumatically inflated, for example, with air or other gas (e.g., nitrogen). More specifically, air is injected into the space between the interior of the tire and the rim to inflate the tire.

[0003] During operation, the tire is inflated to absorb the forces of the vehicle as it travels over the road. The tire and associated inflation pressure may be selected to absorb these forces while minimizing any deformation. However, in many cases, excessive forces applied to the tire may cause the tire and / or rim to deform, puncture, or blow out. Ordinary forces may also cause the tire's tread to wear, while excessive forces may also cause the tread to wear rapidly, which may shorten tire life and reduce the structural integrity of the wheel.

[0004] To address the shortcomings of pneumatic based wheels, non-pneumatic wheels were developed. Non-pneumatic means that air or other gas is not injected to inflate the internal volume of the tire. One approach to non-pneumatic wheels is to use a mechanical spring. For example, U.S. Patent No. 911,975 to Gustafson discloses a spring wheel. The auxiliary spokes are arranged in pairs between the main spoke pairs, and thus the members of each of the auxiliary spokes pass through opposite sides of the corresponding intersecting bracket pairs. Each of the auxiliary spokes includes a pair of telescopic members that are pivotally connected at their outer ends to ears formed on the hub and extend into corresponding members at the opposite ends of the outer ends.

[0005] U.S. Patent No. 1,601,518 in the name of Weston discloses a resilient side wheel comprising radial arms. The connection between the hub and the rim member may be provided by pivot pins in the outer ends of these arms, on which there are connecting rods journalled thereto. The connecting rods are pivotally articulated with curved rods which in turn pivot on bracket arms extending inwardly from a part circular plate mounted on the inner periphery of the tire retaining rim.

[0006] Another approach includes a disc between the hub and the outer rim. For example, U.S. Patent No. 1,808,886 in the name of Courtney also discloses a disc or sidewall between the hub and the rim. The disc engages a stud extending from the hub and extends obliquely from the outer flange to the hub. The disc assists the tire and rim of the wheel by resisting any tendency to displace laterally due to stresses generated when the wheel turns.

[0007] U.S. Patent No. 1,979,935 in the name of Henap discloses a hydraulic spoke wheel. Each of the hydraulic spokes comprises a telescopic section in the form of an outer section and an inner section. The outer section has a stud extending from one end. The inner section extends from the outer section and is equipped with a rod at its extended end.

[0008] U.S. Patent No. 6,041,838 in the name of Al-Sabah discloses a wheel including spokes positioned in a spaced relationship from one another. Each of the spokes has a first end connected to the rim and a second end connected to a plate member end of a hub plate member in an offset position offset from its corresponding radial axis. The offset position of each of the spokes is further defined by each of the spokes being connected to a corresponding one of the plate member ends at a predetermined angle (e.g., less than 90 degrees) to its radial axis and defining an operational offset spoke axis that intersects the radial axis of the plate member end at a predetermined angle.

[0009] U.S. Patent No. 6,698,480 in the name of Cornellier discloses shock absorbing spokes, each of which has a central cylindrical tube. Each tube has an inner cap with a hole and an outer cap with a hole. Each spoke has an inner piston, a rod with a hole, and a pin. The pin pivotally connects one of the spokes to the hub. Each spoke has an outer piston, a rod with a hole, and a pin. The pin pivotally connects one of the spokes to the rim assembly. The inner piston and the outer piston divide the space within each tube into an inner chamber, an outer chamber, and a central chamber.

[0010] Despite advances in both pneumatic and non-pneumatic tire wheels, there remains a need for improved wheel technology, particularly for example for large construction or mining vehicles. The expense of wheel replacement and the downtime experienced during wheel replacement can add significant expense to a construction or mining project. Summary of the invention

[0011] A wheel assembly to be coupled to a vehicle hub may include an inner rim to be coupled to the vehicle hub, an outer rim surrounding the inner rim, and a plurality of gas springs operatively coupled between the inner rim and the outer rim to provide a gas suspension that allows relative movement between the inner rim and the outer rim. Each of the plurality of gas springs may include a cylinder having an inner surface and a piston movable within the cylinder. The piston may include a shaft, a piston head coupled to the shaft and having at least one recess therein, and at least one biasing member located within the at least one recess. Each gas spring may also include at least one damping member adjacent to the at least one biasing member and located within the at least one recess to frictionally engage the inner surface of the cylinder.

[0012] For example, at least one biasing member may comprise a body of resilient material surrounding the shaft.At least one damping member may comprise a plurality of rigid bodies.

[0013] For example, the piston head may have a plurality of first pin receiving passages. The at least one damping member may have a plurality of second pin receiving passages aligned with the plurality of first pin receiving passages to accommodate corresponding retaining pins during assembly.

[0014] For example, the cylinder may comprise a first metal and the at least one damping member may comprise a second metal that is softer than the first metal.The recess may comprise a circumferential recess.

[0015] The wheel assembly may include a seal carried by the piston head. The outer rim may carry a tread.

[0016] Related method aspects relate to methods of manufacturing a wheel assembly to be coupled to a vehicle hub. The method may include operatively coupling a plurality of gas springs between an inner rim to be coupled to the vehicle hub and an outer rim surrounding the inner rim to provide a gas suspension that allows relative movement between the inner rim and the outer rim. Each of the plurality of gas springs may include a cylinder having an inner surface and a piston movable within the cylinder. The piston may include a shaft, a piston head coupled to the shaft and having at least one recess therein, at least one biasing member positioned within the at least one recess, and at least one damping member adjacent to the at least one biasing member and positioned within the at least one recess to frictionally engage the inner surface of the cylinder. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 is a side view of a vehicle having a wheel assembly according to an embodiment.

[0018] Figure 2 is a perspective view of a wheel assembly according to an embodiment.

[0019] Figure 3 yes Figure 2 Another perspective view of the wheel assembly.

[0020] Figure 4 yes Figure 2 Another perspective view of the wheel assembly.

[0021] Figure 5 yes Figure 2 A perspective view of a portion of a wheel assembly.

[0022] Figure 6 yes Figure 2 A perspective view of the inner rim, disc and attachment bracket of the wheel assembly.

[0023] Figure 7 is a perspective view of a portion of a wheel assembly including a tread assembly and a removable sidewall according to an embodiment.

[0024] Figure 8 is a perspective view of a portion of a wheel assembly according to an embodiment.

[0025] Fig. 9 is another perspective view of a portion of a wheel assembly according to an embodiment.

[0026] Fig.10 yes Fig. 9 A perspective view of a tread member support.

[0027] Fig.11 yes Fig. 9 A perspective view of a portion of a tread assembly.

[0028] Fig.12 yes Fig. 9 A perspective view of a tread member of a tread assembly.

[0029] Fig.13 is a perspective view of an inner clamping member of a wheel assembly according to an embodiment.

[0030] Fig.14 is a perspective view of an outboard clamping member of a wheel assembly according to an embodiment.

[0031] Fig.15 is a perspective view of a portion of a wheel assembly including an outboard clamping member according to an embodiment.

[0032] Fig.16 is a cross-sectional view of a portion of an outer rim, retention features, and tread assembly according to an embodiment.

[0033] Fig.17 is a cross-sectional view of a portion of a tread assembly according to another embodiment.

[0034] Fig.18 is a perspective view of a wheel assembly according to another embodiment.

[0035] Fig.19 yes Fig.18 Schematic diagram of the lateral stop.

[0036] Fig. 20 is a schematic diagram of a portion of a wheel assembly including a local controller for controlling an operational response of a gas spring, according to an embodiment.

[0037] Fig.21 is a schematic diagram of a portion of a wheel assembly including a local controller for controlling an operational response of a gas spring according to another embodiment.

[0038] Fig. 22 is a perspective view of an inner removable side wall of a wheel assembly according to an embodiment.

[0039] Fig.23 is a perspective view of an outer removable side wall of a wheel assembly according to an embodiment.

[0040] Fig.24 is a perspective view of a wheel assembly according to another embodiment.

[0041] Fig.25 is a schematic diagram of a portion of a wheel assembly including a sensor for measuring a distance between an inner rim and an outer rim according to another embodiment.

[0042] Fig.26 is a side cross-sectional view of a portion of a wheel assembly according to another embodiment.

[0043] Fig. 27 yes Fig.26 A perspective cutaway view of a portion of a wheel assembly.

[0044] Fig.28 yes Fig. 27 A perspective view of the cover ring and the flexible seal.

[0045] Fig.29 yes Fig. 27 Another perspective view of the cover ring and flexible seal.

[0046] Fig.30 yes Fig. 27 A perspective view of a flexible seal.

[0047] Fig.31 yes Fig. 27 Another perspective view of the cover ring and the flexible seal.

[0048] Fig.32 is a perspective view of a portion of a wheel assembly according to another embodiment.

[0049] Fig.33 yes Fig.32 A perspective view of the inboard lateral stop of the wheel assembly.

[0050] Fig.34 is a perspective view of a wheel assembly according to another embodiment.

[0051] Fig.35 yes Fig.34 A perspective view of a portion of a wheel assembly without the lightening openings in the inner ring.

[0052] Fig.36 yes Fig.35 A side view of a portion of a wheel assembly.

[0053] Fig.37 yes Fig.34 A perspective view of an inner lateral stop and an outer lateral stop of a wheel assembly.

[0054] Fig.38 is a perspective view of a portion of a wheel assembly according to an embodiment.

[0055] Fig.39 is a perspective view of a portion of a wheel assembly according to an embodiment.

[0056] Fig.40 is a perspective view of a tread body according to an embodiment.

[0057] Fig.41 yes Fig.40 Side view of the tread body in FIG.

[0058] Fig.42 is a perspective view of a gas spring and a hydraulic damper according to an embodiment.

[0059] Fig.43 yes Fig.42 Schematic cross-sectional view of a gas spring and a hydraulic damper.

[0060] Fig.44 is a schematic diagram of a mine material processing device according to an embodiment.

[0061] Fig.45 yes Fig.44 A perspective view of a wheel assembly of a mining material handling equipment.

[0062] Fig.46 is a perspective view of a portion of a wheel assembly for use with mining material handling equipment according to another embodiment.

[0063] Fig.47 yes Fig.46 A front view of a portion of a wheel assembly.

[0064] Fig.48 yes Fig.46 A side view of a tread member of a wheel assembly.

[0065] Fig.49 is a perspective view of a portion of a wheel assembly for use with mining material handling equipment according to another embodiment.

[0066] Fig.50 is a schematic diagram of a wheel assembly according to another embodiment.

[0067] Fig.51 yes Fig.50 A partial cross-sectional view of a gas spring with an associated integral hydraulic damper.

[0068] Fig.52 yes Fig.50 Another partial cross-sectional view of a gas spring with an associated integral hydraulic damper.

[0069] Fig.53 yes Fig.50 Another partial cross-sectional view of a gas spring with an associated integral hydraulic damper.

[0070] Fig.54 yes Fig.50 An enlarged partial cross-sectional view of a portion of a gas spring with an associated integral hydraulic damper.

[0071] Fig.55 is a partial cross-sectional view of a gas spring with an associated integral hydraulic damper according to another embodiment.

[0072] Fig.56 is a cross-sectional view of a portion of a wheel assembly according to another embodiment.

[0073] Fig.57 is a cross-sectional view of a portion of a wheel assembly according to another embodiment.

[0074] Fig.58 is a cross-sectional view of a portion of a wheel assembly according to another embodiment.

[0075] Fig.59 is a schematic diagram of a wheel assembly according to another embodiment.

[0076] Fig.60 yes Fig.59 Schematic cross-sectional view of a portion of a gas spring.

[0077] Fig.61 yes Fig.59 A perspective view of a portion of the piston of a gas spring.

[0078] Fig.62 yes Fig.59 Schematic cross-sectional view of a portion of the piston of a gas spring.

[0079] Fig.63 yes Fig.59 A perspective view of another part of the piston of the gas spring. DETAILED DESCRIPTION

[0080] The present invention will now be described more fully with reference to the accompanying drawings below, in which preferred embodiments of the present invention are shown. However, the present invention can be implemented in many different forms and should not be construed as being limited to the embodiments set forth herein. On the contrary, these embodiments are provided so that this disclosure will be thorough and complete, and the scope of the present invention will be fully communicated to those skilled in the art. Throughout the text, the same reference numerals refer to the same elements, and in alternative embodiments, apostrophes are used to indicate similar elements.

[0081] First reference Figures 1 to 5, a wheel assembly 30 to be coupled to a wheel hub 21 of a vehicle 20 includes an inner rim 31 to be coupled to the vehicle wheel hub. The inner rim 31 can be coupled to the wheel hub 21 of the vehicle 20 using fasteners passing through fastener receiving passages 24 in an inwardly extending flange ring 25. Illustratively, the flange ring 25 is laterally centered within the inner rim 31, but may be positioned in another arrangement depending on the desired mounting arrangement with the wheel hub 21. Other coupling arrangements may be used to couple the inner rim 31 to the wheel hub 21.

[0082] The wheel assembly 30 also includes an outer rim 33 surrounding the inner rim 31. The outer rim 33 can have a diameter of at least 3.5 feet, and more particularly, at least 4 feet. Those skilled in the art will appreciate that with a diameter of at least 3.5 feet, the wheel assembly 30, and more particularly the outer rim 33, is particularly advantageous for relatively large or heavy machines, such as, for example, earthmoving equipment and mining equipment. A typical overall outer diameter of such a wheel assembly can be 100 inches or more. The outer rim 33 can have a thickened portion 38 along its inner circumference. For example, the thickened portion 38 can be provided by welding a separate reinforcement ring in place, or the thickened portion can also be formed integrally with the outer rim 33.

[0083] Additional references Figure 6 , the disc 40 is coupled to the inner rim 31 and defines a closable gap 41 with an adjacent inner portion of the outer rim 33. The disc 40 also includes weight-reducing openings 43 therein. Illustratively, each of the weight-reducing openings 43 has a generally circular or annular shape. The weight-reducing openings 43 may have another shape, such as an elliptical, hexagonal, and / or contoured to reduce stress. Those skilled in the art will appreciate that weight reduction may improve the fuel efficiency of the vehicle 20 and / or may extend the useful life of the wheel assembly 30.

[0084] The disk 40 also includes spaced apart thickened wall portions 42. The spaced apart thickened wall portions 42 may be located on both the inside and outside surfaces of the disk 40. Each thickened wall portion 42 may provide increased strength or support as a connection point or attachment point, and / or receive increased stress thereat, as will be described in further detail below. For example, the thickened wall portions 42 may be provided by welding an additional metal body in place, or they may be integrally formed with the disk 40. Those skilled in the art will appreciate that the thickened wall portions 42 may be solid extensions of the disk 40 (i.e., integrally formed with and / or constructed from the disk) and / or in the form of discrete bodies, such as those used as mechanical reinforcements.

[0085] The inner rim 31, the outer rim 33 and the disc 40 may be formed of a high strength and strong material, such as steel. As will be appreciated by those skilled in the art, other materials may also be used.

[0086] The gas springs 50 are operatively coupled between the inner rim 31 and the outer rim 33. For example, each gas spring 50 may be a double-acting gas spring and include a double-acting cylinder 51 and an associated piston 52. Of course, in some embodiments, each gas spring 50 may be a single-acting gas spring. More than one type of gas spring may be used. For example, the gas springs 50 may be air springs and / or nitrogen springs. The gas springs 50 may also contain other gases.

[0087] Illustratively, the gas springs 50 are arranged in pairs on opposite sides of the disk 40. More specifically, the gas springs 50 diverge outward from the inner rim 31 to the outer rim 33. A respective attachment bracket 53a for each gas spring 50 is coupled to a respective thickened wall portion 42 of the disk 40 (e.g., adjacent the inner rim 31). Each attachment bracket 53a may include a generally U-shaped or V-shaped base bracket that receives an end of a piston 52 therein (e.g., between arms of the U-shaped or V-shaped bracket). Fasteners secure the ends of the pistons 52 of the gas springs 50 to the base bracket, and thus, each gas spring is coupled adjacent to a respective thickened wall portion 42 of the disk 40 and adjacent to the inner rim 31. A similar attachment bracket 53b is coupled to the outer rim 33 adjacent to the inner and outer side surfaces. Thus, the gas springs 50 are pivotably coupled between the inner rim 31 and the outer rim 33.

[0088] As will be appreciated by those skilled in the art, the gas springs 50 provide a gas suspension for relative movement between the inner rim 31 and the outer rim 33. The travel of the gas springs 50 allows the discs 40 to define a mechanical stop. In other words, the gas springs 50 keep the outer rim 33 spaced apart from the inner rim 31. However, if the pressure on any of the gas springs 50 causes the gas spring to reach its limit under load or the gas spring fails, the discs 40 act as mechanical stops to limit the relative movement between the inner rim 31 and the outer rim 33. In other words, the discs 40 and gas springs 50 can be considered to provide a run-flat capability.

[0089] For example, the initial charge pressure of the gas spring 50 when the gas spring is in the form of a double-acting gas spring will now be described, for example, relative to the initial pressure in the wheel assembly 30 when little or no external load is applied (i.e., freewheeling). In particular, the chamber associated with the piston side of the cylinder 51 is typically smaller (e.g., about 10% smaller) than the chamber associated with the full-bore side of the cylinder. Therefore, when the piston 52 is centered within the cylinder 51 so that the extension and compression have relatively equal travel, the piston side chamber pressure is higher (e.g., about 10% higher) than the full-bore side chamber pressure.

[0090] Thus, while isobaric inflation of the double-acting cylinder 51 may be convenient, it results in the creation of an offset piston 52 which in turn results in the application of an offset force to assemble the gas spring 50 within the wheel assembly 30. To accomplish this, the inner rim 31 and the outer rim 33 may be temporarily secured in a rigid fixture. However, the use of a rigid fixture may make it increasingly difficult to replace the gas spring 50 in the field. Therefore, to increase the ease of field replacement of the gas spring 50, a welding ring may be coupled to the inner rim 31 and the outer rim 33 and to a turnbuckle to temporarily lock the inner rim and the outer rim in place. As will be appreciated by those skilled in the art, a similar arrangement may also be used in a workshop.

[0091] Thus, the result is a prestressed inner rim 31 suspended to the outer rim 33. The prestress can ensure that the lateral stops 44, 45 (described below) are inactive or under pressure. By varying the inflation pressure, the suspension can be pre-compressed. Although tension suspension and compression suspension can be considered equivalent, tension suspension can be more advantageous than compression suspension as will be appreciated by those skilled in the art.

[0092] Another assembly technique can include applying a higher inflation pressure at the piston side (e.g., approximately 10% more) to center the piston 52 at approximately the half-stroke position. This results in no initial load on the gas spring 50 at the wheel assembly 30 and facilitates assembly without the need for temporary fixation in a fixture. Therefore, the wheel assembly 30 can be considered neither prestressed nor pre-compressed, but neutral. For example, a full-diameter side chamber pressure that is higher than the piston side chamber pressure (e.g., approximately 10% higher) can be applied. Gas can be released from the full-diameter side chamber until the piston 52 is centered relative to the full stroke. Alternatively, a piston side chamber pressure that is higher than the full-diameter side chamber pressure (e.g., approximately 10% higher) can be applied. Releasing gas from the cylinder 51 can be considered easier than additional inflation, however, this may use more gas (e.g., nitrogen) than other methods, resulting in increased costs.

[0093] The wheel assembly 30 also includes an inner side lateral stop 44 carried by the inner side surface of the outer rim 33. More specifically, the inner side lateral stop 44 is positioned adjacent to the thickened wall portion 42. The wheel assembly 30 also includes an outer side lateral stop 45 carried by the outer side surface of the outer rim 33. Similar to the inner side lateral stop 44, the outer side lateral stop 45 is adjacent to the thickened wall portion 42. Each thickened wall portion 42 is positioned between a pair of inner side lateral stops 44 and outer side lateral stops 45. The inner side lateral stops 44 and the outer side lateral stops 45 together with the outer rim 33 can be conceptually considered to be in the form of an L-shaped bracket. Illustratively, the inner side lateral stop 44 and the outer side lateral stop 45 each have a support plate 61 (e.g., having a rectangular shape) that is transverse to the outer rim 33 and has a triangular side member 62.

[0094] As will be appreciated by those skilled in the art, the inner lateral stop 44 and the outer lateral stop 45 cooperate to limit the relative lateral movement of the disc 40 and the outer rim 33. In other words, for example, turning of the vehicle 20 can cause lateral movement of the disc 40 relative to the outer rim 33. The inner lateral stop 44 and the outer lateral stop 45 can limit the amount of lateral movement of the disc 40 relative to the outer rim 33, thereby maintaining the structural integrity of the wheel assembly 30. Of course, the inner lateral stop 44 and the outer lateral stop 45 include other and / or additional components or elements that cooperate to limit the relative lateral movement of the disc 40 and the outer rim 33.

[0095] Now refer to Figures 7 to 16 The wheel assembly 30 illustratively includes a tread assembly 70 carried by the outer rim 33. Each tread assembly 70 includes a tread component support 71. Each tread component support 71 can be in the form of an arcuate metal plate having openings 69a, 69b therein ( Fig.10 ) and can be coupled to the outer periphery of the outer rim 33. In other embodiments, one or more of the tread component supports 71 can be flat plates. The middle one of the openings 69b can receive a pin 83 therein, as will be described in further detail below. In some embodiments, the tread component supports 71 may not be metal (e.g., steel). Those skilled in the art will appreciate that, given the arcuate shape of the tread component supports 71, several tread assemblies 70 are coupled in an end-to-end relationship around the outer rim 33.

[0096] The tread member 72 is coupled or attached (e.g., glued, fastened, etc.) to the tread member support 71, and the clamping device 73 removably secures the tread member support to the outer rim 33. There may be more than one tread member 72 coupled to the tread member support 71. The tread member 72 includes an elastomer 85 having a tread pattern 86 defined in its outer surface. The elastomer 85 may include rubber or other materials, which may be selected based on the desired friction, traction, or other properties (e.g., based on the use of the vehicle 20). In other embodiments, the material of the tread member 72 may be a metal such as steel. The tread pattern 86 may be similarly selected based on the desired traction or other properties (e.g., based on the use of the vehicle 20). In addition, briefly refer to Fig.17 In another embodiment of the tread assembly 70', each tread member 72' and the tread member support 71' may include a common material that is integrally formed as a unitary unit, which common material may or may not be a metal such as steel. In other words, each tread member 72' and the tread member support 71' define a single unit or body of the same material (e.g., an all-metal tread member support and tread member).

[0097] Additional details of the clamping device 73 will now be described. The clamping device 73 illustratively includes an inner clamping member 74 coupled to the inner side portion of the outer rim 33. The inner clamping members 74 each have a first groove-shaped recess 75 that receives an adjacent portion of the tread member support 71. The inner clamping members 74 are removably coupled to the inner side portion of the outer rim 33. The inner clamping members 74 are illustratively arranged in an end-to-end relationship and each inner clamping member is coupled to an adjacent corresponding portion of the outer rim 33. In some embodiments, the inner clamping members 74 can be fixed, such as welded or fixedly coupled to the inner side portion of the outer rim 33 and / or a single inner clamping member can be used.

[0098] The inner clamping member 74 is coupled to the inner side of the outer rim 33 by a fastener 79a (e.g., a threaded fastener) to facilitate removal and replacement, such as when the tread member 72 is worn or needs to be replaced. The threaded fastener 79a can extend through the opening 89 in the inner clamping member 74 and engage the corresponding threaded opening 81a in the outer rim 33.

[0099] The clamping device 73 also illustratively includes an outboard clamping member 76 coupled to the outboard side portion of the outer rim 33. Similar to the inboard clamping member 74, the outboard clamping members 76 each have a second groove-shaped recess 77 that receives an adjacent portion of the tread member support 71 therein. The outboard clamping members 76 are removably coupled to the outboard side portion of the outer rim 33. The outboard clamping members 76 are illustratively arranged in an end-to-end relationship, and each outboard clamping member is coupled to an adjacent corresponding portion of the outer rim 33. In some embodiments, a single outboard clamping member 76 may be coupled to the outboard side portion of the outer rim 33 and extend along the circumference of the outer rim.

[0100] Outer clamping member 76 is coupled to the outboard side of outer rim 33 by fasteners (e.g., threaded fasteners) to facilitate removal and replacement, such as when tread member 72 is worn or requires replacement of the tread member. The threaded fasteners may extend through openings 78 in outboard clamping member 76 and engage corresponding threaded openings 81 b in outer rim 33.

[0101] Adjacent portions (e.g., along the outer circumference) of the tread member support 71 and the outer rim 33 define a retaining feature therebetween. The retaining feature illustratively takes the form of or includes a pin 83 carried by the outer rim 33 and a pin receiving opening 84 in the tread member support 71. The pin 83 and the pin receiving opening 84 can advantageously prevent relative movement between the tread member support 71 and the outer rim 33, and also facilitate replacement of the tread member 72 (e.g., easy alignment), for example, thereby reducing downtime of the vehicle 20.

[0102] Now briefly refer to Fig.18 and Fig.19 In another embodiment, the inner lateral stop 44" and the outer lateral stop 45" are biased toward the disk 40". More specifically, the inner lateral stop 44" and the outer lateral stop 45" each include an arm 46" extending radially inward from the inner inner surface and the outer inner surface of the outer rim 33". A transverse arm 47" is connected to the end of each arm 46". Each transverse arm 47" carries a plug 48", which is biased toward the disk 40" by a biasing member 49" (e.g., a spring, such as a coil spring). Other biasing devices may be used. Elements labeled 24", 25", 30", 31", 41", 43", 45", 50", 51", 52", 70", 76", 79a", 79b", 85", 86" and 98b" are similar to those described above with corresponding numbers but without double primes.

[0103] Now refer to Fig. 20, one or more of the gas springs 50 may have a controllable response. For example, the gas spring 50 may have either or both a controllable gas pressure and a controllable gas volume. Any number of gas springs 50 may have a controllable response. By having a controllable response, each gas spring 50 may be operated or controlled, for example, for certain operating conditions and / or environments, as will be explained in further detail below. More particularly, the wheel assembly 30 may include a local controller 87 (e.g., including a processor and / or circuit) coupled to the gas spring 50. The local controller 87 may be coupled to any number of gas springs 50. The local controller 87 may be carried within the outer rim 33, such as inside the outer rim, or carried by the disc 40. The local controller 87 may be carried by other elements of the wheel assembly 30. The local controller 87 may also include corresponding actuators and / or valves to control the response of the gas spring 50 and cooperate with the accumulator 91, which is also coupled to the gas spring to serve as a pressure and / or volume reservoir for the gas spring.

[0104] The wheel assembly 30 may also include a local sensor 88 coupled to the local controller 87. The local controller 87 may control (e.g., monitor and / or adjust) the operational response of the gas spring 50 based on the local sensor 88. For example, the local controller 87 may adjust the pressure or volume of the gas spring 50 but not control the operation (e.g., extension / retraction) of the gas spring. For example, alternatively or additionally, the local controller 87 may also adjust the operation (e.g., extension / retraction) of the gas spring 50.

[0105] The local sensor 88 can be, for example, an acceleration sensor, and cooperates with the local controller 87 to control the controllable response of the gas spring 50 based on the sensed acceleration (e.g., braking, steering, etc.). The local sensor 88 can be another type of sensor, such as a force sensor. There can be more than one local sensor 88. In some embodiments, the local controller 87 can cooperate with the local sensor 88 to generate a notification, for example, when the sensed value exceeds a threshold. The notification can be transmitted within the vehicle 20 (e.g., in the cab) or remotely transmitted from the vehicle. In other words, the local controller 87 can cooperate with the local sensor 88 independently of or without controlling the operating response of the gas spring 50.

[0106] Now briefly refer to Fig.21In another embodiment, the remote control 92'" can be carried remotely from the wheel assembly 30, for example, in a wheel well of the vehicle 20 or in a truck cab. The remote control 92'" can be used in conjunction with the local sensor 88'" or other sensor (e.g., remote from the wheel assembly 30). The remote control 92'" can also be used in conjunction with the local controller 87'" to achieve changes in the operating response of the gas spring 50. Wiring from the remote control 92'" can extend to the local controller 87'" and / or the remote control can wirelessly communicate with the local controller. The elements labeled 51'", 52'" and 91'" are similar to those described above with corresponding numbers but without triple primes.

[0107] Those skilled in the art will appreciate that the local controller 87 controls the operational response of the gas springs 50 while the wheel assembly 30 is rolling. For example, if the vehicle 20 makes a relatively sharp turn or applies brakes during its motion, the local controller 87 can independently control the operational response of each or selected ones of the gas springs 50 based on the turn or brake (e.g., increase the pressure in the gas springs of the front wheel assembly). Other motions of the vehicle 20 may cause changes in the operational response, such as failure of any of the gas springs 50, debris in the tread member 72, and / or contact of the disc 40 with the outer rim 33.

[0108] Now refer to Fig. 22 and Fig.23 , the wheel assembly 30 may include an inner removable sidewall 93 and an outer removable sidewall 94. The inner removable sidewall 93 and the outer removable sidewall 94 are each illustratively in the form of a circular or annular cover carried by the outer rim 33. More specifically, the inner removable sidewall 93 and the outer removable sidewall 94 each have an opening 95, 105 therein to allow, for example, the wheel assembly 30 to be coupled to the hub 21. Respective flanges 103, 106 extend inwardly within the openings 95, 105. The inner removable sidewall 93 and the outer removable sidewall 94 can each be coupled to the inner and outer sides of the outer rim 33 by fasteners 97a, 97b, and also coupled to the inner rim 31 by fasteners 107a, 107b. Fasteners 97a, 97b can be received through fastener receiving passages along the periphery of each of the inner removable sidewall 93 and the outer removable sidewall 94 and secured to corresponding, respectively aligned threaded passages 98a, 98b in the outer rim 33. The threaded passages 98a, 98b in the outer rim 33 form a second inner row of threaded passages with the outer row of threaded passages 81a, 81b for securing the clamping device 73 to the outer rim ( Figure 7 ).

[0109] Reference now Fig.24In another embodiment, the outer removable sidewall 94"" can have a removable inner panel 101"", which, when removed, allows access to the interior of the wheel assembly 30"", such as the inner rim, via corresponding fasteners 102"". Similar to the outer removable sidewall described above, the outer sidewall 94"" is connected to the outer rim by fasteners 97b"" on the inner side of the outer clamping member or adjacent to the outer clamping member 76"" (which is also secured to the outer rim by fasteners 79b"". The elements labeled 51"", 52"", 91"", 70"" and 72"" are similar to the elements described above with corresponding numbers but without quadruple primes.

[0110] As will be appreciated by those skilled in the art, the inner removable sidewall 93 and the outer removable sidewall 94 may be particularly advantageous for reducing the amount of dust and / or debris within the interior of the wheel assembly 30 (e.g., between the inner rim 31 and the outer rim 33). Thus, the components of the wheel assembly 30 (e.g., the disc 40 and the gas spring 50) may have enhanced protection from damage, such as from environmental factors (e.g., rocks, dust, dirt, water, etc.) and may therefore have a longer service life. In some embodiments, the wheel assembly 30 may not include the inner removable sidewall 93 and the outer removable sidewall 94.

[0111] Reference now Fig.25 In another embodiment, the sensors 188a, 188b sense the relative motion, for example, by sensing the distance between the inner rim 131 and the outer rim 133. More specifically, the sensors 188a, 188b may be in the form of a three-axis accelerometer. Of course, the sensors 188a, 188b may be other types of sensors, for example, laser ranging sensors, ultrasonic sensors, linear variable differential transformer (LVDT) sensors, and / or other contact or non-contact displacement sensors.

[0112] When the sensors 188a, 188b take the form of three-axis accelerometers, one of the accelerometers is carried by the inner rim 131 defining an inner accelerometer, while the other accelerometer is carried by the outer rim 133 defining an outer accelerometer. The inner accelerometer 188a and the outer accelerometer 188b are aligned by their axes so that the relative motion between the inner rim 131 and the outer rim 133 as a sensed acceleration can be converted (e.g., each acceleration is integrated) by, for example, an odometry circuit 187 coupled to the accelerometers 188a, 188b.

[0113] Each of the sensors 188a, 188b may be different from one another. For example, an ultrasonic sensor may be used with the internal accelerometer 188a and the external accelerometer 188b to sense or measure displacement (e.g., tangent to the internal and external accelerometers). Of course, a laser range finder may also be used in place of the ultrasonic sensor or in combination with the ultrasonic sensor and / or the internal accelerometer 188a and the external accelerometer 188b. The measurement circuit 187 may be carried by the wheel assembly, the vehicle, or may be remote from the vehicle.

[0114] A temperature sensor 188c may be carried by the outer rim 133 (e.g., in or on the inner surface of the outer rim) and coupled to the measurement circuit 187 to sense temperature within the wheel assembly, e.g., when a cover or inner or outer removable sidewall is used. A humidity sensor 188d may alternatively or additionally be carried by the outer rim 133 (e.g., in or on the inner surface of the outer rim) and coupled to the measurement circuit 187 to sense humidity within the wheel assembly, e.g., when a cover or inner or outer removable sidewall is used. Data representing humidity, acceleration or distance data (e.g., raw data or processed data) and / or temperature may be remotely communicated from the wheel assembly or vehicle via a wireless transmitter 190 coupled to the measurement circuit 187 for downstream processing.

[0115] Reference now Figure 26 to Figure 31 In another embodiment, the wheel assembly 230 includes a rigid inner cover ring 293, which is coupled to the inner side of the outer rim 233, such as by fasteners 207a. The rigid inner cover ring 293 extends radially inwardly toward the inner rim 231. More specifically, the rigid inner cover ring 293 and the inner rim 231 define a radially and axially extending inner gap. A flexible inner seal 209a, such as in the form of an inner bellows seal, is coupled between the rigid inner cover ring 293 and the inner rim 231, such as by corresponding fasteners 208a, so as to be coupled to the inner rim (e.g., for use with a clamping device 212a, such as a metal tie or other material). The flexible inner seal 209a closes the radially and axially extending inner gap and allows relative movement between the inner rim 231 and the outer rim 233. Illustratively, the inner bellows seal 209a has a Z-shaped cross-section. For example, the flexible inner seal 209a may be different types of flexible seals and may have cross-sections of different shapes. The flexible inner seal 209a may include rubber and / or elastomeric materials. The flexible inner seal 209a may include other materials and / or additional materials.

[0116] The wheel assembly 230 also includes a rigid outer cover ring 294 coupled to the outer side of the outer rim 233, for example, by fasteners 207b. The rigid outer cover ring 294 extends radially inwardly toward the inner rim 231. More specifically, the rigid outer cover ring 294 and the inner rim 231 define a radially and axially extending outer gap. A flexible outer seal 209b, for example in the form of an outer bellows seal, is coupled between the rigid outer cover ring 294 and the inner rim 231, for example, by corresponding fasteners 208b (and, for example, corresponding clamping devices 212b). The flexible inner seal 209b closes the radially and axially extending outer gap and allows relative movement between the inner rim 231 and the outer rim 233. Illustratively, the outer bellows seal 209a has a Z-shaped cross-section. For example, the flexible outer seal 209b can be a different type of flexible seal and can have a cross-section of a different shape.

[0117] In addition, a corresponding pleated cover 210 (eg, a bellows) is coupled to each gas spring 250. In particular, the pleated cover 210 covers the piston so that dust, dirt, and / or debris can be prevented from entering the piston ( Fig.26 ). As will be appreciated by those skilled in the art, reducing the amount of dust, dirt, and / or debris that comes in contact with the piston can extend the useful life of the gas spring 250.

[0118] The flexible outer seal 209b may include rubber and / or elastomeric materials. The flexible outer seal 209b may include other and / or additional materials. In some embodiments, the rigid outer cover ring 294 and the flexible outer seal 209b may not be used. The elements marked 224, 225, 240, 241, 242, 243, 244, 245, 262, 281a and 283 are similar to the corresponding elements marked 24, 25, 40, 41, 42, 43, 44, 45, 62, 81a and 83 described above (i.e., minus 200).

[0119] Now special reference Fig.31 , similar to the above Figure 22 to Figure 24 In the depicted embodiment, a rigid removable inset or inner panel 201 may be carried within a rigid outer cover ring 294 (e.g., secured to the wheel assembly by fasteners 297b) such that when removed by corresponding fasteners 202, access to the interior of the wheel assembly 230, such as the inner rim, is permitted. An access port or removable cover 211a is spaced within the rigid outer cover ring 294. The removable cover 211a may be, for example, a clear acrylic to permit visual inspection within the wheel assembly without removing the rigid removable inset panel 201 and / or to facilitate access to sensors, controllers, and / or other circuitry, such as those described above. A similar arrangement including an access port or removable cover 211b may be used as a rigid inner cover ring 294, such as described above ( Figure 26 to Figure 27 ). Access ports 211a, 211b may not be used in all embodiments.

[0120] For example, the embodiments of the wheel assembly 30 described herein are particularly advantageous relative to conventional pneumatic tires, particularly on relatively large vehicles (e.g., heavy machinery). For example, conventional pneumatic tires for heavy machinery have a relatively high cost and may have a relatively short service life in certain environments. In addition, particularly with respect to heavy machinery, failure of a conventional tire may result in an increased probability of damage to the heavy machinery. Even further, failure of a conventional tire may cause the vehicle 20 to be inoperable or unusable for a relatively long period of time, resulting in economic losses and loss of productivity, particularly with respect to certain types of vehicles or heavy machinery that operate around the clock.

[0121] The wheel assembly 30 can address these shortcomings of conventional tires. More specifically, the wheel assembly 30 can improve performance while reducing operating costs (e.g., through the controllable operating response of the gas spring 50). In addition, the wheel assembly 30 can be field repairable, meaning that the tread member 72 can be replaced in the field. For example, in the event of a gas spring 50 failure, repairs can also be performed in the field.

[0122] The method aspect relates to a method of manufacturing a wheel assembly 30 to be coupled to a wheel hub 21 of a vehicle 20. The method includes operatively coupling a plurality of gas springs 50 between an inner rim 31 of a wheel hub 21 to be coupled to the vehicle 20 and an outer rim 33 surrounding the inner rim. The method also includes mounting a plurality of tread assemblies 70 to the outer rim 33. Each tread assembly 70 may be mounted by coupling at least one tread member 72 to a tread member support 71 and positioning a clamping device 73 to removably secure the tread member support to the outer rim 33.

[0123] Another method aspect relates to a method of manufacturing a wheel assembly 30 to be coupled to a wheel hub 21 of a vehicle 20. The method includes operatively coupling a plurality of gas springs 50 between an inner rim 31 on a wheel hub 21 to be coupled to the vehicle 20 and an outer rim 33 surrounding the inner rim 31 to provide a gas suspension for relative movement between the inner rim and the outer rim. The method also includes coupling a disc 40 to the inner rim 31, the disc and an adjacent inner portion of the outer rim 33 defining a closable gap 41 to define a mechanical stop to limit relative movement between the inner rim and the outer rim.

[0124] Another method aspect relates to a method of manufacturing a wheel assembly 30 to be coupled to a wheel hub 21 of a vehicle 20. The method includes operatively coupling a plurality of gas springs 50 between an inner rim 31 of a wheel hub 21 to be coupled to the vehicle 20 and an outer rim 33 surrounding the inner rim to provide a gas suspension for relative movement between the inner rim and the outer rim. The method also includes coupling a disc 40 to the inner rim 31 and defining a closable gap 41 with an adjacent inner portion of the outer rim 33. The method may also include positioning a plurality of inner side lateral stops 44 carried by an inner side inner surface of the outer rim 33 and positioning a plurality of outer side lateral stops 45 carried by an outer side inner surface of the outer rim such that the plurality of inner side lateral stops and the plurality of outer side lateral stops cooperate to limit relative lateral movement of the disc 40 and the outer rim.

[0125] Another method aspect relates to a method of manufacturing a wheel assembly 30 to be coupled to a wheel hub 21 of a vehicle 20. The method includes operatively coupling a plurality of gas springs 50 between an inner rim 31 of a wheel hub 21 to be coupled to the vehicle 20 and an outer rim 33 surrounding the inner rim. At least one gas spring 50 of the plurality of gas springs has a controllable operational response. The method also includes coupling a local controller 87 to at least one gas spring 50 to control the operational response of the at least one gas spring.

[0126] Another related method aspect relates to a method of operating a wheel assembly 30 to be coupled to a wheel hub 21 of a vehicle 20. The wheel assembly 30 includes an inner rim 31 to be coupled to the wheel hub 21 of the vehicle 20, an outer rim 33 surrounding the inner rim, and a plurality of gas springs 50 operatively coupled between the inner rim and the outer rim. At least one gas spring of the plurality of gas springs 50 has a controllable operational response. The method includes operating a local controller 87 coupled to the at least one gas spring 50 to control the operational response of the at least one gas spring.

[0127] Another method aspect relates to a method of sensing relative movement (e.g., distance) between an inner rim 131 of a wheel assembly 30 to be coupled to a wheel hub 21 of a vehicle 20 and an outer rim 133 of the wheel assembly. The inner rim 131 is to be coupled to the wheel hub 21 of the vehicle 20 and an outer rim 133 surrounding the inner rim. The wheel assembly 30 includes a plurality of gas springs 50 operatively coupled between the inner rim 131 and the outer rim 133 and allowing relative movement therebetween. The method includes using at least one sensor 188a, 188b to sense relative movement between the inner rim 131 and the outer rim 133 during operation or rolling of the wheel assembly.

[0128] Another method aspect relates to a method of manufacturing a wheel assembly 30 to be coupled to a wheel hub 21 of a vehicle 20. The method includes coupling an inner rim 231 to a wheel hub 21 of a vehicle 20 and positioning an outer rim 233 around the inner rim. The method also includes operatively coupling a plurality of gas springs 50 between the inner rim 231 and the outer rim 233 to allow relative movement between the inner rim and the outer rim. The method also includes coupling a rigid inner cover ring 293 to an inner side of the outer rim 233 and extending radially inward toward the inner rim 231 and coupling a flexible inner seal 209a between the rigid inner cover ring and the inner rim.

[0129] Reference now Fig.32 In another embodiment of the wheel assembly 330, an outer ring 340 or disk is coupled to the outer rim 333. This is in contrast to the above-described embodiment in which the ring or disk 40 is coupled to the inner rim 331. In this embodiment, the outer ring 340 coupled to the outer rim 333 and the adjacent inner portion of the inner rim 331 define a closable gap 341 to define a mechanical stop to limit relative movement between the inner and outer rims. Similar to the above-described embodiments, the outer rim 333 can have a diameter of at least 3.5 feet.

[0130] Similar to the above-described embodiments, outer ring 340 also includes lightening openings 343 therein. Lightening openings 343 each illustratively have a generally circular or annular shape. Lightening openings 343 may also have another shape, such as an elliptical, hexagonal, and / or a profile for stress relief.

[0131] The gas springs 350 are operatively coupled between the inner rim 331 and the outer rim 333. For example, each gas spring 350 can be a double-acting gas spring and include a double-acting cylinder 351 and an associated piston 352. Of course, in some embodiments, each gas spring 350 can be a single-acting gas spring. More than one type of gas spring 350 can be used. For example, the gas spring 350 can be an air spring and / or a nitrogen spring. The gas spring 350 can also contain other gases.

[0132] Illustratively, the gas springs 350 are arranged in pairs on opposite sides of the outer ring 340. More specifically, the gas springs 350 radiate outwardly from the inner rim 331 to the outer rim 333. A respective attachment bracket 353 for each gas spring 350 is coupled to the inner rim 331. Each attachment bracket 353 may include a generally U-shaped or V-shaped base bracket that receives an end of a piston 352 therein (e.g., between arms of the U-shaped or V-shaped bracket). Fasteners secure the ends of the pistons 352 of the gas springs 350 to the base bracket 353. Similar attachment brackets 353 are coupled to the outer rim 333 adjacent to the inner and outer side surfaces. Thus, the gas springs 350 are pivotally coupled between the inner rim 331 and the outer rim 333.

[0133] Similar to the embodiments described above, as will be appreciated by those skilled in the art, the gas spring 350 provides a gas suspension for relative movement between the inner rim 331 and the outer rim 333. The gas spring 350 has a travel that allows the outer ring 340 to define a mechanical stop. In other words, the gas spring 350 keeps the outer rim 333 spaced apart from the inner rim 331. However, if the pressure on any of the gas springs 350 causes the gas spring to reach its limit under load or the gas spring fails, the outer ring 340 can act as a mechanical stop to limit the relative movement between the inner rim 331 and the outer rim 333. In other words, the outer ring 340 and the gas spring 350 can be considered to provide a run-flat capability. Since the gas spring 350 is similar to the gas spring described with respect to the embodiments described above, no further details of the gas spring need be described.

[0134] Additional references Fig.33, the wheel assembly 330 also includes an inner side lateral stop 344 coupled between the inner side of the outer rim 333 and the inner side of the inner rim 331. More specifically, the inner side lateral stop 344 is illustratively in the form of a hinge retainer or a scissor hinge. Each inner side lateral stop 344 includes an inner hinge bracket 346a, 346b and an inner elastomer 347, such as a polyurethane body, carried by the hinge bracket adjacent to the outer rim 333. More specifically, the inner elastomer 347 is coupled to an outer side lateral stop mounting bracket 349a, which is coupled to the outer rim 333. The inner hinge brackets 346a, 346b are coupled by a hinge pin 348. In some embodiments, the outer side lateral stop mounting bracket 349a may not be used because the inner elastomer 347 may be directly coupled to the outer ring 340, such as by a hinge pin 348. Hinge bracket 346b is coupled to inner rim 331 via inner lateral stop mounting bracket 349b coupled to the inner rim by hinge pin 348, which is coupled to the inner lateral stop mounting bracket. In some embodiments, hinge bracket 346b can be coupled to inner rim 331 without inner lateral stop mounting bracket 349b, for example, directly coupled to the inner rim via hinge pin 348.

[0135] The wheel assembly 330 also includes an outer side lateral stop 345 coupled between the outer side of the outer rim 333 and the outer side of the inner rim 331. More specifically, the outer side lateral stop 345 is illustratively in the form of a hinge retainer or scissor hinge similar to the inner side lateral stop 344. That is, each outer side lateral stop 345 includes an outer side hinge bracket 346a, 346b and an outer side elastic body 347, such as a polyurethane body, carried by the hinge bracket adjacent to the outer rim 333. More specifically, the outer side elastic body 347 is coupled to an outer side stop mounting bracket 349a, which is coupled to the outer rim 333. The hinge brackets 346a, 346b are coupled by a hinge pin 348. In some embodiments, the outer side lateral stop mounting bracket 349a may not be used because the outer side elastic body 347 may be directly coupled to the outer ring 340, such as by a hinge pin 348. Hinge bracket 346b is coupled to inner rim 331 via inner lateral stop mounting bracket 349b coupled to the inner rim by hinge pin 348, which is coupled to the inner lateral stop mounting bracket. In some embodiments, hinge bracket 346b can be coupled to inner rim 331 without inner lateral stop mounting bracket 349b, for example, directly coupled to the inner rim via hinge pin 348.

[0136] Those skilled in the art will recognize that, similar to the lateral stops described with respect to the above embodiments, the inner lateral stop 344 and the outer lateral stop 345 limit the relative movement between the outer rim 333 (and therefore the outer ring 340) and the inner rim 331. In other words, for example, turning of the vehicle may cause lateral movement of the outer ring 340 relative to the inner rim 331. The inner lateral stop 344 and the outer lateral stop 345 can limit the amount of lateral movement of the outer ring 340 relative to the inner rim 331, thereby maintaining the structural integrity of the wheel assembly 330. Of course, the inner lateral stop 344 and the outer lateral stop 345 can include other and / or additional components or elements that cooperate to limit the relative lateral movement of the outer ring 340 and the outer inner rim 331.

[0137] The other elements shown, such as the fastener receiving channel 324 in the inwardly extending flange ring 325, the tread assembly 370, and the clamping device 373 including the inner clamping member 374 and the fastener 379a are similar to the corresponding elements described in relation to the above-mentioned embodiments. Therefore, these elements related to the present embodiment need not be discussed further.

[0138] The method aspect relates to a method of manufacturing a wheel assembly 330 to be coupled to a vehicle hub. The method includes operatively coupling a plurality of gas springs 350 between an inner rim 331 to be coupled to the vehicle hub and an outer rim 333 surrounding the hub to provide a gas suspension for relative movement between the inner rim and the outer rim. The method may also include coupling an outer ring 340 to the outer rim 333, the outer rim and the adjacent inner portion of the inner rim defining a closable gap 341 to define a mechanical stop to limit relative movement between the inner rim and the outer rim.

[0139] Reference now Figure 34 to Figure 35 In another embodiment of the wheel assembly 330', the outer ring 340a' is coupled to the outer rim 333', and the inner ring 340b' is coupled to the inner rim 331'. The adjacent portions of the inner ring 340b' and the outer ring 340a' define a closable gap 341' to define a mechanical stop to limit the relative movement between the inner rim 331' and the outer rim 333'. Similar to the above embodiment, the outer rim 333' can have a diameter of at least 3.5 feet.

[0140] The outer ring 340a' has an outer ring body 363a' and an outer ring edge cap 364a' carried by the inner edge of the outer ring body. The inner ring 340b' also includes an inner ring body 363b' and an inner ring edge cap 364b' carried by the outer edge of the inner ring body. The inner ring edge cap 364a' and the outer ring edge cap 364b' provide a mechanical stop with increased surface area to limit the relative movement between the inner rim 331' and the outer rim 333'.

[0141] Similar to the above-described embodiment, the outer ring 340a' also includes a weight-reducing opening 343a'. The inner ring 340b' also includes a weight-reducing opening 343b'. The weight-reducing openings 343a', 343b' each illustratively have a generally circular or annular shape. The weight-reducing openings 343a', 343b' can have another shape, such as an elliptical shape, a hexagonal shape, and / or a profile for reducing stress.

[0142] The gas springs 350' are operatively coupled between the inner rim 331' and the outer rim 333'. Each gas spring 350' may be, for example, a double-acting gas spring and include a double-acting cylinder 351' and an associated piston 352'. Of course, in some embodiments, each gas spring 350' may be a single-acting gas spring. More than one type of gas spring 350' may be used. For example, the gas spring 350' may be an air spring and / or a nitrogen spring. The gas spring 350' may also include other gases.

[0143] Illustratively, the gas springs 350' are arranged in pairs on opposite sides of the outer ring 340a'. More particularly, the gas springs 350' radiate outwardly from the inner rim 331' to the outer rim 333'. A corresponding attachment bracket 353' of each gas spring 350' is coupled to the inner ring 340b', and more particularly, to the inner ring body 363b'. Each attachment bracket 353' can include a generally U-shaped or V-shaped base bracket in which the end of the piston 352' is received (e.g., between the arms of the U-shaped or V-shaped bracket). Fasteners secure the end of the piston 352' of the gas spring 350' to the base bracket. Similar attachment brackets 353' are coupled to the outer rim 333' adjacent to the inner and outer side surfaces. Thus, the gas spring 350' can be pivotally coupled between the inner rim 331' and the outer rim 333'.

[0144] Similar to the above-described embodiments, as will be appreciated by those skilled in the art, the gas spring 350' provides a gas suspension for relative movement between the inner rim 331' and the outer rim 333'. The gas spring 350' has an operating stroke that allows the outer ring 340a' to define a mechanical stop. In other words, the gas spring 350' keeps the outer rim 333' spaced apart from the inner rim 331'. However, if the pressure on any of the gas springs 350' causes the gas spring to reach its limit under load or the gas spring fails, the outer ring 340a' can act as a mechanical stop to limit the relative movement between the inner rim 331' and the outer rim 333'. In other words, the outer ring 340a' and the gas spring 350' can be considered to provide a run-flat capability. Since the gas spring 350' is similar to the gas spring described with respect to the above-described embodiments, no further details of the gas spring need to be described.

[0145] Additional references Fig.37 , the wheel assembly 330' also includes an inner side lateral stop 344' carried between the inner side of the outer rim 333' and the inner side of the inner rim 331'. More specifically, the inner side lateral stop 344' is illustratively in the form of a hinge retainer or a scissor hinge. Each inner side lateral stop 344' includes an inner hinge bracket 346a', 346b' and an inner elastomer 347', such as a polyurethane body, carried by the hinge bracket adjacent to the inner side of the outer ring 340a'. The inner elastomer 347' is connected to the wall portion of the outer ring 340a' by a hinge pin 348'. The hinge brackets 346a', 346b' are connected together by the hinge pin 348'. The hinge bracket 346b' is connected to the wall portion of the inner ring 340b' by the hinge pin 348'.

[0146] The wheel assembly 330' also includes an outer side lateral stop 345' carried between the outer side of the outer rim 333' and the outer side of the inner rim 331'. More specifically, the outer side lateral stop 345' is illustratively in the form of a hinge retainer or a scissor hinge. Each outer side lateral stop 345' includes an outer side hinge bracket 346a', 346b' and an outer side elastic body 347', such as a polyurethane body, carried by the hinge bracket adjacent to the outer side of the outer ring 340a'. The outer side elastic body 347' is connected to the wall portion of the outer ring 340a' opposite to the corresponding portion of the inner side lateral stop 344' by a hinge pin 348', which can be shared with the hinge pin of the inner side stop. The hinge brackets 346a', 346b' are connected by the hinge pin 348'. The hinge bracket 346b' is coupled to a wall portion of the inner ring 340b' opposite to a corresponding portion of the inner lateral stop 344' by a hinge pin 348', which can be shared with the hinge pin of the inner lateral stop. As can be appreciated by those skilled in the art, the inner lateral stop 344' is similar in structure to the outer lateral stop 345', but is located opposite to the outer lateral stop (i.e., located on the inner side).

[0147] Those skilled in the art will appreciate that the inner lateral stop 344' and the outer lateral stop 345' limit the relative movement between the outer ring 340a' and the inner ring 340b'. In other words, for example, turning of the vehicle may cause lateral movement of the outer ring 340a' relative to the inner ring 340b'. The inner lateral stop 344' and the outer lateral stop 345' can limit the amount of lateral movement of the outer ring 340a' relative to the inner ring 340b', thereby maintaining the structural integrity of the wheel assembly 330'. Of course, the inner lateral stop 344' and the outer lateral stop 345' may include other and / or additional components or elements that cooperate to limit the relative lateral movement between the outer ring 340a' and the outer inner rim 331'.

[0148] The other elements shown, such as tread assembly 370' and clamping device 373' including inner clamping member 374' and fastener 379a' are similar to corresponding elements described with respect to the above-described embodiment. Therefore, these elements need not be discussed further with respect to the present embodiment.

[0149] A method aspect relates to a method of manufacturing a wheel assembly 330' to be coupled to a vehicle hub. The method includes operatively coupling a plurality of gas springs 350' between an inner rim 331' to be coupled to the vehicle hub and an outer rim 333' surrounding the hub to provide a gas suspension for relative movement between the inner rim and the outer rim. The method also includes coupling an outer ring 340a' to the outer rim 333' and coupling an inner ring 340b' to the inner rim 331', the inner ring and the adjacent inner portion of the outer ring defining a closable gap 341' to define a mechanical stop to limit relative movement between the inner rim and the outer rim.

[0150] Reference now Figure 38 to Figure 39 In another embodiment of the wheel assembly 430, an outer ring 440 or disk is coupled to the outer rim 433 adjacent to the inner side of the outer rim. The outer ring 440 coupled to the inner side of the outer rim 433 defines a closable gap 441 with an adjacent inner portion of the inner side of the inner rim 431 to define a mechanical stop to limit relative movement between the inner rim and the outer rim. Similar to the above embodiment, the outer rim 433 can have a diameter of at least 3.5 feet.

[0151] The gas springs 450 are operatively coupled between the inner rim 431 and the outer rim 433. Each gas spring 450 may be, for example, a double-acting gas spring and include a double-acting cylinder 451 and an associated piston 452. Of course, in some embodiments, each gas spring 450 may be a single-acting gas spring. More than one type of gas spring 450 may be used. For example, the gas spring 450 may be an air spring and / or a nitrogen spring. The gas spring 450 may also contain other gases.

[0152] Illustratively, the gas spring 450 is disposed on the outboard side of the outer ring 440. As will be appreciated by those skilled in the art, the location of the gas spring 450 on the outboard side of the outer ring 440 and the location of the inboard side of the outer ring adjacent the inner rim 431 and the outer rim 433 can advantageously allow for relatively easy access to serviceable components, such as, for example, the gas spring, the hydraulic damper 460, and the lateral stop 444. In other words, the outer ring 440 does not inhibit or prevent access to serviceable components when, for example, the outboard cover of the wheel assembly 430 is removed for service.

[0153] A corresponding attachment bracket 453 of each gas spring 450 is coupled to the inner rim 431. Each attachment bracket 453 may include a generally U-shaped or V-shaped base bracket that receives an end of a piston 452 therein (e.g., between the arms of the U-shaped or V-shaped bracket). Fasteners secure the end of the piston 452 of the gas spring 450 to the attachment bracket 453. A similar attachment bracket 453 is coupled to the outer rim 433. Thus, the gas spring 450 is pivotally coupled between the inner rim 431 and the outer rim 433.

[0154] Similar to the above-described embodiments, as will be appreciated by those skilled in the art, the gas spring 450 provides a gas suspension for relative movement between the inner rim 431 and the outer rim 433. The gas spring 450 has a travel that allows the outer rim 440 to define a mechanical stop. In other words, the gas spring 450 keeps the outer rim 433 spaced apart from the inner rim 431. However, if the pressure on any of the gas springs 450 causes the gas spring to reach its limit under load or the gas spring fails, the outer ring 440 can act as a mechanical stop to limit the relative movement between the inner rim 431 and the outer rim 433. In other words, the outer ring 440 and the gas spring 450 can be considered to provide a run-flat capability. Since the gas spring 450 is similar to the gas spring described with respect to the embodiments described above, no further details of the gas spring need be described.

[0155] Wheel assembly 430 includes a lateral stop 444 coupled between inner rim 431 and outer rim 433 to limit relative lateral movement between the inner rim and the outer rim. Lateral stop 444 is illustratively coupled near the inner side of outer rim 433 and the inner side of inner rim 431. Lateral stop 444 is illustratively in the form of a hinge retainer or a scissor hinge. Lateral stop 444 can be similar to the lateral stop described above and include an elastomer. Of course, lateral stop 444 can include other components and / or can be coupled adjacent to the outer side of inner rim 431 and outer rim 433 alternatively or additionally.

[0156] Hydraulic dampers 460 are illustratively operatively coupled between inner rim 431 and outer rim 433. Hydraulic dampers 460 may be in the form of, for example, oil dampers. Of course, other, additional or different fluids may be included in all or some of the dampers. Each hydraulic damper 460 includes a double-acting hydraulic cylinder 461 and an associated piston 462.

[0157] The respective hydraulic damper 460 is coupled adjacent to the respective gas spring 450. In other words, each hydraulic damper 460 is aligned side-by-side with the respective gas spring 450 (e.g., the gas spring is at approximately the same angle to the inner rim 431 and the outer rim 433 or coupling locations). Thus, for a wheel assembly 430 including six (6) gas springs 450, there will be six (6) hydraulic dampers 460. Similar to the gas springs 450, respective mounting brackets 469 couple each hydraulic damper 460 to the inner rim 431 and the outer rim 433, respectively.

[0158] As will be appreciated by those skilled in the art, the hydraulic dampers 460 can dampen or reduce vibrations and motions caused by movement through or over the ground by the wheel assembly 430. Furthermore, as double-acting hydraulic dampers 460, each hydraulic damper advantageously damps both extension and compression.

[0159] Cable ties 480 are coupled to opposite ends of the gas springs 450. More specifically, each cable tie or safety cable 480 is coupled to a corresponding mounting bracket 453 of each gas spring 450. When the operating stroke of a given gas spring 450 is retracted (i.e., the piston 452 is retracted into the cylinder 451), there is slack in the corresponding safety cable 480. However, if a given gas spring 450 exceeds its operating stroke limit (i.e., the piston 452 extends outward from the cylinder 451 beyond the operating limit), for example, if a gas spring fails, the safety cable 480 will be tightened and can therefore prevent the gas piston from separating from the cylinder in the event of a failure.

[0160] A method aspect relates to a method of manufacturing a wheel assembly 430 coupled to a vehicle hub. The method includes operatively coupling a plurality of gas springs 450 between an inner rim 431 to be coupled to the vehicle hub and an outer rim 433 surrounding the hub to provide a gas suspension for relative movement between the inner rim and the outer rim. The method also includes coupling an outer ring 440 adjacent to an outboard side of the outer rim 433, the outer ring defining a closable gap 441 adjacent to an inner side of the inner rim 431 to define a mechanical stop to limit relative movement between the inner rim and the outer rim. The plurality of gas springs 450 are operatively coupled to the outboard side of the outer ring 440.

[0161] Now refer to Figure 40 to Figure 41, the wheel assembly 430 includes a tread assembly 470, which includes a tread body 472 and a clamping device 473. The tread body 472 is carried by the outer rim 433 and has an outer contact surface 475, an inner side portion and an outer side portion. The tread body 472 may include, for example, rubber. Of course, the tread body 472 may include other and / or additional materials. The tread body 472 also has a first plurality of embedded channels 478 located below the outer contact surface 475 and extending between the inner side portion and the outer side portion. More specifically, the first plurality of embedded channels 478, which illustratively have a circular shape, are open outwardly toward the inner side portion and the outer side portion. In other words, the first plurality of embedded channels 478 can be conceptually considered as grooves extending between the inner side portion and the outer side portion in the tread body 472.

[0162] The tread body 472 also includes a second plurality of circumferential grooves 476 extending downwardly from the outer contact surface 475 and intersecting the first plurality of embedded channels 478. The second plurality of circumferential grooves 476 may have a V-shape, with the wider opening of the V-shape being in the outer contact surface 475. Illustratively, there are five circumferential grooves 476, but those skilled in the art will appreciate that there may be any number of circumferential grooves, for example, based on the type of contact surface and the application of use.

[0163] Tread body 472 also includes a third plurality of frustoconical opening features 477 extending inwardly from outer contact surface 475. Although frustoconical opening features 477 are shown, the opening features may have another shape, such as a cylindrical shape. Third plurality of frustoconical opening features 477 are illustratively aligned along corresponding circumferential grooves in second plurality of circumferential grooves 476. In some embodiments, third plurality of frustoconical opening features 477 may not be aligned with second plurality of circumferential grooves 476. For example, third plurality of frustoconical opening features 477 may be spaced around outer contact surface 475 and / or may extend downwardly from the outer contact surface to intersect first plurality of embedding channels 478.

[0164] The tread assembly 470 may further include a tread body support 471. The tread body support 471 may be in the form of a metal plate (e.g., an arc-shaped metal plate) coupled to the outer periphery of the outer rim 433. The tread body 472 may be coupled or connected (e.g., glued, fastened, etc.) to the tread body support 471.

[0165] A clamping device or clamping member 473 removably secures the tread body 472 to the outer rim. The clamping device 473 is respectively connected to the inner and outer sides of the outer rim 433 by fasteners 479 (e.g., threaded fasteners) to facilitate removal and replacement, for example, when the tread body 472 is worn or the tread body needs to be replaced. The threaded fastener 479 can extend through the opening in the clamping device 473 and engage the corresponding threaded opening in the outer rim 433. Other types of clamping devices or members can be used, such as those described above with respect to other embodiments. Those skilled in the art will understand that although a single tread body support 471, tread body 472 and clamping device 473 have been described herein, there can be more than one tread body support, tread body and clamping device connected in an end-to-end relationship around the outer rim 433, such as shown.

[0166] Method aspects relate to a method of manufacturing a wheel assembly 430 to be coupled to a vehicle hub. The method may include operatively coupling a plurality of gas springs 450 between an inner rim 431 to be coupled to the hub and an outer rim 433 surrounding the hub to provide a gas suspension that allows relative movement between the inner rim and the outer rim. The method may also include coupling a tread body 472 carried by the outer rim 433 and having an outer contact surface 475, an inner side portion, and an outer side portion. The tread body 472 may also have a first plurality of embedded channels 478 extending below the outer contact surface 475 and between the inner side portion and the outer side portion, and a second plurality of circumferential grooves 476 extending downward from the outer contact surface and intersecting the first plurality of embedded channels.

[0167] The other elements shown, such as the fastener receiving channel 424 in the inwardly extending flange ring 425, the clamping device 473, and the sidewall cover and cover assembly 401 are similar to the corresponding elements described with respect to the above-described embodiment. Further details of the sidewall cover assembly 401 are described in U.S. Patent Application No. 16 / 886,065, the entire contents of which are incorporated herein by reference. Therefore, these elements related to the present embodiment need not be discussed further.

[0168] Now refer to Figure 42 to Figure 43 In another embodiment, each of the gas springs 450' has a cylinder 451' and an associated piston 452' movable within the cylinder. The piston 452' divides the cylinder 451' into a first gas chamber 454a' and a second gas chamber 454b'.

[0169] A respective hydraulic damper 460' is mounted on each gas spring 450' and is operatively coupled between the first air chamber 454a' and the second air chamber 454b'. Each hydraulic damper 460' includes a damper cylinder 461' and first and second pistons 462' movable within the damper cylinder. The first and second pistons 462' of each hydraulic damper 460' define first and second damper air chambers 463a' and 463b' and first and second hydraulic fluid chambers 464a' and 464b'.

[0170] The first damper air chamber 463a' and the second damper air chamber 463b' are coupled to corresponding air chambers in the first air chamber 454a' and the second air chamber 454b' of the gas spring 450', for example, by corresponding conduits 455', 465'. More particularly, when the hydraulic damper 460' is mounted to the gas spring 450', the gas spring conduit 455' and the hydraulic damper conduit 465' can be aligned and matably coupled. A seal 456', such as a sealing gasket, can be located between the gas spring conduit 455' and the hydraulic damper conduit 465' or at an interface between the gas spring conduit and the hydraulic damper conduit. Of course, other mating arrangements allow gas communication between the first air chamber 454a' and the second air chamber 454b' and the first damper air chamber 463a' and the second damper air chamber 463b'. The hydraulic damper 460' illustratively has a port 457' at the opposite end.

[0171] Chamber wall 466' divides damper cylinder 461' into first and second hydraulic fluid chambers 464a', 464b'. Chamber wall 466' illustratively has an orifice 467' therein to allow hydraulic fluid to pass between first and second hydraulic fluid chambers 464a', 464b'.

[0172] The cylinder clamps 458' illustratively mount the respective hydraulic dampers 460' to the respective gas springs 450' in a piggyback configuration. Each cylinder clamp 458' has a figure eight shape. Each cylinder clamp 458' can conceptually be in the form of a double tube clamp that allows the gas spring 450' and the hydraulic damper 460' to be slidably received within respective openings and secured in place using respective fasteners 459'. Although cylinder clamps 458' are shown, those skilled in the art will appreciate that other and / or additional types of cylinder clamps may be used.

[0173] A method aspect relates to a method of manufacturing a wheel assembly 430 to be coupled to a vehicle hub. The method may include operatively coupling a plurality of gas springs 450' between an inner rim 431 to be coupled to the vehicle hub and an outer rim 433 surrounding the hub to provide a gas suspension for relative movement between the inner rim and the outer rim. Each of the plurality of gas springs 450' may include a cylinder 451' and an associated piston 452' that is movable in the cylinder and divides the cylinder into a first air chamber 454a' and a second air chamber 454b'. The method may also include mounting a respective hydraulic damper 460' on each gas spring 450' and operatively coupling between the first air chamber 454a' and the second air chamber 454b'.

[0174] Reference now Figure 44 to Figure 45 In another embodiment, a mine material handling device 510 includes a rotatable drum 511 for handling mine materials. For example, as described herein, wheel assemblies 530a to 530f are illustratively configured for rotation of the rotatable drum 511.

[0175] Similar to the other wheel assemblies, each wheel assembly 530a to 530f includes an inner rim 531, an outer rim 533 surrounding the inner rim, and a gas spring 550 operatively coupled between the inner rim and the outer rim. The outer ring 540 is coupled to the outer rim 533 and defines a closable gap 541 with the adjacent portion of the inner rim 531 as described in the above embodiments to define a mechanical stop to limit movement between the inner rim and the outer rim. Other elements of the wheel assembly 530a shown but not specifically described, such as the damper 560 within the inwardly extending flange ring 525, the tread body 572, the lateral stop 544, the gas spring and damper mounting brackets 553, 569, and the fastener receiving channel 524 are similar to the elements described above.

[0176] The drive motor 515 is coupled to the inner rim 531 of the wheel assemblies 530a, 530b. More particularly, the drive motor 515 can be coupled to the wheel assembly via a fastener receiving channel 524 within the inwardly extending flange ring 525. The drive motor 515 can include, for example, an electric motor coupled to a transmission system. In some embodiments, the drive motor 515 can directly drive the wheel assemblies 530a to 530f. The other wheel assemblies 530c to 530f can be considered as idler wheel assemblies and can not be driven, but are allowed to rotate freely or independently of the drive motor 515. In some embodiments, the corresponding drive motor 515 can be coupled to the inner rim 531 of each wheel assembly 530a to 530f.

[0177] Reference now Figures 46 to 48In another embodiment, a tread body 572', such as a rubber tread body, is carried by the outer rim 533'. The tread body 572' has an outer contact surface 575', an inner side portion, and an outer side portion. An embedding channel 578' is located below the outer contact surface 575' and extends between the inner side portion and the outer side portion. The embedding channel 578' is illustratively circular. Of course, the embedding channel 578' can also be other shapes.

[0178] For example, a U-shaped circumferential groove 576' extends downward from the outer contact surface 575' to expose an embedding channel 578' at its intersection 579'. An opening feature 577' extends inward from the outer contact surface 575'. The opening feature 577' is illustratively circular or has an annular shape. The opening feature 577' can have another shape.

[0179] As will be appreciated by those skilled in the art, tread body 572' illustratively has a circular shape to allow the tread body to be changed by slidably removing the tread body from outer rim 533'. Replacement of tread body 572' is performed by sliding the tread body on outer rim 533'. In some embodiments, tread body 572' may not be coupled to outer rim 533' because the forces typically generated on the vehicle (e.g., from relatively hard brakes) may be reduced when used in mining material handling equipment (i.e., rotating the rotatable drum). Elements shown but not specifically described, such as outer ring 540' and gas spring mounting bracket 553' are similar to those described above.

[0180] Reference now Fig.49 In another embodiment of the wheel assembly 530" for mining material handling, each wheel assembly can be segmented, for example. More specifically, the inner rim 531" can include, for example, arcuate inner rim segments 532a" to 532d" coupled together in an end-to-end relationship to define an annular inner rim.

[0181] Each arcuate inner rim segment 532a" to 532d" has an end flange 518a", 518b" at the opposite end. More specifically, a corresponding inner flange 518a", 518b" is located at each end of the arcuate inner rim segments 532a" to 532d" for connecting adjacent arcuate inner rim assemblies in an end-to-end relationship. Each inner flange 518a", 518b" has an opening or inner flange fastener receiving channel therein to receive an inner flange fastener therethrough when aligned with the adjacent end flange.

[0182] The wheel assembly 530" also includes an outer rim 533" having an annular shape. Similar to the annular inner rim 531", the annular outer rim 533" is segmented, or defined by arcuate outer rim segments 539a" to 539h" that are connected together. Although eight arcuate outer rim segments 539a" to 539h" are shown, those skilled in the art will understand that there may be any number of arcuate outer rim segments, for example, and as shown, the number of arcuate outer rim segments may not need to match the number of arcuate inner rim segments 532a" to 532d".

[0183] Each arcuate outer rim segment 539a" to 539h" also has an end flange 516a", 516b" at the opposite end. More specifically, a corresponding outer flange 516a", 516b" is located at each end of the arcuate outer rim segments 539a" to 539h" for connecting adjacent ones of the arcuate outer rim segments. Each outer flange 516a", 516b" has an opening or outer flange fastener receiving channel 517" therein to receive an outer flange fastener therethrough when aligned with the adjacent outer flange. Elements shown but not specifically described, such as the fastener receiving channel 524" within the inwardly extending flange ring 525", and further details of the segmented wheel assembly are described in U.S. patent application No. 16 / 865,231, the entire contents of which are incorporated herein by reference.

[0184] The method aspect relates to a method for processing mining materials. The method includes operating a plurality of wheel assemblies 520a to 520f to rotate a rotatable drum 511 to process mining materials. Each wheel assembly 520a to 520f includes an inner rim 531, an outer rim 533 surrounding the inner rim, and a plurality of gas springs 550 operatively coupled between the inner rim and the outer rim.

[0185] Another method aspect relates to a method of manufacturing an apparatus 510 for processing mine materials. The method includes arranging a plurality of wheel assemblies 520a to 520f for rotating a rotatable drum 511 to process mine materials. Each wheel assembly 520a to 520f includes an inner rim 531, an outer rim 533 surrounding the inner rim, and a plurality of gas springs 550 operatively coupled between the inner rim and the outer rim.

[0186] Reference now Fig.50In another embodiment, a wheel assembly 630 illustratively includes an inner rim 631 to be coupled to a vehicle wheel hub. An outer rim 633 surrounds the wheel hub, and more particularly surrounds the inner rim 631. An outer ring 640 or disk is coupled to the outer rim 633 adjacent to the inner side of the outer rim. The outer ring 640 coupled to the inner side of the outer rim 633 defines a closable gap 641 with an adjacent inner portion of the inner side of the inner rim 631 to define a mechanical stop to limit relative movement between the inner rim and the outer rim.

[0187] The gas spring with associated integrated hydraulic damper 650 is operatively coupled between the inner rim 631 and the outer rim 633 to provide suspension for relative motion between the inner rim and the outer rim. Similar to the embodiments of the gas spring described above, the gas spring with associated integrated hydraulic damper 650 has an operating stroke that allows the outer ring 640 to define a mechanical stop. As will be appreciated by those skilled in the art, the gas spring with associated integrated hydraulic damper 650 functions similarly to the described gas springs and hydraulic dampers that provide suspension and provide damping.

[0188] Reference now Figure 51 to Figure 54 , further details of the gas springs with associated integrated hydraulic dampers 650 will now be described. Each gas spring with associated integrated hydraulic dampers 650 includes a first cylinder 651a and a second cylinder 651b. The second cylinder 651b is slidable within the first cylinder 651a. In other words, the second cylinder 651b can be conceptually considered to be a piston that is movable within the first cylinder 651a.

[0189] The first seal 656 is carried by the end of the second cylinder 651b. The first seal 656 defines a first air chamber 654a and a second air chamber 654b within the first cylinder 651a. The shaft 662 is coupled to the end of the first cylinder 651 and extends within the first cylinder and into the second cylinder 651b. The shaft 662 defines a hydraulic fluid chamber 663 within the second cylinder 651b. Each gas spring having an associated integrated hydraulic damper 650 also includes an enlarged orifice body 668 coupled to the shaft 662 to define a hydraulic damper with the second cylinder 651b. The enlarged orifice body 668 has an orifice 669 therein to allow hydraulic fluid to flow therethrough. Although three orifices 669 are shown, any number of orifices may be present.

[0190] Carried within the second cylinder body 651b is a flow restrictor 666. The flow restrictor 666 illustratively includes an orifice 667 therein to allow hydraulic fluid to pass therethrough.

[0191] Gas ports 657a, 657b are coupled to first and second gas chambers 654a, 654b, respectively, of each gas spring having an associated integrated hydraulic damper 650. Hydraulic fluid port 657c is coupled to second cylinder 651b. Although two gas ports and one hydraulic fluid port are shown, those skilled in the art will appreciate that there may be any greater number of gas and hydraulic fluid ports 657a-657c.

[0192] Each gas spring with an associated integrated hydraulic damper 650 also includes a first mounting bracket 653a and a second mounting bracket 653b coupled to the first cylinder 651a and the second cylinder 651b, respectively. Similar to the above-mentioned mounting brackets, the first mounting bracket 653a and the second mounting bracket 653b are used to mount the gas spring with an associated integrated hydraulic damper 650 between the inner rim 631 and the outer rim 633.

[0193] Those skilled in the art will appreciate that a gas spring with an associated integrated hydraulic damper 650 can advantageously provide gas suspension and damper functionality while conserving space within the wheel assembly (i.e., between the inner rim 631 and the outer rim 633). More particularly, as those skilled in the art will appreciate, a gas spring with an associated integrated hydraulic damper 650 provides this functionality through a Kelvin coupling mechanism.

[0194] Brief reference Fig.55 In another embodiment, the shaft 662', the first seal 656', the end of the first cylinder 651a' and the end of the second cylinder 651b' opposite the first seal may be threaded. By providing threads on the ends of the shaft 662', the first seal 656' and the first cylinder 651a' and the second cylinder 651b', the gas spring with the associated integral hydraulic damper 650' can be adjusted to obtain a desired spring and damper response. The volume compensator (e.g., in the form of a reservoir and diaphragm not shown) can be spring loaded, in which case a gas-filled column may not be desired. Other elements shown but not specifically described, such as the first cylinder body 651a', the enlarged orifice body 668' and associated orifice 669', the first and second air chambers 654a', 654b', the second cylinder wall 666' and associated orifice 667', the hydraulic fluid chamber 663', the ports 657a' to 657c', and the first and second mounting brackets 653a', 653b' are similar to the elements described above.

[0195] A method aspect relates to a method of manufacturing a wheel assembly 630 to be coupled to a vehicle hub. The method includes operatively coupling a plurality of gas springs with associated integrated hydraulic dampers 650 between an inner rim 631 to be coupled to the vehicle hub and an outer rim 633 surrounding the hub to provide suspension for relative movement between the inner rim and the outer rim. Each of the plurality of gas springs and associated integrated hydraulic dampers 650 includes: a first cylinder 651a and a second cylinder 651b slidable in the first cylinder; a first seal 656 carried by an end of the second cylinder, the first seal defining a first air chamber and a second air chamber in the first cylinder; and a shaft 662 extending within the first cylinder and into the second cylinder, thereby defining a hydraulic fluid chamber. Each of the gas springs with associated integrated hydraulic dampers 650 also includes an enlarged orifice body 668 coupled to the shaft 662, thereby defining a hydraulic damper together with the second cylinder 651b. Now referring to Fig.56 In another embodiment, a wheel assembly 730 illustratively includes an inner rim 731 to be coupled to a vehicle hub. An outer rim 733 surrounds the hub, and more particularly, the outer rim surrounds the inner rim 731. A tread 770 is carried by the outer rim.

[0196] The gas spring 750 is operatively coupled between the inner rim 731 and the outer rim 733 to provide suspension for relative motion between the inner rim and the outer rim. As will be appreciated by those skilled in the art, the gas spring 750 may include the elements described herein to achieve damping, and / or an additional damper (not shown) coupled between the inner rim 731 and the outer rim 733 may be used to provide damping.

[0197] The inner flange 771 extends radially outward from the inner side of the inner rim 731 to define an inner mechanical stop. The inner flange 771 includes a flange body 772 and flange lips 773a, 773b extending outward from the flange body. The radially inner flange lip 773a is coupled to the inner rim by a fastener 777.

[0198] The outer flange 774 extends radially outward from the outer side of the inner rim 731 to define an outer mechanical stop. Similar to the inner flange 772, the outer flange 774 includes a flange body 775 and flange lips 776a, 776b extending outward from the flange body. The radial inner flange lip 776a is connected to the inner rim 731 by a fastener 777.

[0199] The inner sidewall 781 and the outer sidewall 782 extend radially inward from the outer rim 733. The inner sidewall 781 and the outer sidewall 782 are removably coupled to the inner side and the outer side of the outer rim 733, for example, using fasteners 783. Of course, the inner sidewall 781 and the outer sidewall 782 can be coupled to the outer rim 733 using other and / or coupling techniques. The inner sidewall and / or the outer sidewall 781, 782 can be removed to provide access to the gas spring 750 and other hardware that can be positioned between the inner rim 731 and the outer rim 733.

[0200] The inner sidewall 781 and the outer sidewall 782 define overlapping areas overlapping the inner flange 771 and the outer flange 774, respectively. An elastomer 784 is located in each overlapping area. A fabric (e.g., felt) or other material body 785 may also be coupled to the elastomer 784 in the overlapping area. The elastomer 784 and the fabric body 785 may be in sliding contact with either of the flanges 771, 774 or the sidewalls 781, 782. The elastomer 784 and the fabric body 785 may provide a seal to help prevent contaminants from entering the space between the inner rim 731 and the outer rim 733 while allowing relative movement between the inner rim and the outer rim. For example, the sidewalls 781, 782 with the elastomer 784 and the fabric body 785 may provide, for example, a damping between 2% and 4% in the lateral direction.

[0201] The inner elastomeric ring 786 and the outer elastomeric ring 787 are illustratively carried by the inner surface of the outer rim 733. The inner elastomeric ring 786 and the outer elastomeric ring 787 are aligned with the inner flange 771 and the outer flange 774, respectively. During operation, as will be appreciated by those skilled in the art, as the wheel assembly 730 moves during vehicle motion, the gas spring 750 allows relative movement between the inner rim 731 and the outer rim 733 until a mechanical stop. During operation of the mechanical stop, the elastomeric rings 786, 787 contact the radially outward flange lips of the inner flange lip 773b and the outer flange lip 776b. For example, the elastomeric rings 786, 787 can allow loads of up to 20,000 pounds.

[0202] The wheel assembly 730 can advantageously provide increased fuel efficiency for a vehicle driven by an internal combustion engine by providing less road resistance. For example, for an electric vehicle, the reduction in road resistance can equate to an extended driving range for a given battery charge. In addition, the inner and outer mechanical stops can operate as a "run-flat" function, so that the vehicle does not need to carry a spare tire, thereby reducing vehicle weight and improving operating efficiency.

[0203] Reference now Fig.57In another embodiment, in addition to the inner flange and the outer flange, a middle flange 778' extends radially from the middle of the outer rim 733'. The middle flange 778' includes a flange body 779' and a flange lip 788' extending from the flange body and extending outwardly toward the outer side of the wheel assembly 730'. The outer rim 733' may include, for example, an inner rim segment 734a' and an outer rim segment 734b', each of which presents a U-shape and is coupled together by fasteners 735'. The middle flange 778' may be coupled between the inner rim segment 734a' and the outer rim segment 734b' by fasteners 735'. In other words, the middle flange 778' is sandwiched between the adjacent arms of the inner rim segment 734a' and the outer rim segment 734b' of the U. The flange lip 788' defines a mechanical stop with the inner rim 731 ', and more particularly, the elastomeric ring 786' is aligned with the flange lip.

[0204] The inner rim inner sidewall 791' and the inner rim outer sidewall 792', which are coupled to the inner and outer side portions of the inner rim 731', for example, by fasteners 793', replace the inner and outer flanges and define overlapping areas with the inner and outer sidewalls 781' and 782'. For example, as described above, the lateral stopper 745' is illustratively coupled between the inner rim 731' and the outer rim 733' in the form of a hinge retainer and limits the relative lateral movement between the inner and outer rims. Elements such as the tread 770', fasteners 783', elastic body 784', fabric body 785', and gas spring 750' are similar to those described above.

[0205] Reference now Fig.58 In another embodiment, the inner rim 731" and the outer flange 774" are integrally formed as an integral unit. The outer rim 733" and the outer sidewall 782" are also integrally formed as an integral unit. Of course, the inner rim 731" and the inner flange 771", and the outer rim 733" and the inner sidewall 781" can be integrally formed as an integral unit. In this way, access to the interior of the wheel assembly 730" can be provided through one of the inner side and the outer side of the wheel assembly. In some embodiments, the inner sidewall 781", the outer sidewall 782" and the outer rim can be integrally formed as a unit, and / or the inner flange and the outer flange and the outer rim can be integrally formed as a unit. Elements such as the tread 770", fasteners 783", 777", lateral stops 745", elastomeric rings 786", 787", flange bodies 772", 775", flange lips 773a", 773b", elastomer 784", fabric body 785", and gas spring 750" are similar to those described above.

[0206] The method aspect relates to a method of manufacturing a wheel assembly 730 to be coupled to a vehicle hub. The method includes operatively coupling a plurality of gas springs 750 between an inner rim 731 to be coupled to the vehicle hub and an outer rim 733 surrounding the inner rim to provide a gas suspension that allows relative movement between the inner rim and the outer rim. The method also includes positioning an inner flange 771 to extend radially outward from an inner side of the inner rim 731 to define an inner mechanical stop with the outer rim 733. The method also includes positioning an outer flange 774 to be spaced apart from the inner flange 771 and to extend radially outward from an outer side of the inner rim 731 to define an outer mechanical stop with the outer rim 733.

[0207] Reference now Figure 59 to Figure 63 In another embodiment, the wheel assembly 830 includes an inner rim 831 to be coupled to a vehicle hub. The wheel assembly 830 also includes an outer rim 833 surrounding the inner rim 831. A disk or ring 840 may be located between the inner rim 831 and the outer rim 833 to define a closable gap.

[0208] The wheel assembly 830 also includes a gas spring 850 operatively coupled between the inner rim 831 and the outer rim 833 to provide a gas suspension that allows relative movement between the inner rim and the outer rim. Each gas spring 850 includes a cylinder 851 and a piston 852 movable within the cylinder. The cylinder 851 comprises a first metal.

[0209] Piston 852 illustratively includes a shaft 853 and a piston head 854 coupled to the shaft. Piston head 854 includes a recess 855 therein, and more particularly, a circumferential recess.

[0210] The piston 852 also includes a biasing member 856 within the recess 855. More particularly, the biasing member 856 is in the form of a body of elastomeric material that surrounds the shaft 853 and operates as a spring to provide a radially outward bias. Although a single biasing member 856 is shown, those skilled in the art will appreciate that there may be any number of biasing members, the biasing member may be another material, such as metal, and / or the biasing member may be another shape or type of biasing member.

[0211] The piston 852 also includes a damping member 857 adjacent to the biasing member 856. The damping member 857 is located in a recess between the biasing member 856 and an adjacent portion of the inner surface of the cylinder 851. The damping members 857 are arranged circumferentially around the axis or more particularly around the biasing member 856 in a side-by-side relationship. The damping members 857 are illustratively in the form of a rigid body, and each damping member includes a second metal that is softer than the first metal (i.e., the metal of the cylinder 851). The second metal may include, for example, bronze. There may be any number of damping members 857, including one. The damping members 857 may be spaced apart or abutted. As will be understood by those skilled in the art, the biasing member 856 radially biases the damping member 857 outwardly so that the damping member frictionally engages the inner surface of the cylinder 851.

[0212] The damping member 857 may provide increased damping for the wheel assembly 830. For example, the increased damping may be between 4% and 6%. One skilled in the art will appreciate that an increase in the amount of damping provided by the damping member 857 may generate increased heat, and adjusting to have less damping may not be desirable because the less damping may not adequately attenuate motion.

[0213] A seal 858 is carried by the piston head 854. The seal 858 is carried in a circumferential recess that is axially separated from the recess that carries the biasing member 856 and the damping member 857. The seal 858 illustratively has a channel 859 therein to define a U-shape.

[0214] The piston head 854 also includes a first pin receiving passage 861. The damping member 857 has a second pin receiving passage 862 therein. The second pin receiving passage 862 is aligned with the first pin receiving passage 861 to accommodate a corresponding retaining pin (not shown) during assembly. As will be appreciated by those skilled in the art, the damping member 857 extends outwardly when biased to engage the inner surface of the cylinder 851. During assembly of the gas spring 850, it is desirable to retract the damping member 857 so that the piston 852 can be inserted into the cylinder 851.

[0215] Once in place within the cylinder 851, the pins may be pulled or removed from the first and second pin receiving channels 861, 862, allowing the damping member 857 to expand radially to contact the inner surface of the cylinder 851. Contact with the inner surface of the cylinder 851 causes the damping member 857 to expand axially to remain in the recess.

[0216] A related method aspect relates to a method of manufacturing a wheel assembly 830 to be coupled to a vehicle hub. The method may include operatively coupling a plurality of gas springs 850 between an inner rim 831 to be coupled to the vehicle hub and an outer rim 833 surrounding the inner rim to provide a gas suspension that allows relative movement between the inner rim and the outer rim. Each of the plurality of gas springs 850 may include a cylinder 851 having an inner surface and a piston 852 movable within the cylinder. The piston 852 may include a shaft 853, a piston head 854 coupled to the shaft and having a recess 855 therein, at least one biasing member 856 located within the recess, and at least one damping member 857 adjacent to the at least one biasing member and located within the recess to frictionally engage with the inner surface of the cylinder.

[0217] Although several embodiments have been described herein, those skilled in the art will appreciate that any one or more elements from any one or more embodiments may be used in combination with any one or more elements from any other one or more embodiments. In addition, although reference is made herein to inner and outer, those skilled in the art will appreciate that in many embodiments, elements described with respect to inner may be used as outer, and vice versa, and / or those elements described as inner may be used with elements described as outer, and vice versa.

[0218] Many modifications and other embodiments of the invention will occur to one skilled in the art having benefit of the teachings presented in the foregoing description and the associated drawings. Therefore, it should be understood that the invention is not limited to the specific embodiments disclosed and that modifications and embodiments are intended to be included within the scope of the appended claims.

Claims

1. A wheel assembly to be coupled to a vehicle wheel hub, the wheel assembly include: an inner wheel rim to be coupled to the vehicle wheel hub; an outer rim surrounding the inner rim; and a plurality of gas springs operatively coupled between the inner rim and the outer rim to provide a gas suspension that allows relative movement between the inner rim and the outer rim, each of the plurality of gas springs comprising: a cylinder having an inner surface, and a piston movable within the cylinder and comprising: axis, a piston head coupled to the shaft and having at least one recess therein, At least one biasing member is positioned within the at least one recess, and at least one damping member is adjacent to the at least one biasing member and positioned within the at least one recess to frictionally engage the inner surface of the cylinder.

2. The wheel assembly according to claim 1, It is characterized in that The at least one biasing member includes at least one body of resilient material surrounding the shaft.

3. The wheel assembly according to claim 1, It is characterized in that The at least one damping member includes a plurality of rigid bodies.

4. The wheel assembly according to claim 1, It is characterized in that The piston head has a plurality of first pin receiving passages, and the at least one damping member has a plurality of second pin receiving passages aligned with the plurality of first pin receiving passages to accommodate corresponding retaining pins during assembly.

5. The wheel assembly according to claim 1, It is characterized in that The cylinder comprises a first metal; and wherein the at least one damping member comprises a second metal that is softer than the first metal.

6. The wheel assembly according to claim 1, It is characterized in that The at least one recess comprises at least one circumferential recess.

7. The wheel assembly of claim 1 including a seal carried by the piston head.

8. The wheel assembly of claim 1 including a tread carried by the outer rim.

9. A wheel assembly to be coupled to a vehicle wheel hub, the wheel assembly include: an inner wheel rim to be coupled to the vehicle wheel hub; an outer rim surrounding the inner rim; and a plurality of gas springs operatively coupled between the inner rim and the outer rim to provide a gas suspension that allows relative movement between the inner rim and the outer rim, each of the plurality of gas springs comprising: a cylinder having an inner surface, and a piston movable within the cylinder and comprising: axis, a piston head coupled to the shaft and having at least one recess therein, at least one biasing member located within the at least one recess and comprising at least one body of elastomeric material surrounding the shaft, and at least one damping member adjacent the at least one biasing member and positioned within the at least one recess to frictionally engage the inner surface of the cylinder; and A seal is carried by the piston head.

10. The wheel assembly according to claim 9, It is characterized in that The at least one damping member includes a plurality of rigid bodies.

11. The wheel assembly according to claim 9, It is characterized in that The piston head has a plurality of first pin receiving passages, and the at least one damping member has a plurality of second pin receiving passages aligned with the plurality of first pin receiving passages to accommodate corresponding retaining pins during assembly.

12. The wheel assembly according to claim 9, It is characterized in that The cylinder comprises a first metal; and wherein the at least one damping member comprises a second metal that is softer than the first metal.

13. The wheel assembly according to claim 9, It is characterized in that The at least one recess comprises a circumferential recess.

14. A method of manufacturing a wheel assembly to be coupled to a vehicle hub, the method include: A plurality of gas springs are operatively coupled between an inner rim to be coupled to the vehicle wheel hub and an outer rim surrounding the inner rim to provide a gas suspension allowing relative movement between the inner rim and the outer rim, each of the plurality of gas springs comprising a cylinder having an inner surface and a piston movable within the cylinder, the piston comprising a shaft, a piston head coupled to the shaft and having at least one recess therein, at least one biasing member within the at least one recess, and at least one damping member adjacent to the at least one biasing member and located within the at least one recess to frictionally engage the inner surface of the cylinder.

15. The method according to claim 14, It is characterized in that The at least one biasing member includes at least one body of resilient material surrounding the shaft.

16. The method according to claim 14, It is characterized in that The at least one damping member includes a plurality of rigid bodies.

17. The method according to claim 14, It is characterized in that The piston head has a plurality of first pin receiving passages, and the at least one damping member has a plurality of second pin receiving passages aligned with the plurality of first pin receiving passages to accommodate corresponding retaining pins during assembly.

18. The method according to claim 14, It is characterized in that The cylinder comprises a first metal; and wherein the at least one damping member comprises a second metal that is softer than the first metal.

19. The method according to claim 14, It is characterized in that The at least one recess comprises at least one circumferential recess.

20. The method of claim 14, comprising positioning a seal carried by the piston head.

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